Turbomachinery Advisor | A Submodule in Honeywell Asset Performance Management Software

Enhance your turbomachinery performance and reliability by leveraging the power of digital and embedded expertise.

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Total Train Performance Advisor

Supporting your data-driven decision making

Over time, the performance of turbomachinery slowly deteriorates from its original condition. Continuous thermodynamic performance monitoring is essential to achieving operational cost savings without sacrificing process uptime.

Total Train Performance Advisor (TTPA) quantifies the degradation of a turbomachinery train by comparing its current performance to that of an original, healthy machine. With its accurate performance modeling and easy-to-understand visualizations, TTPA helps your team make the right operating decisions for your critical turbomachinery trains.

Wide Variety of Gas Compositions

Powerful Visualizations

Intuitive KPIs

Sophisticated model generation and plant-wide scalability

TTPA consists of three calculation modules to support a wide-range of process applications:

Compressor Performance Advisor (CPA) – based on ASME PTC-10 standard

Steam Turbine Performance Advisor (TPA)

Heat Exchanger Performance Advisor (HPA)

A sophisticated mathematical model is generated for each type of equipment based on original equipment manufacturer (OEM)-supplied performance data. Optional on-site tests help establish even more accurate performance baselines. A wide variety of gas compositions found in various processes is supported with the Benedict-Webb-Rubin-Starling (BWRS) equations of state, making TTPA a scalable solution to monitor your turbomachinery assets even in off-design conditions.

Delivering the right information, at the right time, to the right people

TTPA calculates and displays easy-to-understand health parameters

  • Key Data Points
    Those that are critical to understanding the health of a compressor, such as compression ratio and efficiency deviation, are summarized in a simple graphical dashboard.
  • Immediate Alerts
    Percent deviation indicators and configurable alarms immediately notify asset owners when asset performance degradation is detected.
  • Process Stability Detection
    An algorithm helps improve data quality by executing calculations only when the process is at steady-state.

Performance Monitoring System (PMS)

The PMS conducts a real-time comparison of the actual compressor, intercooler and turbine performance parameters to their baseline equipment values, which are most often obtained from OEM data or field experimental characteristics. The baseline efficiency of the compressor changes as a function of the operating parameters and gas composition, while turbine efficiency calculations depend on steam conditions, rotating speed and flow. Accurate estimation of the baseline performance, which covers a wide range of conditions, plays an important role in identifying degradation.

The CPA calculates process gas properties using the BWRS equations of state. Gas composition is manually entered into CPA for each section, though a communication link can be used for automatically updating gas composition when such information is available. The TPA estimates turbine isentropic efficiency utilizing built-in steam tables for enthalpy and entropy as functions of temperature and pressure. These calculation methods help avoid nuisance detection of degradation and calculations only occur with valid data collected during steady-state conditions. The main calculation results are communicated to the plant historian, and the system archives input and output parameters, preserving graphical data history.

Instrumentation requirements

The PMS is designed to perform calculations for each compressor section and reliable measurements for calculations are captured throughout the engineering phase.

Operator and engineering interface

For operators, viewing the compressor and operating points on their respective performance maps offers significant benefits and the PMS enhances this through improved calculation accuracy and additional baseline models for identifying degradation. In addition to estimating efficiencies, the CPA estimates discharge pressure, discharge temperature, polytropic head and power consumption baseline values for the existing inlet conditions. Knowledge of baseline parameters can assist in identifying drifting measurements—if a monitored parameter exceeds deviation threshold, the CPA provides an alarm.

The compressor map graphic shows the actual surge and control lines, as read from the antisurge controller, superimposed on the OEM characteristics (blue curves). The green performance characteristic is the estimated baseline curve, corresponding to the current suction conditions and rotating speed. The blue dot is the current operating point—under ideal circumstances, it would be located on the yellow line. The extraction turbine map shows the actual operating point on the baseline extraction map. The baseline map is dynamic, with adjustments based on steam inlet and outlet conditions.

Seamless integration with plant systems

TTPA calculates variables and deviation alarms are passed to the Distributed Control System (DCS) via Modbus communication, which is preferred over Object Linking and Embedding for Process Control (OPC) communication due to an existing link. The data is then integrated into the plant historian and represented in the plant KPI dashboards, allowing operation management to have a simple synopsis of the machinery performance.

TTPA is powerful as a standalone solution but also easily integrates with plant historians and supervisory systems. The data produced by CPA can be integrated with and utilized by various third-party applications supporting OPC Data Access (OPC DA), ensuring visibility for timely actions.

Compressor performance calculations

The CPA follows the ASME PTC-10 methodology when constructing a performance model. Differences between static and stagnation pressure are neglected, and CPA obtains gas properties from BWRS equations of state. For a single section adiabatic compression, the compressor characteristics are approximated as below, and this non-dimensional parameter set allows for proper mapping of the compressor baseline curve and the actual operating point at varying compressor operating conditions.

Turbine calculations

The TPA calculates the steam flow, shaft power and isentropic efficiency of the steam turbine and estimates deviation from the baseline performance. It provides a graphical interface with real-time plotting of baseline steam flow (W) versus shaft power (Jsh) curve, compensated for the existing steam conditions and the current operating point. The TPA displays multiple curves for extraction machines, each corresponding to a given extraction flow. When the conditions in turbine exhaust are below the saturation line, it estimates efficiency based upon consumed power, which can be calculated from the driven load parameters, such as a compressor or a generator. It provides means of correcting baseline data centered on rotating speed, steam flow and steam pressure and temperature.

Intercooler calculations

The intercooler performance advisor calculates and monitors the deviation of the actual heat transfer coefficient from the nominal, and as the cooler fouling increases, its heat transfer coefficient reduces, resulting in additional compression work.

Optimizing your performance

Performance monitoring systems create opportunities for accurate analysis, which allow for the design, development and implementation of optimization solutions that are custom designed for each unique situation. The implementation of these systems often features standard software products optimized by knowledgeable experts before integration with plant systems to ensure technical solutions work in the targeted operations environments.