Method for graphical interpretation of technical condition of gas pumping units in process parameter control system

Abstract

FIELD: data processing.SUBSTANCE: method for graphical interpretation of the technical condition of gas pumping units (GPU) in the integrated automated process control system (IAPCS) designed to monitor the main operating parameters of the units, assess the condition of the flow path of the high-pressure gas turbine (HPGT) to determine the need for flushing in the form of deviations of the operating parameters from the formula values, and the coefficient of technical characteristics (CTC), implemented using a chatbot with generative AI that digitizes graphs for determining the operating parameters presented in equipment passports on paper media, for subsequent approximation of points by a polynomial in order to obtain an equation describing the digitized curve required for integration into the IAPCS, allowing for the automatic calculation of the main GPU parameters, the calculation of deviations of the main gas turbine unit operating parameters from the formula values to determine the need for flushing the HPGT, the calculation of the CTC of the gas turbine unit and the centrifugal blower, the calculation of the CTC of the gas turbine unit concerning fuel gas and displaying the initial and calculated information on the IAPCS screen for remote monitoring of the operating parameters of the units and the operational assessment of the GPU condition in real time.EFFECT: ensuring the accuracy of determining the operating parameters of the gas pumping unit.1 cl, 4 dwg

Description

[0001] The invention relates to the field of data processing using electrical devices, in particular the process of graphical interpretation of the operating parameters of gas pumping units (GPU) with a gas turbine engine (GTE) DG90 and display in an automated information system for controlling process parameters (IACS TP) to improve the efficiency of its operation.

[0002] Parametric diagnostics of the gas turbine unit determines the operating indicators of the units, such as: the efficiency of the gas turbine unit (GTU), the efficiency of the centrifugal supercharger (CS), the technical condition factor (TCF) of the GTU, the TCF of the CS, etc.

[0003] Determination of the GPU performance indicators is carried out on the basis of [STO Gazprom 2-3.5-253-2008 "Quality control of equipment during delivery and operation. Gas pumping units with a gas turbine drive. Air-cooled gas units"], which regulates the methodology of thermal engineering and gas-dynamic tests.

[0004] The purpose of data processing is to assess the compliance of the thermal and gas-dynamic characteristics of the gas compressor units with technical specifications. Based on the assessment of the entire fleet of units, a rational choice is made for distributing the workload of compressor shops and stations. This assessment is also used to monitor the quality of repairs performed.

[0005] A method for calculating the operating parameters of a gas-turbine unit is known based on [STO Gazprom 2-2.3-250-2008 “Methodology for determining the output indicators of the gas-turbine unit GPA-C-8, GPU-10, GPU-16”], which includes methods, an algorithm, stages, parameters and the procedure for carrying out calculations to obtain the characteristics of the actual technical condition of the gas-turbine unit based on the use of the results of measurements of their output indicators by standard measuring equipment.

[0006] The disadvantages of this method for assessing the conformity of the thermal and gas-dynamic characteristics of gas compressor units (GCUs) include the high sensitivity of calculations to errors in the GCU operating parameters. Also, when conducting thermal tests according to the standard, it is necessary to change the GCU operating mode (and therefore the compressor shop (CS)), which is not always possible due to the operating conditions of the main gas pipeline. To determine the contamination parameters of the gas-air duct (GAC) flow path, it is necessary to perform a series of calculations (if the GCU automatic control system does not have specified parameters) and select the speed according to the formula values, which is not always possible. Conducting tests and determining the contamination parameters of the GAC flow path requires specialists with a certain level of experience and knowledge.

[0007] When assessing the technical condition of a gas compressor unit, it is important to correctly determine the rated efficiency. During post-repair testing, certain operating modes of the gas compressor unit (GCU) occur where the GCU operates below its nominal capacity, leading to excessive fuel gas consumption. Situations often arise where the final GCU efficiency rating after repair differs between calculations performed by the service center (STO) and when manually determining the GCU efficiency using the GCU operating parameter charts provided in the equipment data sheets on paper. This raises questions about the actual technical condition of the GCU or the specific operating conditions of the unit.

[0008] The "manual method" is labor-intensive and leads to errors. Incorrectly determined CBP efficiency gives an incorrect picture of the gas compressor's technical condition, which negatively impacts the rational distribution of compressor station loads and reduces the energy efficiency of the gas transmission system.

[0009] The objective of the invention is to implement a method for monitoring the main parameters of a gas compressor unit, assessing the condition of the flow part of a gas turbine unit to determine the need for flushing in the form of deviations of operating parameters from formula values ​​and the technical condition coefficient in the information system, ensuring a reduction in costs and the accuracy of determining parameters by reducing errors.

[0010] The technical result of the invention is to ensure accurate determination of gas compressor unit operating parameters, promptly assess the unit's condition in real time, and ensure that the gas compressor unit is operated according to its technical condition. Real-time monitoring of the gas compressor unit's condition enables prompt action to restore the equipment to a satisfactory condition, halt the development of malfunctions, and ensure energy-efficient operation of the gas transmission system, thereby reducing costs associated with excess fuel gas consumption.

[0011] The technical condition factor is the key indicator of energy consumption (fuel gas) during gas compression. Deviations in gas turbine operating parameters from standard values ​​are the key indicator for assessing the condition of the gas turbine's flow path and determining the need for its cleaning. Timely cleaning of the gas turbine's flow path reduces energy consumption (fuel gas) during gas compression. Visualizing gas turbine unit operating parameters can significantly reduce costs and improve safety by ensuring energy-efficient and reliable operation.

[0012] The stated problem and the stated technical result are solved and achieved by using a graphical interpretation of the gas compressor unit's technical condition in the process parameter control system, eliminating the traditional "manual method" of determining parameters using formulaic dependency graphs with a pencil and ruler. This method inevitably leads to errors that accumulate during calculations for each unit operating mode.

[0013] When assessing the technical condition of the CBP, it is important to correctly determine the rated efficiency. During post-repair testing, there are operating modes of the gas compressor unit (GCU) in which the CBP operates below its nominal capacity, leading to excessive fuel gas consumption. The CBP efficiency is calculated using the formula:

[0014]

[0015] where – actual nominal efficiency;

[0016] – nominal passport efficiency.

[0017] For example, the calculation yielded an actual nominal efficiency of 75.9, while the nominal rated efficiency is 83.0. Accordingly, using the formula, the calculated efficiency of the central heating system is 0.91, which, according to STO Gazprom 2-3.5-253-2008, corresponds to a "Satisfactory" rating. This raises the question of the actual technical condition of the gas pumping unit or the specific operating conditions of the unit.

[0018] To resolve this issue, the graphs for determining the operating parameters of the fuel gas pump (CBN), presented in the equipment datasheets on paper, are used. The rated efficiency in this mode, determined manually using the efficiency versus fuel gas flow graph, is 78.0. Therefore, the determined efficiency coefficient of the fuel gas pump (CTP) is 0.97, corresponding to a "Good" rating.

[0019] After a gas turbine engine overhaul, the maximum deviations of its actual performance indicators from the specified values ​​are determined and must be monitored during operation. For example, a drop in air pressure downstream of the high-pressure compressor (HPC) indicates a reduction in power, while an increase in temperature downstream of the low-pressure compressor (LPC) indicates unacceptable contamination of the flow path, the need for cleaning of which is assessed based on these deviations. These values ​​are determined using paper charts, which are also labor-intensive and inaccurate. For this purpose, the graphs of the dependences of the gas turbine engine performance indicators are also digitized. The resulting deviations, based on these charts, are entered into the engine's data sheet and used during subsequent operation to assess its condition.

[0020] Due to the high sensitivity of calculations to errors in the parameters being determined during thermal and gas-dynamic tests according to STO, the graphs of the dependences of the polytropic efficiency of the central heating system on the fuel gas flow rate were digitized, as well as the dependences of the gas turbine operating indicators, such as the dependences of the excess air pressure behind the HPC, the temperature of the combustion products behind the low-pressure turbine (LPT) and the rotor speed (RSR) on the HPC rotor speed.

[0021] Graph digitization is performed in four stages: scanning, processing, digitization, and approximation. After scanning, the image is adjusted to full contrast, sharpness is increased, and the graph line is highlighted in bright red. For digitization and approximation, a chatbot with generative artificial intelligence (AI) is used, which generates an xlsx file or a text list of X and Y coordinates. The chatbot with generative AI approximates the points with a polynomial and calculates the coefficient of determination, showing that our mathematical model explains 99.9% of the variable's variation, which is impossible to achieve manually.

[0022] The polynomial data is used in the process automation system (PAS). The PAS includes a set of sensors that interact with the gas processing unit (GPU) and collect and transmit information about its operating parameters to the lower level of the system, which is designed to obtain operating parameters, store them, and transmit them to the upper level of the system, which includes visual monitoring functionality for operating parameters.

[0023] The disadvantage of the existing automated process control system is the lack of operational and continuous monitoring of the technical condition of the gas pumping unit in real time.

[0024] The IASU TP, taking into account the modifications, provides remote monitoring of operating parameters in real time and improves the safety of gas compressor unit operation based on the actual technical condition, significantly reducing costs by ensuring energy-efficient and reliable operation of the units.

[0025] The technical result is achieved due to the fact that in the automated process control system containing a set of sensors connected to the gas turbine unit and transmitting information about the operating parameters to the lower level, which has the functionality of receiving operating parameters from the sensors, storing them and transmitting them to the upper level of the system, which in turn has the ability to visually monitor the operating parameters, a form for entering the form (passport) characteristics of all gas turbine units, the functionality of graphical interpretation of the technical condition level of the gas turbine unit calculated using approximated functional dependencies is implemented.

[0026] The lower level of the automated process control system (APCS) has a mathematical processing unit containing the nominal values ​​of the parameters programmed into the calculation algorithm. This mathematical processing unit is linked to the operation history database unit, which stores the received data, and to a comparison unit, which compares the nominal parameters with the operating parameters. Based on the comparative analysis results, the comparison unit interacts with the automation unit connected to the gas compressor unit, which generates control signals to the gas compressor unit based on the signal from the comparison unit. The comparison unit, in turn, is linked to the warning log unit, which records and processes signals received from the comparison unit. The upper level is a graphical interface comprising the following modules:

[0027] - The operating parameter trend monitoring module is a data visualization system in the form of trends, demonstrating changes in operating parameters online or over a selected time interval. The trends clearly display the maximum permissible values ​​of all monitored parameters. If any parameter reaches its limit, the system automatically records this event and makes a corresponding entry in the warning log.

[0028] - The dependency trend module displays operating parameter dependency trends in real time or over a selected time interval. The dependency graphs display lines representing the formula values ​​of operating parameters. The resulting dependencies for the formula values ​​of parameters with warning and emergency limits are presented on the remote user interface as lines on approximated graphs, while the operating parameters during gas compressor operation are displayed as dots. It is also possible to view actual parameter values ​​for the previous period. The dependency graphs are expressed as polynomial equations obtained using a chatbot with generative AI.

[0029] - the warning log module is a system component that provides the display of information about reaching the maximum permissible values ​​of operating parameters, as well as recording the period of time of operation at maximum permissible values;

[0030] - The GPU mnemonic diagram module is a system component that provides a real-time display of the operating parameters of the selected unit on a mnemonic diagram with the ability to update the data. The user selects the desired unit from the list of GPUs connected to the system. The displayed mnemonic diagram for the selected unit displays the values ​​of the most significant operating parameters. The data is continuously updated on the remote user interface.

[0031] - the gas turbine engine formula values ​​module is designed to enter the passport values ​​of the gas turbine engine performance indicators. It is necessary because the formula values ​​are individual for each engine and also change after each factory repair;

[0032] - The GPU performance module is a window displaying the technical characteristics of the GPU on the graphical interface with color-coded ranges based on the criteria for determining the technical condition class. This GPU performance block, displayed on the remote user interface, includes data including the effective power of the gas turbine, the effective efficiency of the gas turbine, the specific fuel gas consumption, the actual nominal power of the gas turbine, the effective efficiency of the fuel gas pump, the actual nominal efficiency of the fuel gas pump, the GTU efficiency coefficient, the fuel gas efficiency coefficient, the fuel gas efficiency coefficient for fuel gas, the actual nominal fuel gas consumption, and deviations of the GPU operating parameters from the specified values. The calculation of the main parameters is based on these values. Formulas programmed in the calculation algorithm are used to determine these values.The determination of the values ​​of deviations in the operating parameters of a gas turbine engine is carried out using formula graphs of dependencies and is carried out on the basis of determining the formula value of the parameter corresponding to the value of the given operating parameter;

[0033] - the GPU ranking module is a window displaying information on the ranking of GPUs for making decisions on removing the GPU for repair or further operation, as well as prioritizing the start-up of units, taking into account their current technical condition and efficiency.

[0034] A key element of the operation and maintenance of gas turbine units with a DG90 engine is continuous monitoring of their operating condition. Detecting emerging defects and preventing them at an early stage, as well as making timely and correct decisions to eliminate them before emergency situations arise, with sufficient information, will significantly reduce costs, improve safety, and ensure energy-efficient and reliable operation of the units by saving fuel gas.

[0035] Data collected during regular monitoring of the technical condition of gas compressor units (GCUs) allows us to predict their future performance and determine the actual remaining service life before potential failure. This comprehensive analysis enables the development of effective measures to optimize operating modes, identify potential sources of problems, and propose specific solutions for their elimination. This analysis can be used to formulate recommendations for equipment modernization and maintenance planning. Furthermore, it enables the identification of potentially hazardous areas that could trigger emergency situations and the proactive implementation of preventive measures to prevent them.

[0036] The IASU TP, taking into account the modifications, includes the following functions:

[0037] - graphical interpretation of the operating parameters of the gas pumping unit;

[0038] - assessment of the actual state of the gas pumping unit in real time;

[0039] - ranking of gas-powered units by technical condition.

[0040] The claimed invention is explained by images:

[0041] - Fig. 1 shows the general diagram of the modified IACS TP;

[0042] - in Fig. 2 - module of trends of dependencies of GPU parameters;

[0043] - in Fig. 3 – module of formula values ​​of the gas customs declaration;

[0044] - in Fig. 4 - the GPA indicators module, in the form of a graphical interface.

[0045] The APCS allows for the accumulation, storage, and transmission of data from all gas processing units (GPUs) in real time and the display of information on a graphical user interface. Furthermore, any GPU connected to the system can be selected for remote monitoring.

[0046] Sets of measuring sensors are installed on the gas control unit (Fig. 1) in controlled areas. These sensors transmit signals to the lower level of the system, where data is collected. The information is then sent to a mathematical processing unit, which converts analog signals from the sensors into digital ones.

[0047] After commissioning the gas compressor unit, nominal parameters are entered into the calculation algorithms of the mathematical module. Since atmospheric conditions are not constant, some of the nominal parameters are converted to standard conditions.

[0048] During gas compressor operation, the sensors transmit information about current parameter values, which are considered operating parameters. The obtained operating parameter values ​​are sent to the lower level of the system, which has the functionality to receive, store, and transmit data to the upper level.

[0049] Alarm limits and maximum permissible value limits are set for each operating parameter. The data received from the sensors is then sent to the comparison unit. This data serves as the basis for remote monitoring and trend control of the parameters.

[0050] The comparison unit analyzes incoming data from the gas compressor unit. The system compares operating parameter values ​​with nominal parameters. Based on this comparison, the degree of deviation of incoming parameters over a specified period is calculated. If a parameter deviates, a signal is generated indicating the unit's operating status.

[0051] In the event of a deviation or exceeding of the operating parameter values ​​of the maximum permissible values ​​or emergency limits, a signal about this event is sent to the automation unit, which generates a control signal to the engine units.

[0052] Next, the specified signal from the comparison unit is sent to the warning log unit, which records the event and provides warning signals for deviations of operating parameters from emergency limits and maximum permissible values. The generated data is then transmitted to the upper level of the system, where the specified information is visualized on the graphical interface.

[0053] Operating performance data is accumulated and stored in the database block. This block allows for the collection and storage of GPU operation data over a specified period of time in various operating modes. This enables analysis of the impact of operating modes on the reliability and service life of the GPU.

[0054] Data is transmitted via the data collection and transmission server to the upper level of the system, which includes visual monitoring of operating parameters. Received and processed data on the gas compressor unit's operating parameters is displayed on the user interface in modules. A specialist can switch between modules in real time to visually monitor the parameters and assess the gas compressor unit's condition to determine the necessary measures for further operation.

[0055] The functionality is provided for generating a custom group of trends in any time interval for in-depth analysis of the gas compressor unit's condition. Based on the analysis of each parameter, a specialist makes a decision on whether to continue or discontinue further operation.

[0056] The IACS TP with improved functionality allows engineering centers supporting the operation of equipment to accumulate an electronic database, conduct a comprehensive analysis of the obtained results, and subsequently improve and update the IACS TP operating algorithms.

[0057] The operation of the modified IACS TP is examined using examples.

[0058] The system interface allows the user to access the GPU indicators module. A specific GPU can be selected from the list (Fig. 3). The selected unit's window then displays operating parameters, including deviations, such as the reduced combustion product temperature downstream of the LPT. The window features color-coded ranges based on the criteria for determining the technical condition class. Operating parameter In this particular case, it is at the maximum permissible limit of > +25°C. Exceeding the operating parameter within this window is a diagnostic indicator that triggers a warning alarm. Such events may indicate, for example, contamination of the main water supply system's flow path. This is how a preliminary assessment of the technical condition is formed.

[0059] The trend control module also allows you to display the time trend of operating parameters for a certain period before the parameter reaches the maximum permissible value, which allows for a retrospective analysis of the operation of the units.

[0060] In the dependency module, operating points are displayed on coordinate planes, such as the dependence of the reduced combustion product temperature downstream of the LPT on the rotor speed of the HPC. Approximate formula function lines obtained during engine testing at the manufacturer are plotted on the coordinate plane. By analyzing the movement of the operating point within the parameter's permissible limits, as well as the historical position of this operating point and its speed within the permissible limits for the current specific time period, a specialist can determine how much time remains before the parameter reaches warning and emergency limits and make a decision on further operation.

[0061] Thus, the implementation of the proposed method for graphical interpretation of the operating parameters of a gas pumping unit with a DG90 gas turbine engine in the APCS allows for remote monitoring of the operating parameters of the units, promptly assessing the state of the gas pumping unit in real time, significantly reducing costs by saving fuel gas, and ensuring safe operation of the equipment based on its actual technical condition.

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