FACTORS IMPACTING RELIABILITY - GAS TURBINES

Critical factors affecting or impacting the reliability of gas turbines include:

  1. Component quality: The quality of components used in the gas turbine greatly affects its reliability. Using high-quality components can reduce the likelihood of failures and improve overall reliability.

  2. Maintenance practices: Regular maintenance is essential for the reliable operation of gas turbines. Poor maintenance practices can lead to failures, unplanned downtime, and reduced reliability.

  3. Operating conditions: The operating conditions of a gas turbine can affect its reliability. Extreme temperatures, high humidity, and dusty environments can increase the likelihood of failures and reduce reliability.

  4. Design and engineering: The design and engineering of gas turbines greatly affect their reliability. Poor design and engineering can lead to failures, increased maintenance needs, and reduced reliability.

  5. Age and usage: The age and usage of gas turbines can also affect their reliability. Older gas turbines and those that are heavily used may have more frequent failures and require more maintenance.

Procedures, studies, actions, and recommendations:

  1. Regular maintenance and inspections should be performed according to the manufacturer’s recommendations.

  2. Upgrades and retrofits should be considered to improve component quality and address design or engineering issues.

  3. Condition monitoring techniques should be used to detect potential issues before they become failures.

  4. Operating conditions should be carefully monitored and controlled to minimize the likelihood of failures.

  5. Consider using predictive maintenance techniques such as vibration analysis, oil analysis, and thermography to identify potential issues before they lead to failures.

WHY, WHEN, WHERE, WHAT, WHICH, HOW TO APPLY RELIABILITY FACTORS IN ENGINEERING & DESIGN

To apply reliability studies and analysis as part of the engineering and design process in gas turbines, with the objective of improving maintainability, reliability, availability, and safety in existing plants and new projects for power generation plants, oil, gas, and petrochemical industries, let’s address the questions of why, when, where, what, which, and how:

  1. Why Apply Reliability Studies and Analysis:

    • Reliability studies and analysis help identify potential failure modes, their causes, and their impact on the performance and availability of gas turbines.
    • They provide insights into the reliability characteristics of the system, enabling improvements in design, component selection, and maintenance strategies.
    • By proactively assessing reliability, appropriate measures can be implemented to reduce failures, improve uptime, and enhance safety.

  2. When to Apply Reliability Studies and Analysis:

    • Reliability studies and analysis should be conducted during the early stages of the engineering and design process for gas turbines.
    • It is crucial to consider reliability factors from the concept and planning phase to ensure that design decisions align with reliability objectives.
    • Reliability assessments should also be performed periodically throughout the life cycle of the gas turbines to track performance, identify areas for improvement, and support maintenance decisions.

  3. Where to Apply Reliability Studies and Analysis:

    • Reliability studies and analysis should be applied to both existing plants and new projects involving gas turbines.
    • Existing plants can benefit from reliability studies to identify areas for improvement, evaluate the effectiveness of maintenance practices, and implement targeted enhancements.
    • In new projects, reliability studies are essential to ensure that the design meets reliability requirements, guiding decisions on component selection, redundancy, and maintenance strategies.

  4. What to Consider in Reliability Studies and Analysis:

    • Identify critical components and subsystems within the gas turbine system that significantly impact reliability, such as blades, bearings, combustion systems, and control systems.
    • Evaluate failure modes and their effects on reliability, considering factors like component wear, fatigue, corrosion, and system-level issues.
    • Analyze operational conditions, maintenance practices, and environmental factors that may influence reliability.

  5. Which Methods and Techniques to Use:

    • Utilize reliability analysis techniques such as failure mode and effect analysis (FMEA), fault tree analysis (FTA), and reliability block diagrams (RBD) to assess system reliability and identify potential failure modes.
    • Conduct statistical analysis of failure data to determine failure rates, mean time between failures (MTBF), and mean time to repair (MTTR) for critical components.
    • Use tools such as reliability prediction software to estimate system reliability based on component reliability data and operational profiles.

  6. How to Apply Reliability Studies and Analysis:

    • Define reliability objectives and metrics, such as desired system uptime, availability targets, and reliability growth goals.
    • Collect relevant data on component reliability, failure history, maintenance records, and operational conditions of the gas turbines.
    • Analyze the data to identify common failure modes, their causes, and their impact on system reliability.
    • Implement design improvements based on the findings, such as selecting more reliable components, improving maintenance procedures, and enhancing system redundancy.
    • Continuously monitor and track reliability performance, analyze failure data, and update reliability models to drive ongoing improvements.

PROCEDURES, ACTIONS, STUDIES, MITIGATION, RECOMMENDATIONS TO APPLY RELIABILITY FACTORS IN ENGINEERING & DESIGN

To apply reliability factors in the design and engineering of gas turbines with the aim of improving maintainability, reliability, availability, and safety in existing plants and new projects for power generation plants, oil, gas, and petrochemical industries, the following procedures, actions, studies, mitigations, and recommendations can be considered:

  1. Reliability Planning:

    • Define reliability goals and objectives for the gas turbine system, considering the desired levels of reliability, availability, and safety.
    • Establish reliability specifications and requirements based on industry standards, codes, and regulations.
    • Develop a reliability plan that outlines the steps and activities to achieve the desired reliability outcomes.

  2. Failure Mode and Effects Analysis (FMEA):

    • Conduct a comprehensive FMEA to identify potential failure modes, their causes, and their effects on system reliability.
    • Prioritize failure modes based on their criticality and likelihood of occurrence.
    • Develop mitigation strategies and design improvements to reduce the likelihood and impact of identified failure modes.

  3. Reliability-Centered Maintenance (RCM):

    • Apply RCM principles to determine the appropriate maintenance tasks, intervals, and strategies for critical components of the gas turbine.
    • Prioritize maintenance activities based on their impact on reliability and safety.
    • Implement condition-based maintenance techniques, such as vibration analysis, oil analysis, and thermography, to detect potential issues and take proactive maintenance actions.

  4. Component Selection and Quality:

    • Select components from reputable manufacturers with a proven track record of reliability and quality.
    • Consider the reliability data and performance characteristics of components during the selection process.
    • Establish quality control measures to ensure that components meet the required reliability and performance standards.

  5. Redundancy and Backup Systems:

    • Evaluate the criticality of components and subsystems in the gas turbine system and implement redundancy where necessary.
    • Design backup systems that can quickly and seamlessly take over in the event of component failures.
    • Consider the use of standby equipment, redundant control systems, and emergency shutdown systems to improve system availability and safety.

  6. Reliability Testing and Validation:

    • Conduct reliability testing during the design and development stages to assess the performance and reliability of the gas turbine system.
    • Perform accelerated life testing, environmental testing, and reliability growth testing to identify and address potential weaknesses and improve system reliability.
    • Validate the reliability of the system through field testing and monitoring to ensure that it meets the expected performance and reliability targets.

  7. Documentation and Lessons Learned:

    • Maintain comprehensive documentation of the design, engineering, and reliability-related decisions throughout the lifecycle of the gas turbine system.
    • Establish a system for capturing and sharing lessons learned from past projects and maintenance activities.
    • Continuously review and update the documentation based on feedback, field experience, and reliability data.
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