a. Type of gases and fluids used in the various processes. The equa-tion of state and other thermodynamic relationship, which govern these gases and fluids.
b. Type of fuel used in the prime movers. If the fuel analysis is available including the fuel composition and the heating values of the fuel.
c. Materials used in various hot sections such as combustorliners,turbinenozzles, and blades. This includes stress and strain proper-ties as well as .arson-Miller parameters.
d. Performance maps of various critical parameters such as powerand heat consumption as a function of ambient conditions, pres-sure drop in filters, and the effect of backpressure. Compressorsurge, efficiency, and head maps.
3.
Determine the instrumentation, which exists, and their actual loca-tion. .ocation of the instrumentation from the inlet or exit of the machinery is important so that proper and effective compensation may be provided for the various measured parameters. In some cases additional instrumentation will be needed. Experience indicates that older plants require 10-20% more instrumentation depending upon the age of the plant.
4. .nce
the data points have been decided, limits and alarm must be set.This is a long and challengingtask, as the limits on many points are
not given in the operation manuals. In somecases, the criticality of the equipment may necessitate that the alarm threshold on certain points be lowered to give early warning of any deterioration of the system. It should be noted that since this is a condition monitoring system early alarm warnings are in most cases desirable.
5. Types of reports and summary charts should be planned to optimize the data and to present it in the most useful manner to the plantoperations, and maintenance personnel.
6. The types of D-CS and the control systems available in the plant. The protocol of these systems and their relationships to the condition monitoring system. The slave or master relationship is important in setting up the protocols.
7. Diagnostics for the system requires noting any unusual characteristicsof the machinery, especially in older plants, which have a history of operation inspections and overhauls.
8. Costs of operations such as fuelcosts, laborcosts, down timecosts, overhaulhours, interest rates are necessary in computingparameters such as time of majorinspections, off-line cleaning, and overhauls.
.lant .ower Optimization
.n-line optimization processes for large utility plants is gaining tremen-dous favor. Plant optimization is gaining importance with Combined Cycle Power Plants as these plants are operated over a wide range of power in day-to-day operation. .n-line optimization may be defined as the place whereeconomics,operation, and maintenance meet.At firstsight, it may be imagined that process integration is not connected to condition managementor inspection, and this has been the case in the past. However, there is every incentive for complete integration of all these production-related techno-logies, since the condition monitoring of the various components in a plantare upgraded constantly, thus the operational curves with degradation of each unit are no longer stagnant.
Process integration was developed initially as a means of optimizing the design of chemical and petrochemical process plants. Process optimization is still only a pre-construction or pre-production exercise. This is surprising because many process plants are designed for batch manufacture of a rangeof products, each of which will require continuously changing optimization parameters. Process optimization and re-optimization ..on the fly.. can enable companies to meet variations in market demand and maximize production efficiency and overall profitability.
When embodied in a modern integrated plant environment, dynamic planthealth assessment, process modeling and process integration provide themeans to augment plant reliability, availability and safety with maximum capacity and flexibility.
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