Methods and systems for maintenance of turbomachinery
First Claim
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1. A system comprising:
- a processor configured to execute;
a condition based replacement life (CBRL) approval system configured to receive a turbomachinery component data from a plurality of sensors;
to determine if a component deterioration is observable based on the turbomachinery component data; and
if the component deterioration is observable, to approve a turbomachinery component for CBRL use based on the turbomachinery component data;
derive a maximum part life that exceeds a manufacturer originally estimated life for the turbomachinery component based on an analysis of an outage rate, a scrap profile, or a combination thereof, wherein the scrap profile comprises a number of parts for the turbomachinery component that fall out of operations, are found to be undesired for operations, or a combination thereof;
a CBRL validation system configured to validate the turbomachinery component into a validated turbomachinery component by applying a validation analysis based on a plurality of validation zones, wherein each validation zone in the plurality of validation zones comprises a time prior to a fired hours milestone at which the turbomachinery component is inspected to observe the deterioration, wherein the processor is configured to validate, via the CBRL validation system, a validated turbomachinery component to operate in a turbomachinery beyond a service time of the turbomachinery component, wherein a first service time for a first validation zone for the turbomachinery component comprises a manufacturer recommended number of fired hours, a second service time for a second validation zone for the turbomachinery component comprises a hot gas path inspection (HGPI) interval, a third service time for a third validation zone for the turbomachinery component comprises a combustion inspection (CI) interval, and a fourth service time for a fourth validation zone for the turbomachinery component comprises a major inspection (MI) interval, and wherein the validated turbomachinery component improves the operational life of the turbomachinery by operating in the turbomachinery beyond the service time.
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Abstract
In one embodiment, a system includes a condition based replacement life (CBRL) approval system configured to receive a turbomachinery component data and to approve a turbomachinery component for CBRL based on the turbomachinery component data. The system further includes a CBRL validation system configured to repair the turbomachinery component into a repaired turbomachinery component, wherein the repaired turbomachinery component is configured to operate in a turbomachinery beyond a service time of the turbomachinery component.
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Citations
17 Claims
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1. A system comprising:
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a processor configured to execute; a condition based replacement life (CBRL) approval system configured to receive a turbomachinery component data from a plurality of sensors;
to determine if a component deterioration is observable based on the turbomachinery component data; and
if the component deterioration is observable, to approve a turbomachinery component for CBRL use based on the turbomachinery component data;derive a maximum part life that exceeds a manufacturer originally estimated life for the turbomachinery component based on an analysis of an outage rate, a scrap profile, or a combination thereof, wherein the scrap profile comprises a number of parts for the turbomachinery component that fall out of operations, are found to be undesired for operations, or a combination thereof; a CBRL validation system configured to validate the turbomachinery component into a validated turbomachinery component by applying a validation analysis based on a plurality of validation zones, wherein each validation zone in the plurality of validation zones comprises a time prior to a fired hours milestone at which the turbomachinery component is inspected to observe the deterioration, wherein the processor is configured to validate, via the CBRL validation system, a validated turbomachinery component to operate in a turbomachinery beyond a service time of the turbomachinery component, wherein a first service time for a first validation zone for the turbomachinery component comprises a manufacturer recommended number of fired hours, a second service time for a second validation zone for the turbomachinery component comprises a hot gas path inspection (HGPI) interval, a third service time for a third validation zone for the turbomachinery component comprises a combustion inspection (CI) interval, and a fourth service time for a fourth validation zone for the turbomachinery component comprises a major inspection (MI) interval, and wherein the validated turbomachinery component improves the operational life of the turbomachinery by operating in the turbomachinery beyond the service time. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method, comprising:
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approving via processor, a turbomachinery component for use in a condition based replacement life (CBRL) activity, wherein the approving the turbomachinery component comprises; determining if a first deterioration of the turbomachinery component is observable in a field environment via a plurality of sensors; determining if a second deterioration of the turbomachinery component is observable in a service and repair shop; approving the turbomachinery component based at least in part on the determining the if the first and the second deteriorations are observable; deriving a maximum part life that exceeds a manufacturer originally estimated life for the turbomachinery component based on an analysis of and outage rate, a scrap profile, or a combination thereof, wherein the scrap profile comprises a number of parts for the turbomachinery component that fall out of operations, are found to be undesired for operations, or a combination thereof; and validating the turbomachinery component after the approving the turbomachinery component for use in the CBRL activity, wherein the validating the turbomachinery component comprises; inspecting the turbomachinery component, repairing the turbomachinery component, or a combination thereof; tracking a usage of the turbomachinery component in a turbomachinery after the inspecting, the repairing, of the combination thereof; evaluating a performance of the turbomachinery component in the turbomachinery, wherein the evaluating the performance of the approved turbomachinery component in the turbomachinery comprises creating a plurality of validation zones each validation zone comprising a time prior to a fired hours at which a status review of defect trends is performed on a fleet of turbomachinery having the turbomachinery component, wherein the CBRL activity comprises using the turbomachinery component as a validated turbomachinery component in the turbomachinery beyond a service time of the turbomachinery component, wherein a first service time for a first validation zone for the turbomachinery component comprises a manufacturer recommended number of fired hours, a second service time for a second validation zone for the turbomachinery component comprises a hot gas path inspection (HGPI) interval, a third service time for a third validation zone for the turbomachinery component comprises a combustion inspection (CI) interval, and a fourth service time for a fourth validation zone for the turbomachinery component comprises a major inspection (MI) interval, and wherein the validated turbomachinery component improves the operational life of the turbomachinery by operating in the turbomachinery beyond the service time. - View Dependent Claims (11, 12, 13, 14)
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15. A system, comprising:
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a processor configured to execute; an approval system configured to approve a turbomachinery component for use in a turbomachinery beyond a service time of the turbomachinery component, and to determine if a first deterioration of the turbomachinery component is observable via a plurality of sensors; derive a maximum part life that exceeds a manufacturer originally estimated life for the turbomachinery component based on an analysis of an outage rate, a scrap profile, or a combination thereof, wherein the scrap profile comprises a number of parts for the turbomachinery component that fall out of operations, are found to be undesired for operations, or a combination thereof; and a validation system configured to inspect the turbomachinery component, to repair the turbomachinery component, or a combination thereof;
to apply a validation analysis of the turbomachinery component based on a plurality of validation zones to derive a validated turbomachinery component, wherein each validation zone in the plurality of validation zones comprises a time prior to a fired hours milestone at which the turbomachinery component is inspected to observe the deterioration and to use the turbomachinery component in a turbomachinery after the inspection, the repair, or the combination thereof, of the turbomachinery component, wherein a first service time for a first validation zone for the turbomachinery component comprises a manufacturer recommended number of fired hours, a second service time for a second validation zone for the turbomachinery component comprises a hot gas path inspection (HGPI) interval, a third service time for a third validation zone for the turbomachinery component comprises a combustion inspection (CI) interval, and a fourth service time for a fourth validation zone for the turbomachinery component comprises a major inspection (MI) interval, and wherein the validated turbomachinery component improves the operational life of the turbomachinery by operating in the turbomachinery beyond the service time. - View Dependent Claims (16, 17)
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Specification