Paper No: 05-IAGT-2.5
INDUSTRIAL APPLICATION OF
GAS TURBINES COMMITTEE
Machinery Management Solutions
InSight System
by
Carlos A. Aylwin
and
Arthur Stack
of
Solar Turbines
San Diego California
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
Machinery Management Solutions
InSight System
Overview
As a leader in the design, manufacture and service of industrial gas turbines, Solar Turbines
has developed gas turbine control systems that facilitate today’s Remote Monitoring and
Diagnostic capabilities - greatly expanding its service capabilities. RM&D technology has
evolved substantially and has made available an extensive array of turbomachinery operational
information. This information can be processed using smart systems to provide not only
diagnostic capabilities, but also a comprehensive suite of services to meet operational
objectives while reducing life cycle costs
Leveraging web-based technology, the package data is transmitted, stored, analyzed and
displayed leading to recommendations, which effectively manage package system health:
improving operational practices and anticipating problems.
A web based collaborative workspace manages the technical information and enhances the
accessibility by both the operator and the OEM. This workspace consolidates a project’s
lifecycle of documents, drawings, specifications and maintenance programs enhancing the
information flow – wherever, whenever needed.
This paper will focus on Solar’s Machinery Management Services – InSight System, available to
worldwide operators of Solar Turbomachinery systems and provides a platform for a
comprehensive web based service support system, which greatly expands on today’s RM&D
technology.
Introduction
Control systems incorporating Programmable Logic Controllers or PLC’s are the industry
standard for gas turbine control as well as many other process systems. These PLC controls
have the capability to compile operating information for a wide array of systems and
instrumentation for extended periods of time. This data can be viewed and interpreted as
indicative of the performance or health of the system.
The interpretation of this data has been traditionally carried out by Maintenance managers with
years of experience in the operation of gas turbine systems. This expertise is coupled with the
financial targets for the unit, station or pipeline so that downtime cost and risk are evaluated vs
the possible drop in production.
Gradually, the operational data for a gas turbine system has migrated well beyond the
immediate package control panel via extensive communication systems, to central control
rooms. The data is compiled and trends evaluated which drive maintenance plans. To take
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
these RM&D systems to the next level requires that the decisions based on the data be made
by smart systems that automatically analyze the operational data.
The maintenance instructions also need to take into consideration the overall resources needed
to accomplish the tasks. These resources included manpower, parts, instructions, safety norms,
OEM specifications and recommendations.
Solar Turbines is committed to providing superior value and operational excellence for its
customers. Following years of research, Solar has developed a set of Machinery Management
Solutions that are designed to support world-class performance of turbo machinery.
Based upon discussions with many customers, an assessment of products, and a review of
proven and new technologies, the evaluation indicated that to be successful, a broad equipment
health machinery management approach needed to be incorporated into the system design.
InSight System uses Solar’s rich knowledge base and experience, along with smart tools and
programs to provide safe, reliable, and efficient turbo machinery operations. Solar’s goal is to
decrease customer operation and maintenance costs and extend the life cycle of turbo
machinery. Solar has realigned many pieces of its business model to accommodate InSight
System. As an example, shifting practices and commercial expectations to align with condition
based maintenance and overhauls.
Solar has also established flexible scope contracts that are transparent, measurable and
performance based. This will provide the ability to continually measure the value to the
customer and adjust the scope as operating requirements change.
Taking advantage of our abilities to gather, analyze and interpret data, a highly motivated team
was formed to provide an answer. In the time since this project was initiated, a significant
amount of research, development, innovation and testing has been completed. A wide range of
pilot testing on products ranging from the Mercury 50 to the Titan 130 was undertaken to
determine what data should be collected and analyzed to achieve the system objectives.
In 2004 Solar initiated the first full commercial launch of a Machinery Management contract
incorporating the processes and technology that comprise InSight System.
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
InSight System
The approach that was developed to meet customer objectives addresses the key conditional,
operational and environmental factors that significantly influence package system design,
turbine life and operating reliability.
This comprehensive approach was achieved by means of enabling capabilities that include:
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Advanced diagnostics
Condition monitoring
Auto alert system
Remote troubleshooting
Certified condition assessment
Information management
Maintenance management
Collaborative communications
HSE management system
To provide demonstrated value to customer operations, the development strategy for InSight
System was to produce a tool that maximized equipment up time by optimizing maintenance
and providing rapid on site and remote technical support along with direct access to Solar
global resources
For the customer this strategy had to directly
translate to:
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Figure 1. Life Cycle Cost Optimization
Highest standards of operational health
and safety
Increased reliability and availability
Failure Avoidance
Reduced life-cycle cost
Extended operating cycles
The program balances customer requirements
for maximum production and availability
against optimized life cycle costs.
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
Development of InSight System
One of the key enablers for the InSight
System was the use of remote monitoring to
provide high value diagnostics and early
detection of adverse conditions and trends.
This ability is considered to be the cornerstone
of effective machinery health management.
The starting point was to evaluate engine
returns and Field Service call out reports to
determine the development opportunities and
priorities. The data shown in Figure 2 is an
evaluation of the engines returned to Solar’s
overhaul facility from 1997 to 2001. Each
overhaul report contained only the reported
reason for return and not the cause.
The data indicates that seventy-eight percent
(78%) of the engines sent to the Overhaul
Facility in this period were returned for either
time related reasons (that is the engines had
accumulated 25,000 or more operating hours)
or for operator convenience (the owner
deemed it convenient for operational or
business reasons to return the engine at that
time). Solar believes many of these engines
were in fact capable of continued and safe
operation.
Solar then completed a Failure Modes and
Effects Analysis (FMEA) to determine the
probable causes for the return of the
remaining twenty one percent (21%) of
engines that were returned with less than
25,000 operating hours and had reported
symptoms or faults believed to require
overhaul or significant repair.
Engine Returns > 25,000 Hours
11%
69%
11%
9%
Site Related
Product Related
Scheduled
Operator Convenience
Figure 2. Engine Returns with More than
25,000 Operating Hours
Engine Returns < 25,000 Hours
17%
38%
20%
12%
Returns were categorized into five major areas
segregated by reported reasons for return
(see Figure 3). The leading cause for return
resulted from the findings of borescope
inspections, followed by vibration, mechanical
noise, oil systems and an additional reason
given as “other”.
Mechanical Noise
Oil
Borescope
13%
Vibration
Other
Figure 3. Engine Returns with Less than 25,000
Operating Hours
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
It was evident from the analysis that many of the returns resulted from environmental conditions
such as the quality of air, fuel, oil, and unique site operating parameters. It also become
apparent that many of these causes were predictable, if not preventable, had the appropriate
corrective action been taken in time.
As an additional step to better understand where to focus in terms of package system
diagnostic development, Solar also completed an analysis of field service call out reports. Not
only did this provide an indicator of where troubleshooting expertise was most needed, it also
highlighted the importance of easy access to the current package documentation, including
Service Bulletins, design details and packages specifications.
To deliver on the commitment to assist in the safe extension of time between overhaul (TBO),
Solar Turbines identified the key engine parameters that need to be monitored, trended and
controlled.
Solar believes that a decision to extend TBO beyond the traditional goal of 30,000 hours is the
result of a process, not the outcome of an event. Customer experience and overhaul data
suggest that with full-load operation, a TBO of 30,000 hours is typical and, with the proper
attention to operating conditions, extended service times can be obtained. Customer
experience also indicates that, when operating at part load under good conditions, overhaul
cycles well beyond 30,000 hours can be achieved. More experience has been accumulated with
conventional combustion systems than with SoLoNOx (dry low emission) engines, which
represent a more complicated case; however, overhaul data and customer experience indicate
that operating life extensions are achievable with all Solar's products.
Guiding Principles
Once Solar started to evaluate the higher-level requirements to reduce life cycle cost, increase
availability and extend operating cycles, a larger set of site-specific parameters came into play.
Solar found that the impact of each factor varied significantly from site to site and little
information existed to quantify or measure their impact.
Availability, for example, is dependent upon a total support network starting from the operating
environment and extending back through the supply chain. Availability values vary from the
80% to the high 90% range for the same product. Variations in contributing factors such as the
formula itself, administration, maintenance, skills, spare parts and logistics all combine to have
an enormous impact on overall equipment and site performance.
Combining all of the analyses gave rise to three high level but significant conclusions:
1. Effective Machinery Management requires a thorough understanding of the operating
environment and application, and must have the ability to influence it.
2. The ability to refine and develop new diagnostic capabilities requires in-depth product
design knowledge as well as the specific application.
3. Life cycle cost reduction and value creation requires a comprehensive approach to
Equipment Health Management utilizing a measurable process and access to a broad
range of systems, skills and experience.
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
Based on these findings, Solar set core objectives for Insight System and continues today with
these same guiding principles:
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Embedded and automated application of knowledge
Centralized data management and decentralized support
Customized solutions that complement customer operations
Ability to quickly turn data into information
Processes that drive actions and systems
Measurable results
Advanced diagnostics and condition assessments combined with optimized maintenance are
expected to result in the ability to run for extended periods and lengthen overhaul cycles.
Figure 4. Enabling Capabilities
InSight System Enabling Capabilities
The cost of an outage and call out can be significant when lost production and customer related
costs are also taken into consideration. A field service technician can arrive at site only to
discover that the reported symptom and expected fix are incorrect. This invariably leads to
delays in getting the right information, parts and tools required to remedy the problem.
Increased up-time requires rapid response capabilities and a proactive response. Diagnostics,
combined with remote troubleshooting and accurate technical information, are targeted to meet
this objective.
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
Remote Monitoring and Diagnostics
Remote Monitoring and Diagnostics (RM&D) is an integral part of InSight System. Live data
monitoring and remote viewing is available through the web-enabled version of Solar’s TT4000
display and monitoring system. This allows a user to view real-time replications of the TT4000
display screens via the Internet with read-only access.
In addition to real-time access to display screens, the system also permits access to, and
downloading of, trigger and event logs for detailed remote troubleshooting evaluation and
decision support.
The most powerful aspect of the RM&D system is the automated analysis of operating data
within Solar’s centralized monitoring and diagnostic data management system. This system
uses data reduction techniques, statistical tools and algorithmic subroutines to provide the
advanced diagnostic information needed to evaluate equipment condition. The diagnostic
system evaluates calculated variables compared to both theoretical and practical fixed limits
and statistical mean-variance criteria. The system can detect when process variables approach
predetermined “control” limits, or if the process is changing in an abnormal fashion. These
smart diagnostic functions are typical of sound engineering analytical techniques that a Solar
engineer would employ when troubleshooting or evaluating equipment prior to making any
maintenance, repair or overhaul decisions. Reports generated by the system include, but are
not limited to:
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Unit summary report
Unit alert report combustion analysis
Vibration analysis
Fuel system analysis
Lube oil system analysis
Driven equipment assessment
Package equipment assessment
Performance report
The system is a fully configured and integrated solution and is designed to be easy to enable
with a simple Internet connection, providing secure access from anywhere in the world. Remote
diagnostic file downloads are automatically processed and posted through Internet servers. The
filtering and normalizing of data that once took days can now be completed in minutes. Data is
filtered to facilitate easier isolation of adverse trends.
Mathematical algorithms are then applied automatically that look for specific or multi variable
trends and changes that could indicate a negative trend or condition. The resulting information
is then plotted and posted to InSight System for daily updating of customers reports.
Continued development is planned for overall system diagnostics to take into account the
increasing complexity of the equipment and variations in operating environments. This
development work also provides an opportunity for Solar to disseminate some of the lessons
learned from our global fleet data and ensure that the appropriate diagnostics are available
when new products or upgrades are introduced.
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
Solar has also developed the ability to link diagnostic outputs to automatically drive
maintenance events and are closing the loop so that when a maintenance event such as a
water wash or filter change occurs, it is posted to the diagnostic plot for notification of the event.
LiveView and Remote Troubleshooting
The LiveView function in the InSight System provides remote troubleshooting features that
include real-time graphical imaging and remote viewing of operations in progress. This feature
reduces the requirement to send a field engineer to site through the ability to remotely monitor
the control panel and provide immediate phone based technical and troubleshooting support.
In many cases detailed history files and trigger logs are required to analyze a significant event.
LiveView provides the ability to download these high-resolution data files over the Internet for
advanced analysis.
This real time site information aids in the decision making process by facilitating more confident
and objective decision-making. The ability to get simultaneous input from experts in other
locations via the web and telephone allows for timely and accurate technical support and
reduced downtime.
Certified Condition Assessment
The OEM certified condition assessment is limited to what Solar believes is the minimum site
related Information and intervention required. This assessment, combined with the diagnostics
data will enable Solar to provide our customers with key information and health
recommendations required to successfully extend operating intervals
Effective Equipment Health Management is more than just a function of remote monitoring and
diagnostics. The operating environment, the skills of the operator, and the maintenance history
significantly impact reliability and availability. OEM certified condition assessment visits are
conducted to determine equipment physical condition and operating environment.
The reports generated by these visits make recommendations for extended operation and/or
corrective actions. These visits, combined with remote monitoring and diagnostics support, and
condition-based maintenance practices, provide the means to extend turbine life safely and
manage risk
Information Management
Owners and operators need accurate and reliable information to optimize assets, reduce costs
and meet aggressive operating goals. InSight System gives owners, operators and
maintenance/support personnel immediate access to accurate and reliable information such as
Operations and Maintenance manuals, service bulletins, project photographs, illustrated parts
listings and technical documentation.
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
Collaborative Communications
Accessible and structured information sharing systems have been designed into InSight
System. Collaborative Workspace is a web-based documentation management tool for
communication and information management. It permits organizationally and geographically
dispersed personnel, from both the customer and Solar, to work together in a highly efficient
manner.
The Collaborative Workspace is a consolidated document management system featuring file
management, document “check-in” and “check-out” (with revision control, timelines, project
plans/resources, workflow, and drawing editing and management with embedded auditing
capability. It allows Solar’s Fleet Manager, customers and designated support personnel to
collaborate over a secure web connection using their Internet browsers.
The system has the ability to stage the entire lifecycle of a project, providing essential
documentation to operations, maintenance, and management staff wherever the web reaches.
Typical documents stored and managed include fleet data and statistics, management reports,
technical reports, key performance indicators, schedules, drawings, software, test reports and
equipment assessments.
Maintenance Management
Solar also has significant Maintenance Management capabilities, which includes the
implementation of best practices and equipment-specific templates within a computerized
maintenance management system. InSight System facilitates a shift from time to conditionbased maintenance by reducing risk and increasing life-cycle benefits.
These practices are adapted based on unit criticality, component reliability and operating
conditions. Once the maintenance task is completed, the data is correlated to improve the
accuracy of future trends and activities.
Quite often a completed maintenance event may impact a trend. These events need to be
correlated and documented, so that they do not drive unnecessary analysis or actions. Our
vision is to ultimately provide a management system that is initiated during the manufacturing
phase and continues to track data and provide information over the entire product life cycle.
Technical Support and Focal Point
A dedicated Fleet Manager will co-ordinate and manage all of Solar’s services in support of the
customer equipment and act as the focal point for operations and maintenance staff. The Fleet
Manager will have a detailed knowledge of Solar’s products, worldwide organization and
technical support processes. This focal point will drive significant benefits in operational and
business efficiency. Major activities will include:
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Single point contact for customer technical staff
Establish maintenance programs and schedules
Provide technical support
Technical issue resolution and tracking
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
The program is structured to allow a Fleet manager to manage multiple pieces of equipment, at
a variety of sites from any location. Individual unit site or operational needs, such as inventory
management, training or equipment optimization and application reviews, can be easily
integrated into this base program
Health, Safety and the Environment
Solar is committed at all levels to manage our business in accordance with our core values; “No
harm to people, No damage to assets, No harm to the environment”. Solar believes that a
commitment to Quality, Health, Safety and the Environment is the product of individual and
group values, attitudes, and competencies.
Solar’s HSE Management System provides leadership and a systematic approach to managing
"loss control" that ensures HSE integration into our business. Using an auditable and structured
management system that meets or exceeds worldwide standards such as ISO 9001 and 18001,
Solar manages its business to meet or exceed industry best practices, international regulatory
requirements and customer expectations.
InSight System provides a seamless integration of our HSE management system into the
customer’s operations.
Equipment Health Management
With customer input and data drawn from Solar’s vast field experience, dynamic, site-specific
models were developed to help optimize operating and maintenance practices. Equipment
Health Management is the result of these efforts and the application of the technology, people
and processes to bring quantifiable and demonstrable added value to customer operations.
Some of the key functions of Equipment Health Management are:
1. OEM Certified Condition Assessments
2. Solar Technical Focal Point
3. Unlimited Remote Troubleshooting
4. Scheduling and Planning
5. Technical Information Management
6. Condition Monitoring, Diagnostics and Reporting
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.
SUMMARY
Over the past four years Solar has focused heavily on customer operating objectives and has
put in place several enabling technologies. What started off as remote monitoring and
diagnostics has evolved into a comprehensive machinery management system called InSight
System.
Along with the development of the system, Solar is undergoing a significant change to its
support structure, processes and commercial approach as Solar brings new value based
services to customers. InSight System’s capabilities, processes and programs will be easily
accessible and designed to readily turn data into the needed information. This will allow for
immediate proactive actions, problem diagnoses, dispatch of field engineers, expediting of
service parts, mobilization of engine repair teams, or notification to the operator of a potential
problem along with the recommended preventive action.
InSight System will provide for turbomachinery management solutions enabling profitable
growth for customers by increasing life cycle value and decreasing life cycle costs. InSight
System combines the smart tools, technologies, processes and people to allow for operational
excellence and immediate decision support. It is designed to be highly flexible and easily
customized to exact customer needs as the complexity of equipment increases to meet more
stringent safety, production and economic goals.
InSight System ensures a comprehensive approach to machinery management to meet the
demands and realities of oil and gas production and power generation. This system
supplements and enhances existing customer expertise and abilities by leveraging Solar’s
technical support capabilities to maximize equipment performance and customer profitability.
Solar’s Insight System enables effective management, enhanced equipment assessment
capabilities, ability to leverage Solar’s worldwide fleet experience and apply best practices and
new technology to worldwide operations.
Presented at the 16th Symposium on Industrial Application of Gas Turbines (IAGT)
Banff, Alberta, Canada - October 12-14, 2005
The IAGT Committee is sponsored by the Canadian Gas Association. The IAGT Committee shall not be
responsible for statements or opinions advanced in technical papers or in Symposium or meeting discussions.