Information-Software Complex to Monitor the GTU’s Technical Status

To switch to resource-saving “condition-based” operation of compressor station equipment, since 2000 CosmosNefteGaz has been working on development of non-contact torque meters. These meters enable determination of power at the shaft of gas-compressor units (GCU) of various types in real time in the course of GCU commercial operation. The meters may be used to equip test stands of both overhaul plants and manufacturers of gas-turbine units (GTU) and blowers.
These meters underwent all tests as instrumentation for torque measurement; they have certificates of conformance, are approved by the RF Gosgortechnadzor (State Committee for Industrial and Mining Safety Supervision) for application in the oil-and-gas sector, and are also accepted for use by major companies. Novel technical solutions included in the meter design are protected by patents.
To continue working on introduction of torque meters to enable the GCU diagnostics, it is essential to provide for methodological support by the major companies. Together with vibration-based diagnostics, torque and power measurement should be included in the set of standard methods for monitoring the GTU’s technical status, especially for newly designed units. It is necessary to develop appropriate techniques and regulations. Each unit should be equipped with its own torque meter, which will enable continuous monitoring of the unit status at all stages: at the start of operation, during the operation, before and after maintenance.
Another important area is the torque meter application in automated systems used at gas-compressor stations. Direct torque measurement at the GCU shaft provides for very accurate determination of the actual unit capacity, with the error not exceeding 1 percent. However, this parameter only is not sufficient to evaluate the technical status of a GCU. From the diagnostics viewpoint, the most important operational parameter of a GCU is the coefficient of the unit’s technical status (CTS), which is determined as the ratio of actual capacity reduced to standard conditions to the rated capacity of GCU. The real time CTS determination, e.g. on an hourly basis, requires the use of measuring systems based on computers and different-type modern sensors. Thus, efficient application of torque meters is possible in this particular area.
It would be also necessary to create an information-software complex (ISC) designed for assessment of the GCU’s technical status. It is supposed that the ISC will be operated at the main control board of the compressor department. Using the ISC, the operating personnel of the compressor department will be able to get an on-line assessment of the GCU’s as often as it is required (hourly, daily, monthly, etc.). Analysis of the GTU’s technical status at the compressor department will make it possible to switch to “condition-based” GTU maintenance. In addition, the ISC will allow optimizing operating modes for several units of the compressor department, which are running simultaneously, thus reducing the fuel gas consumption.
It is suggested to run the ISC as a part of the system for optimization of fuel gas consumption, which functions at the compressor department level. The system should include the following:
Torque meters of BIKM M-106M type installed on the shaft of each GCU of the compressor department.
A set of devices (sensors and converters) for measuring of operating conditions and gas-dynamic parameters.
A software suite for parametric control and optimization of the compressor department operation.

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