Online Fatigue Monitoring and Predictive Analytics for Improved Flexibility of Plant Operation. Dr.Tomasz Kaminski

Transcription

1 Online Fatigue Monitoring and Predictive Analytics for Improved Flexibility of Plant Operation Dr.Tomasz Kaminski

2 1. Challenges 2. Elements of Condition-Based Maintenance 3. Use of Online Systems for Condition Monitoring 4. Potential of Modern Calculation Methods 5. Predictive Analytics for Trend Forecast

3 Challenges Overview Highly flexible modes of operation More frequent start-ups and shutdowns, faster start-ups higher fatigue Use of new materials Flexible scope for internal inspections possible Ordinance on Industrial Safety and Health, Pressure Equipment Directive Adjusting the set of regulations Partly significant differences between TRD and DIN EN Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 3

4 Lifetime consumption [%] Challenges Increased Low Cycle Fatigue 140 Past Future total lifetime consumption creep damage low cycle fatigue , , , ,000 Operating hours [h] Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 6

5 Elements of Condition-Based Maintenance according to VGB guideline 506 Design Documentation Diagnostics online Diagnostics offline Validated condition of the monitored components Responsibilities of the operating company: Ensuring the safe mode of operation Defining test intervals (shorten or extend) Defining the inspection effort Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 7

6 Potential of Modern Approaches by Combining Online and Offline Tools COOP* (Cycle Optimized Operation of Plants) Tools / Methods 1. Reduction of conservativities Precise assessment of stress Exploiting reserves 2. Establishing safeties Ensuring safe operation Preventing failure Planning inspection intervals FEM, CFD analysis XFEM analyses to estimate crack positions and shapes Damage tolerance analysis to determine inspection intervals Online monitoring systems to achieve a precise consideration of the actual mode of operation and to reduce the calculation effort. * developed by Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 8

7 Systems for Condition Monitoring SR1 For calculating the residual lifetime of highly stressed, thick-walled boiler components designed according to time-dependent material characteristics. SR::SPM Online monitoring system to determine the residual service life of steam pipes based on force and displacement measurements. temperature presure Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 9

8 SR1 Display of Results Overview of Lifetime Consumption Component Operating Operating hours Failure Lifetime Consumption Creep damage Low cycle fatigue Total Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 14

9 Where is Potential for a Flexible Operation? Superheater Header 4 Superheater Header 4 Pressure Temperature Temperature difference Total lifetime consumption Analyzing the mode of operation is difficult due to the complex data Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 15

10 Creep Damage Detecting Unplanned States Continously Trend of the creep demage [%] Trend of the creep gradient [%/h] Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 16

11 Low Cycle Fatigue Detecting Unplanned States Continuously Trend of the damage due to low cycle fatigue [%] Trend of the low cycle fatigue gradient [%/h] Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 17

12 Forecast of Low Cycle Fatigue Base Load vs. Energy Turnaround Base load Energy turnaround The additional consumption can be economically assessed and one can react with a more moderate mode of operation Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 18

13 Summary Features and benefits of online diagnostics: Documenting the mode of operation Calculating the total lifetime consumption continuously Detecting highly stressed parts for inspections Minimizing the required measurements Identifying the potential for a flexible power plant operation Current projects Nearly all newly built power plants in Germany are equipped with SR1. SR1 is the part of all PADO projects in India Lifetime Monitoring of Thick-Walled Components - Projection and Trend Analysis for a Flexible Power Plant Operation 19

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