Method and system for real-time performance degradation advisory for centrifugal compressors

• US 10,088,839 B2
• Filed: 03/01/2013
• Issued: 10/02/2018
• Est. Priority Date: 03/01/2012
• Status: Active Grant

• Current Assignee: Nuovo Pignone Tecnologie SRL (Baker Hughes Company)
• Original Assignee: Nuovo Pignone SRL (Baker Hughes Company)
• Inventors: Saravanapriyan, Arul, Di Pillo, Pier Luigi, Ashour, Osama Naim, Stringano, Giuseppe, Khalidi, Abdurrahman Abdallah
• Primary Examiner(s): Tran, Huan
• Application Number:
  US14/382,063
• Publication Number:
  US 20150057973A1
• Time in Patent Office: 2,041 Days
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F02C 7/00 Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants controlling F02C9/00
• CPC Class Codes: F04B 51/00 Testing machines, pumps, or pumping installations
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: G01K 13/00 Thermometers specially adapted for specific purposes
• CPC Class Codes: G01L 3/10 involving electric or magnetic means for indicating
• CPC Class Codes: G01M 15/14 Testing gas-turbine engines or jet-propulsion engines
• CPC Class Codes: G05B 11/06 in which the output signal represents a continuous function of the deviation from the desired value, i.e. continuous controllers G05B11/26 takes precedence
• CPC Class Codes: G05B 23/0216 Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
• CPC Class Codes: G05B 23/0218 characterised by the fault detection method dealing with either existing or incipient faults
• CPC Class Codes: G05B 23/0245 based on a qualitative model, e.g. rule based; if-then decisions
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: H04L 67/10 in which an application is distributed across nodes in the network software deployment G06F8/60; multiprogramming arrangements G06F9/46

Abstract

A system and computer-implemented method for generating real-time performance advisories for a centrifugal compressor of a fleet of centrifugal compressors are provided. The method includes receiving an actual thermodynamic signature of the compressor, that is unique to the compressor, receiving compressor process parameter values during operation of the compressor, determining, in real-time, an actual performance of the compressor using the compressor process parameter values, determining, in real-time, a predicted performance of the compressor using the received actual thermodynamic signature of the compressor, determining a performance deviation of the compressor using the actual performance and the predicted performance, comparing the performance deviation to a predetermined dynamic threshold range of performance deviation specific to operating speed, and generating a notification to a user using the comparison.

Claims

1. A computer-implemented method for generating real-time performance advisories for a centrifugal compressor of a fleet of centrifugal compressors, the method implemented using a computer device coupled to a user interface and a memory device, the method comprising:

receiving, by a processor associated with the computer device, an actual thermodynamic signature of the centrifugal compressor, that is unique to the centrifugal compressor;

receiving, by the processor associated with the computer device, centrifugal compressor process parameter values during operation of the centrifugal compressor;

determining, by the processor associated with the computer device, in real-time, an actual performance of the centrifugal compressor using the centrifugal compressor process parameter values and a polytrophic thermodynamic algorithm;

determining, by the processor associated with the computer device, in real-time, a predicted performance of the centrifugal compressor using the received actual thermodynamic signature of the centrifugal compressor and a set of thermodynamic transformation-real gas behavior based equations of state;

determining, by the processor associated with the computer device, a performance deviation of the centrifugal compressor using the actual performance of the centrifugal compressor and the predicted performance of the centrifugal compressor;

comparing, by the processor associated with the computer device, the performance deviation of the centrifugal compressor to a predetermined threshold range of performance deviation;

determining, by the processor associated with the computer device, a severity of the performance deviation of the centrifugal compressor based on a degradation of centrifugal compressor performance and a difficulty of mitigating the degradation; and

generating and sending, by the processor associated with the computer device, a notification to a user, based on the determined severity, wherein the notification to the user includes advisory steps to identify sources of a failure that is causing the performance deviation of the centrifugal compressor.

2. The method of claim 1, wherein receiving the actual thermodynamic signature of the centrifugal compressor comprises determining one or more key performance indicators (KPI) for the operation of the centrifugal compressor using the thermodynamic signature specific to the centrifugal compressor.

3. The method of claim 2, further comprising comparing the one or more KPIs to the actual performance to generate one or more KPI performance deviations associated with the one or more KPIs.

4. The method of claim 2, wherein generating the notification to the user, based on the determined severity comprises generating and sending the notification to the user regarding each KPI performance deviation that exceeds a predetermined KPI performance deviation threshold range.

5. The method of claim 1, wherein determining the actual performance of the centrifugal compressor and determining the predicted performance of the centrifugal compressor comprises determining the actual performance of the centrifugal compressor and the predicted performance of the centrifugal compressor corrected based on a load on the centrifugal compressor.

6. The method of claim 1, wherein receiving the actual thermodynamic signature of the centrifugal compressor comprises receiving the actual thermodynamic signature of the centrifugal compressor from a manufacturer of the centrifugal compressor.

7. The method of claim 1, wherein receiving the actual thermodynamic signature of the centrifugal compressor comprises receiving a subset of a plurality of actual thermodynamic signatures for the fleet of centrifugal compressors.

8. The method of claim 1, wherein receiving centrifugal compressor process parameter values during operation of the centrifugal compressor comprises:

receiving, by the processor associated with the computer device, centrifugal compressor suction process parameter values in real-time during operation of the centrifugal compressor; and

receiving, by the processor associated with the computer device, centrifugal compressor discharge process parameter values in real-time during operation of the centrifugal compressor.

9. The method of claim 1, further comprising:

determining, in real-time, a dynamic predicted OEM envelope of the centrifugal compressor using the received actual thermodynamic signature of the centrifugal compressor and the measured process parameters.

10. The method of claim 1, wherein comparing the performance deviation of the centrifugal compressor to the predetermined threshold range of performance deviation comprises:

determining, by the processor associated with the computer device, a severity of the performance deviation of the centrifugal compressor based on a degradation of centrifugal compressor performance and a difficulty of mitigating the degradation; and

generating and sending, by a processor associated with the computer device, the notification to the user, based on the determined severity, wherein the notification to the user includes correlating the performance deviation of the centrifugal compressor and the received centrifugal compressor process parameter values.

11. A system for generating real-time performance advisories for a centrifugal compressor of a fleet of centrifugal compressors, the system comprising:

a memory device;

an user interface; and

a processor configured to;

receive an actual thermodynamic signature of the centrifugal compressor, that is unique to the centrifugal compressor;

receive centrifugal compressor process parameter values during operation of the centrifugal compressor;

determine, in real-time, an actual performance of the centrifugal compressor using the centrifugal compressor process parameter values and a polytrophic thermodynamic algorithm;

determine, in real-time, a predicted performance of the centrifugal compressor using the received actual thermodynamic signature of the centrifugal compressor and a set of thermodynamic transformation-real gas behavior based equations of state;

determine a performance deviation of the centrifugal compressor using the actual performance of the centrifugal compressor and the predicted performance of the centrifugal compressor;

compare the performance deviation of the centrifugal compressor to a predetermined threshold range of performance deviation;

determine, a severity of the performance deviation of the centrifugal compressor based on a degradation of centrifugal compressor performance and a difficulty of mitigating the degradation; and

generate and send a notification to a user associated with the user interface based on the determined severity, wherein the notification to the user associated with the user interface includes advisory steps to identify sources of a failure that is causing the performance deviation of the centrifugal compressor.

12. The system of claim 11, wherein receiving the actual thermodynamic signature of the centrifugal compressor comprises determining one or more key performance indicators (KPI) for the operation of the centrifugal compressor using the thermodynamic signature specific to the centrifugal compressor.

13. The system of claim 12, wherein the process is further configured to compare the one or more KPIs to the actual performance to generate one or more KPI performance deviations associated with the one or more KPIs.

14. The system of claim 12, wherein generating and sending the notification to the user interface, based on the determined severity comprises generating and sending the notification to the user interface regarding each KPI performance deviation that exceeds a predetermined KPI performance deviation threshold range.

15. The system of claim 11, wherein determining the actual performance of the centrifugal compressor and determining the predicted performance of the centrifugal compressor comprises determining the actual performance and the predicted performance corrected based on a load on the centrifugal compressor.

16. The system of claim 11, wherein receiving the actual thermodynamic signature of the centrifugal compressor comprises receiving the actual thermodynamic signature of the centrifugal compressor from a manufacturer of the centrifugal compressor.

17. The system of claim 11, wherein receiving the actual thermodynamic signature of the centrifugal compressor comprises receiving a subset of a plurality of actual thermodynamic signatures for the fleet of centrifugal compressors.

18. The system of claim 11, wherein receiving compressor process parameter values during operation of the centrifugal compressor comprises:

receiving centrifugal compressor suction process parameter values in real-time during operation of the centrifugal compressor; and

receiving centrifugal compressor discharge process parameter values in real-time during operation of the centrifugal compressor.

19. The system of claim 11, wherein the process is further configured to determine, in real-time, a dynamic predicted envelope of the centrifugal compressor using the received actual thermodynamic signature of the centrifugal compressor and the measured process parameters.

20. The system of claim 11, wherein comparing the performance deviation of the centrifugal compressor to a predetermined threshold range of performance deviation comprises:

determining the severity of the performance deviation based on a degradation of compressor performance and a difficulty of mitigating the degradation; and

generating and sending the notification to the user associated with the user interface based on the determined severity, wherein the notification to the user associated with the user interface includes correlating the performance deviation of the centrifugal compressor and the received centrifugal compressor process parameter values.