US20170038276A1 - Monitoring System for Turbomachinery - Google Patents

Abstract

A system for monitoring a plurality of turbomachinery systems is disclosed herein. In embodiments, the system includes a network remote management tools module, and a plurality of monitoring devices. The network remote management tools module includes a diagnostic module and a management module. The diagnostic module monitors the operation of the plurality of turbomachinery systems and the system including the plurality of monitoring devices. The management module updates and maintains the system including the plurality of monitoring devices. A monitoring device of the plurality of monitoring device includes a device remote management module that manages the system through the network remote management tools module.

Description

RELATED APPLICATIONS
• The present application claims the benefit of U.S. Provisional Application No. 62/201,047 filed on Aug. 4, 2015 and titled Monitoring System for Turbomachinery.
TECHNICAL FIELD
• The present disclosure generally pertains to turbomachinery, and is directed toward a monitoring system for turbomachinery and associated equipment.
BACKGROUND
• Turbomachinery, such as gas turbine engines and associated equipment can be controlled and monitored by a control system of the gas turbine engine. Equipment associated with the gas turbine engine can include, inter alia, gas compressors, gearboxes, and fuel systems.
• The present disclosure is directed toward overcoming one or more of the problems discovered by the inventors or that is known in the art.
SUMMARY OF THE DISCLOSURE
• A system for monitoring a plurality of turbomachinery systems, each including a plurality of sensors and a control system that collects sensor data from the sensors periodically, is disclosed herein. In embodiments, the system includes a monitoring connection system, a monitoring system data provider, a plurality of monitoring system servers, a fleet data system, a first monitoring device, a network remote management tools module, and a second monitoring device. The monitoring connection system includes a connection system module that periodically receives the sensor data and event data from the control system from one of the turbomachinery systems of the plurality of turbomachinery systems. The monitoring system data provider periodically receives the sensor data over a network from the monitoring connection system and stores the sensor data in a monitoring system data store. The plurality of monitoring system servers connect to the monitoring system data provider and are located at a data center with the monitoring system data provider.
• The fleet data system located at the data center. The fleet data system periodically receives the event data from the monitoring connection system. The first monitoring device receives the sensor data from the monitoring system data provider and the event data from the fleet data system including receiving alerts for predetermined events as the events occur. The network remote management tools module includes a diagnostic module and a management module. The diagnostic module monitors the operation of the monitoring connection system, the monitoring system data provider, the plurality of monitoring system servers, the fleet data system, and a plurality of monitoring devices that includes the first monitoring device. The management module updates and maintains the monitoring connection system, the monitoring system data provider, the plurality of monitoring system servers, the fleet data system, and the plurality of monitoring devices. The second monitoring device includes a device remote management module that manages the monitoring connection system, the monitoring system data provider, the plurality of monitoring system servers, the fleet data system, and the plurality of monitoring devices through the network remote management tools module.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a schematic illustration of multiple turbomachinery systems connected to a monitoring system.
• FIG. 2 is a schematic illustration of the turbomachinery system ofFIG. 1 including a gas turbine engine.
• FIG. 3 is a functional block diagram of the control system ofFIG. 2.
• FIG. 4 is a functional block diagram of a monitoring device ofFIG. 1.
• FIG. 5 is a functional block diagram of a monitoring device and a monitoring system server ofFIG. 1.
• FIG. 6 is a functional block diagram of a monitoring device and the fleet data system ofFIG. 1.
• FIG. 7 is a schematic illustration of multiple turbomachinery system connected to a second portion of the monitoring system ofFIG. 1.
• FIG. 8 is a flowchart of a method for remotely monitoring turbomachinery, such as thegas turbine engines100 ofFIGS. 1 and 2.
• FIG. 9 is a flowchart of a method for monitoring events for turbomachinery, such as the gas turbine engines ofFIGS. 1 and 2.
• FIG. 10 is a flowchart of an alternate embodiment of a method for monitoring events for turbomachinery, such as thegas turbine engines100 ofFIGS. 1 and 2.
• FIG. 11 is a flowchart of a method for remote management of theturbomachinery systems50 and themonitoring system700 ofFIG. 1.
DETAILED DESCRIPTION
• FIG. 1 is a schematic illustration ofmultiple turbomachinery systems50 connected to amonitoring system700. Eachturbomachinery system50 may include aturbomachinery package60, afirewall650, amonitoring connection system710, and sensors connected thereto. Theturbomachinery package60 includes a turbomachine, such asgas turbine engine100, and acontrol system600 that monitors and controls that turbomachine. Eachturbomachinery system50 may be located at a customer site.
• Themonitoring system700 includes a monitoringsystem data provider720, a monitoringsystem data store730,monitoring system servers740, afleet data system760,monitoring devices800, and themonitoring connection systems710 of theturbomachinery systems50. The monitoring system data provider, themonitoring system servers740 and thefleet data system760 may be located at acentral data center705 remote from theturbomachinery systems50. While the monitoringsystem data provider720 and thefleet data system760 are shown as separate devices, in some embodiments, the monitoringsystem data provider720 and thefleet data system760 are modules on the same system, such as a server. The monitoringsystem data provider720 and thefleet data system760 are connected to eachmonitoring connection system710 over a network.
• The monitoringsystem data provider720 receives ananalog data stream718 from themonitoring connection system710 that may includes, inter alia, data related to the various sensors connected to the turbomachine, such as thegas turbine engine100 and to equipment associated with the turbomachine, gas compressors, gearboxes, fuel systems, batteries, lube oil, enclosure temperatures, driven equipment, electric motor drives, balance of plant, and other systems connected to or on theturbomachinery package60. Theanalog data stream718 may be a single real time data stream. The monitoringsystem data provider720 may include a monitoringsystem data store730 for storing the information received from theanalog data stream718. The monitoringsystem data store730 may be a fast cache, which may allow immediate access to the data as it is stored so that the data can then be sent immediately to themonitoring system servers740 from the monitoringsystem data provider720.
• Themonitoring system servers740 are configured to receive the data of theanalog data stream718 from the monitoringsystem data provider720 and provide the data of at least oneturbomachinery system50 to at least onemonitoring device800. Eachmonitoring device800 is configured to display the information to a user, such as an operator, an engineer, or owner of thegas turbine engine100.
• Thefleet data system760 receives anevent data stream719 from themonitoring connection system710 that includes, inter alia, data related to the various events, such as status bits, alerts, and alarms, related to the turbomachinery and associated equipment monitored by thecontrol system600. Depending on the type of event, thefleet data system760 provides the event related data to themonitoring devices800, sends a notification to a predetermined user, or does both. Themonitoring devices800 receives the sensor data from the monitoringsystem data provider720 and the event data from thefleet data system760 including receiving alerts for predetermined events as the events occur.
• FIG. 2 is a schematic illustration of anexemplary turbomachinery system50 including agas turbine engine100. Thegas turbine engine100 described herein is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. It will be appreciated that other turbomachinery, such as gas compressors and pumps, can be implemented in various configurations within theturbomachinery system50. Referring toFIG. 2, some of the surfaces have been left out or exaggerated for clarity and ease of explanation. Also, the disclosure may reference a forward and an aft direction. Generally, all references to “forward” and “aft” are associated with the flow direction of primary air (i.e., air used in the combustion process), unless specified otherwise. For example, forward is “upstream” relative to primary air flow direction, and aft is “downstream” relative to primary air flow direction.
• In addition, the disclosure may generally reference acenter axis95 of rotation of thegas turbine engine100, which may be generally defined by the longitudinal axis of its shaft120 (supported by a plurality of bearing assemblies150). Thecenter axis95 may be common to or shared with various other engine concentric components. All references to radial, axial, and circumferential directions and measures refer tocenter axis95, unless specified otherwise, and terms such as “inner” and “outer” generally indicate a lesser or greater radial distance from, wherein a radial96 may be in any direction perpendicular and radiating outward fromcenter axis95.
• Thegas turbine engine100 includes aninlet110, ashaft120, a gas producer orcompressor200, acombustor300, aturbine400, anexhaust500, and apower output coupling130. Thegas turbine engine100 may have a single shaft or a dual shaft configuration.
• Thecompressor200 includes acompressor rotor assembly210, compressor stationary vanes (“stators”)250, andinlet guide vanes255. Thecompressor rotor assembly210 mechanically couples toshaft120. As illustrated, thecompressor rotor assembly210 is an axial flow rotor assembly. Thecompressor rotor assembly210 includes one or morecompressor disk assemblies220. Eachcompressor disk assembly220 includes a compressor rotor disk that is circumferentially populated with compressor rotor blades.Stators250 axially follow each of thecompressor disk assemblies220. Eachcompressor disk assembly220 paired with theadjacent stators250 that follow thecompressor disk assembly220 is considered a compressor stage.Compressor200 includes multiple compressor stages.Inlet guide vanes255 axially precede the first compressor stage.
• Thecombustor300 includes one ormore fuel injectors310 and acombustion chamber320.
• Theturbine400 includes aturbine rotor assembly410 andturbine nozzles450. Theturbine rotor assembly410 mechanically couples to theshaft120. As illustrated, theturbine rotor assembly410 is an axial flow rotor assembly. Theturbine rotor assembly410 includes one or moreturbine disk assemblies420. Eachturbine disk assembly420 includes a turbine disk that is circumferentially populated with turbine blades. Aturbine nozzle450, such as a nozzle ring, axially precedes each of theturbine disk assemblies420. Eachturbine nozzle450 includes multiple methods grouped together to form a ring. Eachturbine disk assembly420 paired with theadjacent turbine nozzle450 that precede theturbine disk assembly420 is considered a turbine stage.Turbine400 includes multiple turbine stages.
• Theexhaust500 includes anexhaust diffuser510 and anexhaust collector520.
• One or more of the above components (or their subcomponents) may be made from stainless steel and/or durable, high temperature materials known as “superalloys”. A superalloy, or high-performance alloy, is an alloy that exhibits excellent mechanical strength and creep resistance at high temperatures, good surface stability, and corrosion and oxidation resistance. Superalloys may include materials such as HASTELLOY, INCONEL, WASPALOY, RENE alloys, HAYNES alloys, INCOLOY, MP98T, TMS alloys, and CMSX single crystal alloys.
• Control system600 includes acontroller610 and a human machine interface system (HMI)620. Thecontroller610 is configured to obtain the values of various sensors connected to thegas turbine engine100 and to monitor thegas turbine engine100. The sensors may include, inter alia, various temperature sensors, pressure sensors, flow meters, and the like. The sensors may be used to monitor the temperature of theturbine400, such as the inlet of the power turbine of agas turbine engine100 with a dual shaft configuration, the shaft speed, the load output, and various aspects of the fuel flowing to thefuel injectors310. These aspects may include the upstream and downstream pressures and temperatures of the fuel relative to the control valve that is used to meter fuel flow to thefuel injectors310, and the mass flow rate of the fuel. Thecontroller610 may monitor thegas turbine engine100 for events, such as trigger events, alarms, and shutdowns of thegas turbine engine100.
• TheHMI620 includes a high speed recorder (HSR)630 that is configured to obtain and log the values of the sensors and the status bits of the event types monitored by thecontroller610, including trigger events, such as events related to the operating cycle of the gas turbine engine (start-up, shut-down, change of load, etc.), and alarms generated by thecontrol system600. TheHMI620 may be connected to amonitoring connection system710. In the embodiment illustrated, afirewall650 is connected between theHMI620 and themonitoring connection system710. In other embodiments, thefirewall650 is connected between thecontroller610 and theHMI620, and between thecontroller610 and themonitoring connection system710. In these embodiments, theHMI620 and themonitoring connection system710 may be connected in parallel. Thefirewall650 may be a read only firewall for thecontroller610 to prevent remote access to thecontroller610.
• Themonitoring connection system710 may include aconnection system module712 and aconnection system gateway714. Theconnection system module712 is configured to obtain the sensor data and the event data from thecontrol system600 and provide that data to the monitoringsystem data provider720 and thefleet data system760 respectively using theconnection system gateway714. In the embodiment illustrated, theconnection system module712 obtains the sensor data and the event data from theHMI620. In other embodiments, theconnection system module712 obtains the sensor data and the event data directly from thecontroller610.
• FIG. 3 is a functional block diagram of thecontrol system600 ofFIG. 2. Thecontroller610 may include acontrol module612 and amapping module614. Thecontrol module612 is configured to control thegas turbine engine100 during operation of thegas turbine engine100. Thecontrol module612 may use the values obtained from various sensors to control thegas turbine engine100 through, inter alia, modifying the angular position of the fuel control valve and of the inlet guide vanes.
• Themapping module614 is configured to log an array related to, inter alia, each event and the values obtained from each sensor. A tag may be assigned to, inter alia, each event type and each sensor, to identify the recorded value. Each tag may be associated with a tag name and a unique identifier to identify the associated tag. Each unique identifier may be a recorded value within the array. The unique identifier may be a numeric number used to identify the tag. The tags may be unique to a givengas turbine engine100 or to a given set ofgas turbine engines100. For example, each model type of an original equipment manufacturer'sgas turbine engines100 may have a unique set of tags that are used for the various event types and sensors.
• The recorded value of event status bits may be a Boolean value to identify between two different states of the event. When an event occurs, the unique identifier and the recorded value may be packed into 32 bit words, which may then be packed into the array. For values obtained from the sensors, the recorded value may be a floating point value obtained from a sensor. In embodiments, these values are analog values obtained from the sensors. When a sensor is sampled, the unique identifier and the recorded value may be packed into 32 bit words, which may then be packed into the array. In some embodiments, the array may be separated into an event array and into an analog value array. The unique identifiers and the recorded values for events are packed into the event array, and the unique identifiers and the recorded values obtained from the sensors are packed into the analog value array.
• A timestamp may also be recorded for each event and for each analog value obtained from the sensors. The timestamp is a temporal value, such as the date and time of day, that the event occurred or when the value was sampled. The timestamp may be obtained from the time clock of the controller or by other methods and packed into the array along with the unique identifier and the recorded value.
• Thecontrol system600 may include acontroller data store615. Thecontroller data store615 may be used to store the most recently obtained values for the timestamp and the recorded value for each tag.
• TheHSR630 includes anevent module632 and ananalog module634. Themapping module614 may publish the event data, such as the event array, on a loop cycle over a first predetermined interval. Theevent module632 may be configured to read the event data as soon as it is published and provide that data to theconnection system module712. Theevent module632 may provide the event data to theconnection system module712 on the first predetermined interval.
• Theanalog module634 may operate in parallel with theevent module632. Theanalog module634 is configured to read the values obtained for each sensor from thecontroller610 on a second predetermined interval, such as once every 100 milliseconds. The analog module may be configured to read the analog array and provide the analog array to theconnection system module712. The second predetermined interval may be a shorter interval than that of the first predetermined interval. Theanalog module634 may assign a timestamp to each value obtained from thecontroller610 and record the timestamp in the analog array.
• Control system600 may also include anHMI data store625. TheHMI data store625 may be used by theHMI620 and its various modules to store, inter alia, the data read from thecontroller610
• In the embodiment illustrated inFIGS. 1 and 2, theconnection system module712 sends the event array, the array of event data, to thefleet data system760 in theevent data stream719 and the analog data array, the array of sensor data, to the monitoring system data provider in theanalog data stream718. In other embodiments, theconnection system module712 sends a single array that includes the event and analog data to the monitoringsystem data provider720 in a single data stream. The event array is then provided to thefleet data system760.
• FIG. 4 is a functional block diagram of amonitoring device800 ofFIG. 1. Themonitoring device800 may include aliveview module810, adevice events module830, a device notification module (DN module)850, and a device remote management module (DRMI module)880. Theliveview module810 is configured to obtain the analog data from amonitoring system server740 and display that analog data in real time. Thedevice events module830 is configured to obtain the event data from thefleet data system760 and display the events that have occurred within a preselected timeframe. TheDN module850 is configured to connect to thefleet data system760 to allow the user to select which types of notifications to receive and configure how thefleet data system760 will notify the user. TheDRMI module880 is configured for remote machine provisioning capability, such as the ability to remotely update or configure the data acquisition software of the turbomachinery system50.TheDRMI module880 may only be accessible to or provided tomonitoring devices800 of authorized users, such as project engineers for a service provider. In some embodiments, theDRMI module880 may be located on one or more servers, such as the monitoringsystem data provider720 or themonitoring system server740.
• FIG. 5 is a functional block diagram of amonitoring device800 and amonitoring system server740 ofFIG. 1. As illustrated, theliveview module810 may include agroup module812, adisplay module814, and asearch module816. Themonitoring system server740 may include aserver module745. Theliveview module810 may connect to themonitoring system server740 over a network and request the real time sensor data, such as a stream of the analog data array, sent to the monitoringsystem data provider720 for a selectedturbomachinery system50.
• Theserver module745 may determine whether themonitoring device800 can access the real time sensor data, may determine whether or not to handle the request, and may either process the request or transfer the request to anothermonitoring system server740. Factors on whether to process the request or transfer the request may include the number of data streams themonitoring system server740 is currently providing, and whether it or anothermonitoring system server740 is currently providing a data stream for the selectedturbomachinery system50. When processing the request, theserver module745 obtains the real time sensor data from the monitoringsystem data provider720 and sends the real time sensor data to themonitoring device800.
• As described previously, the sensor data for eachgas turbine engine100 has a set of tags that are used to identify the various sensors of thegas turbine engine100. Depending on the model ofgas turbine engine100, the tag name and unique identifier for a given sensor may be different. Further, not all sensors used on onegas turbine engine100 may be available on anothergas turbine engine100.
• The tags can be organized into groups. These groups can include tags related to one another based on factors, such as the location of the sensors within the engine and which system or sub-system of thegas turbine engine100 the sensor is related to. For the various types and models ofgas turbine engines100, each group and the tags within each group may be organized based the factors and on the availability of the tags within thegas turbine engine100. Examples of the groups include generator power, fuel control mode, operation sequence, and the turbine. The generator power may include, inter alia, a tag for the total power output of the turbomachine, and the fuel control mode may include, inter alia, a tag for the maximum fuel of the turbomachine. Theliveview module810 may include or have access to a list of the various groups associated with each model ofgas turbine engine100.
• Some tags may be located within more than one group. Other tags may be unique to a group. One unique tag for each group may be identified as a critical tag. Each critical tag is associated with only one group. The critical tag may be used to determine whether the tags for a given group are available within the sensor data.
• Thegroup module812 is configured to determine whether the tags for each of the groups are available in the sensor data received from themonitoring system server740. Thegroup module812 may determine which tags for the groups are available by searching the sensor data for the critical tags and determining which of the critical tags are in the sensor data. Thegroup module812 may determine which of the critical tags are available by comparing the unique identifier of each critical tag for each of the groups with the unique identifiers for the tags in the sensor data. Once identified, thegroup module812 may correlate the tags with the groups and provide the groups and the correlated tags to thedisplay module814.
• Thedisplay module814 may be configured to dynamically display a set of groups including the tag names and the recorded values for the tags of those groups on an output display of themonitoring device800. Sets of groups may be organized to provide various summaries of thegas turbine engine100 operation and to display information related to a given system of thegas turbine engine100. Examples of sets of groups include an operation summary, an engine summary, and the fuel system. Thedisplay module814 may determine which set of groups to display based on a user selected input.
• Thedisplay module814 may dynamically display a set of groups by obtaining the size of the output display, determining the size of each group including the number of tags in each group, and organizing the groups within the display to limit the white space on the screen. The horizontal white space in the output display may be limited by selecting the optimal number of columns to display. The number of columns to display may depend on the width of the display device. As the display size including the width increases, more columns can be used to fill the display space. The vertical white space in each column can be limited by minimizing the difference in the number of tags displayed in each column.
• For example, a set of groups may include four groups including a first group with3 tags, a second group with5 tags, a third group with6 tags, and a fourth group with7 tags. The output display on a tabletsized monitoring device800 may be wide enough to display two columns. Thedisplay module814 may configure the first column to display the first and fourth groups and configure the second column to display the second and third groups. However, the output display for a cellular phonesized monitoring device800 may only be wide enough to display a single column. Thedisplay module814 may configure all four groups to be displayed in a single and scrollable column.
• In some embodiments, thedisplay module814 may also be configured to display all of the tags in a scrollable list. The tags may be organized by tag name and may be displayed in one or more columns.
• Search module816 is configured to locate and display a tag based on one or more search terms input by a user. A tag may be identified based on, inter alia, the tag name, unique identifier, and groups the tag is associated with.
• FIG. 6 is a functional block diagram of amonitoring device800 and thefleet data system760 ofFIG. 1. As previously mentioned, themonitoring device800 may include adevice events module830 and aDN module850. Thefleet data system760 may include anetwork events module762, a network notifications (NN)module764, and afleet data store766. Thedevice events module830 is configured to obtain the data of events that have occurred over a selected timeframe, such as the last one or more months, the last one or more years, a calendar month, or a calendar year, from thenetwork events module762 and display the information related to those events on an output display of themonitoring device800.
• Thenetwork events module762 is configured to receive theevent data stream719 from the monitoring connection system710 (referFIG. 1) and store the data related to those events that have occurred over a predetermined timeframe, such as a predetermined number of months or a predetermined number of years, in thefleet data store766. The data related to events may include the tag, the unique identifier, a description of the tag, one or more time stamps related to when the event occurred, and an event type.
• Thenetwork events module762 is further configured to receive a request from thedevice events module830 for the data of events that have occurred over the selected timeframe, to determine whether themonitoring device800 can access the data for those events of a selectedgas turbine engine100, and provide the data for those events that have occurred within the selected timeframe. In some embodiments, thenetwork events module762 provides the data for the events that have occurred over the predetermined timeframe and thedevice events module830 filters the data and only displays the information related to the events that have occurred within the selected timeframe. In other embodiments, thenetwork events module762 pre-filters the data and only sends the information related to the events that have occurred within the selected timeframe. The selected timeframe may be determined by user input.
• In some embodiments, the event information may also be filtered and displayed by event type. Thedevice events module830 may be configured to display only the events related to the event types currently selected by a user. In some embodiments, thedevice events module830 establishes a connection to thenetwork events module762 and thedevice events module830 requests the event data for the events that have occurred within the selected timeframe from thenetwork events module762 when the connection is established.
• TheNN module764 is configured to issue an alert to theDN module850 to notify a user of when an event occurs. The alert may include the event name, the event status and the timestamp related to when the event occurred. TheNN module764 may use one or more methods for notifying the user including push notifications, such as pushing the notification to theDN module850 which is configured to display the notification on themonitoring device800, email notifications, such as emailing the notification to the user, or text notifications, such as sending the notification to the user via a text message. The text message may be sent via short message service (SMS), data, or both. The text message may also be sent via a text messaging service or application. TheDN module850 may instruct theNN module764 on how to send the alert to themonitoring device800 and which type of alert to send to themonitoring device800.
• TheNN module764 may be configured to compare the event status of the tags for the most recently received event data with the event status of the tags for the event data received in the period prior to the most recently received event data for each of the tags in the event data to determine whether the event has occurred. In embodiments, event status is a Boolean value and theNN module764 checks for Boolean values in the tags that change from a value that represents an inactive state to a value that represents an active state to compare the event status for each of the tags.
• TheDN module850 may be configured to accept a user's input to allow a user to select which event types, such as status bits, alarms, and shutdowns, will trigger a notification, to accept a user's input to allow a user to select which type of notification will be used, and to send those selections to theNN module764. TheNN module764 may be configured to use the selections to determine when and how to send a notification to the user.
• FIG. 7 is a schematic illustration ofmultiple turbomachinery system50 connected to themonitoring system700 ofFIG. 1. As illustrated inFIG. 7, themonitoring system700 may also include a network remote management tools module (NRMI)780. TheNRMI module780 may be located in thedata center705 and may run on one or more machines, such as servers located in thedata center705. In some embodiments, theNRMI module780 may be implemented on the monitoringsystem data provider720 or thefleet data system760.
• TheNRMI module780 may include adiagnostic module782 and amanagement module784. Referring toFIGS. 1 and 7, thediagnostic module782 may be configured to obtain and monitor the status details of themonitoring system700 including themonitoring connection systems710 including theconnection system module712, the monitoringsystem data provider720, and thefleet data system760. The status details may include the network connectivity status of themonitoring connection system710 to the remainder of themonitoring system700, the data acquisition status of themonitoring connection system710 from thecontrol system600, the data posting status of themonitoring connection system710 to the remainder of themonitoring system700 including the monitoringsystem data provider720 and thefleet data system760, system status of theoverall monitoring system700, the performance status of themonitoring connection system710 including the CPU and RAM usage, and the service status of thedata center705 including the monitoringsystem data provider720, themonitoring system servers740, and thefleet data system760. Thediagnostic module782 may be configured to diagnose and report the status of each including any errors associated therewith.
• In some embodiments, thediagnostic module782 is also configured to monitor and diagnose theturbomachinery system50. In these embodiments, monitoring the data acquisition status may further include monitoring the data acquisition of theHMI620 from thecontroller610 and of thecontroller610 from the various sensors. In these embodiments, thediagnostic module782 may be configured to receive the sensor data and the event data and to diagnose theturbomachinery system50 based on, inter alia, the sensor data and the event data ant to report the status of one or more systems and sub-systems of theturbomachinery system50.
• Themanagement module784 may be configured to remotely manage including, inter alia, troubleshooting, updating, and maintaining themonitoring system700 including themonitoring connection system710, the monitoringsystem data provider720, themonitoring system servers740, thefleet data system760 and the various modules associated therewith. Managing themonitoring connection system710 may include remotely managing the network connectivity, the data acquisition, and performance of themonitoring connection system710. Updating themonitoring connection system710 may include updating theconnection system module712 by onboarding theconnection system module712 from theNRMI module780 to themonitoring connection system710.
• Managing the monitoringsystem data provider720 and thefleet data system760 may include managing the data posting of each. Managing themonitoring system servers740 may include managing the service and connectivity of themonitoring system servers740 to themonitoring devices800 including troubleshooting the display performance of themonitoring devices800. Themanagement module784 may also provide recommendations to the user to schedule maintenance or further diagnostics of theturbomachinery system50. In some embodiments, providing recommendations includes sending the recommendation to amonitoring device800 with theNN module764.
• TheDRMI module880 may be configured to receive the status details from theNRMI module780 and to display those details to an authorized user on an output display of themonitoring device800. TheDRMI module880 may also be configured remotely manage themonitoring system700 through theNRMI module780. TheDRMI module880 may receive setup inputs, configuration inputs, and software updates from an authorized user and send those inputs and software updates to theNRMI module780.
• Based on the information obtained through theDRMI module880, an authorized user may, inter alia, recommend service, part replacement, repairs, and further onsite diagnostics for theturbomachinery system50. In some embodiments, theDRMI module880 may interface with theNN module764 to send those recommendations to amonitoring device800, such as themonitoring device800 of an owner or manager of theturbomachinery system50. Further, a user, such as an engineer or a fleet manager, may recommend service, part replacement, repairs, and further onsite diagnostics for theturbomachinery system50 based on the information received through one or more of theliveview module810, thedevice events module830, theDN module850, and theNN module764. These recommendations may also be provided using theNN module764.
• While theDRMI module880 is illustrated with theliveview module810,device events module830, andDN module850, theDRMI module880 may be provided separately and may be located on aseparate monitoring device800.
INDUSTRIAL APPLICABILITY
• Turbomachinery system50 may be suited for any number of industrial applications such as various aspects of the oil and gas industry (including transmission, gathering, storage, withdrawal, and lifting of oil and natural gas), the power generation industry, cogeneration, aerospace, agricultural, mining, rail, construction, earthmoving, forestry, and other transportation industries.
• Referring toFIG. 1, a gas (typically air10) enters theinlet110 as a “working fluid”, and is compressed by thecompressor200. In thecompressor200, the working fluid is compressed in anannular flow path115 by the series ofcompressor disk assemblies220. In particular, theair10 is compressed in numbered “stages”, the stages being associated with eachcompressor disk assembly220. For example, “4th stage air” may be associated with the 4thcompressor disk assembly220 in the downstream or “aft” direction, going from theinlet110 towards the exhaust500). Likewise, eachturbine disk assembly420 may be associated with a numbered stage.
• Once compressedair10 leaves thecompressor200, it enters thecombustor300, where it is diffused and fuel is added.Air10 and fuel are injected into thecombustion chamber320 viafuel injector310 and combusted. Energy is extracted from the combustion reaction via theturbine400 by each stage of the series ofturbine disk assemblies420.Exhaust gas90 may then be diffused inexhaust diffuser510, collected and redirected.Exhaust gas90 exits the system via anexhaust collector520 and may be further processed (e.g., to reduce harmful emissions, and/or to recover heat from the exhaust gas90).
• During operation of aturbomachinery system50 including a turbomachine, such asgas turbine engine100, information relating to its operation is captured for controlling, monitoring, and performing diagnostics on theturbomachinery system50. The data captured by thecontroller610 may be read by theHSR630 and logged in batches. These batches may be obtained by themonitoring system700 through themonitoring connection system710. Themonitoring system700 may be used to monitor and diagnose theturbomachinery system50. Themonitoring system700 may provide raw data, statistics, notifications, and recommendations to engineers or to customers. Themonitoring system700 may also include analytic and diagnostic tools for further analysis and diagnostics of theturbomachinery system50 and of themonitoring system700.
• FIG. 8 is a flowchart of a method for remotely monitoring turbomachinery, such as thegas turbine engines100 ofFIGS. 1 and 2. The method includes periodically receiving sensor data from theturbomachinery package60 at amonitoring connection system710 located on site with theturbomachinery package60 at step912. The sensor data may include data related to sensors connected to systems and sub-systems associated with theturbomachinery package60. The sensor data along with any other data received from theturbomachinery package60 may pass through thefirewall650 to prevent remote access to theturbomachinery package60. The sensor data may include multiple tags that include a tag name, a unique identifier, and a recorded value that represents the measurement made by the sensor. In some embodiments, a single site includes multiple turbomachinery packages60. Step912 may include receiving the sensor data frommultiple turbomachinery packages60 concurrently.
• The method also includes periodically sending the sensor data from themonitoring connection system710 to a monitoringsystem data provider720 located remotely from themonitoring connection system710 atstep914. The monitoringsystem data provider720 may be located at adata center705. Step914 may include the monitoringsystem data provider720 receiving the sensor data formultiple turbomachinery packages60 from one or moremonitoring connection systems710.
• The method may further include requesting the sensor data from amonitoring system server740 with amonitoring device800 atstep916. The method yet further includes themonitoring device800 periodically receiving the sensor data from the monitoringsystem data provider720 atstep918. The sensor data may travel from the monitoringsystem data provider720 to themonitoring system server740 and then to themonitoring device800. Using multiplemonitoring system servers740 as intermediary devices may reduce the data flow and the bandwidth used by the monitoringsystem data provider720 since multiple connections requesting the sensor data for the samegas turbine engine100 can be done through the samemonitoring system server740.
• The method still further includes themonitoring device800 determining whether the tags for each group of a plurality of groups are in the sensor data atstep920. Step920 may include determining whether a critical tag for each group of the plurality of groups is in the sensor data and correlating the tags with the groups that have the critical tag in the sensor data. The critical tag is unique to each group. Step920 may also include comparing the unique identifier for each tag in the sensor data with the unique identifier for the critical tag of each group. All of the possible tags may be mapped and associated with one or more critical tags. Thegroup module812 may use the tag map to determine which tags are available based on which of the critical tags are available. The tag map may be updated whenever a new system or new tags become available for monitoring.
• The method also includes periodically displaying at least one of the available groups including the tag name and the sensor value for each tag in the group on an output display of themonitoring device800 at step922. Step922 may include dynamically displaying at least the one available group with at least a second available group by obtaining the size of the output display, determining the size of each group, and organizing the groups within the display to minimize an amount of white space shown on the output display. Multiple sets of groups may be available for display. Step922 may also include reviewing an input selection made at themonitoring device800 to determine which set of groups to display on the output display. Asecond monitoring device800 may be used to monitor the same or different turbomachinery concurrently with afirst monitoring device800 following the same or similar steps as provided herein.
• In some embodiments, the method also includes recommending service to theturbomachinery system50 or scheduling service for theturbomachinery system50 based on, inter alia, the sensor data provided.
• FIG. 9 is a flowchart of a method for monitoring events for turbomachinery, such as thegas turbine engines100 ofFIGS. 1 and 2. The method includes periodically receiving event data from theturbomachinery package60 at amonitoring connection system710 located on site with theturbomachinery package60 atstep932. The event data may include data for events related to systems and sub-systems associated with theturbomachinery package60. The event data along with any other data received from theturbomachinery package60 may pass through thefirewall650 to prevent remote access to theturbomachinery package60. The event data may include multiple tags that include a tag name, a unique identifier, and a Boolean value that represents the current status of the event. In some embodiments, a single site includes multiple turbomachinery packages60. Step932 may include receiving the event data frommultiple turbomachinery packages60 concurrently.
• The method also includes periodically sending the event data from themonitoring connection system710 to afleet data system760 located remotely from themonitoring connection system710 atstep934. Thefleet data system760 may be located at adata center705. The event data may include every event tag and the status of each event or may only include those event tags that include a status that has recently changed. Step934 may include storing the event data for a predetermined period. Step934 may also include thefleet data system760 receiving the event data formultiple turbomachinery packages60 from one or moremonitoring connection systems710.
• The method further includes requesting at least the data related to events that have occurred over a selected timeframe with amonitoring device800 atstep936. The selected timeframe may be equal to or shorter than the predetermined timeframe. The method yet further includes sending at least the data related to the events that have occurred over the selected timeframe from thefleet data system760 to themonitoring device800 atstep938. In some embodiments, the data related to the predetermined timeframe is requested and sent. In other embodiments, only the data related to the selected timeframe is requested and sent.
• The method still further includes displaying at least the data related to the selected timeframe on an output display of themonitoring device800 atstep940. In some embodiments,step940 includes themonitoring device800 filtering the data related to the predetermined timeframe to only display the results related to the selected timeframe. Asecond monitoring device800 may be used to monitor the same or different turbomachinery concurrently with afirst monitoring device800 following the same or similar steps as provided herein.
• In some embodiments, the method also includes recommending service to theturbomachinery system50 or scheduling service for theturbomachinery system50 based on, inter alia, the event data provided.
• FIG. 10 is a flowchart of an alternate embodiment of a method for monitoring events for turbomachinery, such as thegas turbine engines100 ofFIGS. 1 and 2. The method includes periodically receiving event data from theturbomachinery package60 at amonitoring connection system710 located on site with theturbomachinery package60 atstep952. The event data may include data for events related to systems and sub-systems associated with theturbomachinery package60. The method may include passing the event data along with any other data received from the turbomachinery package through thefirewall650 to prevent remote access to theturbomachinery package60. The event data may include multiple tags that include a tag name, a unique identifier, and a Boolean value that represents the current status of the event. In some embodiments, a single site includes multiple turbomachinery packages60. Step952 may include receiving the event data frommultiple turbomachinery packages60 concurrently.
• The method also includes sending the event data from themonitoring connection system710 to afleet data system760 located remotely from themonitoring connection system710 atstep954. Thefleet data system760 may be located at adata center705. The event data may include every event tag and the status of each event or may only include those event tags that include a status that has recently changed. Step954 may also include thefleet data system760 receiving the event data formultiple turbomachinery packages60 from one or more monitoring connection systems710.Steps932 and952 may be a single step performed for both the method ofFIG. 9 and the method ofFIG. 10 concurrently. Similarly, steps934 and954 may be a single step performed for both the method ofFIG. 9 and the method ofFIG. 10.
• The method further includes thefleet data system760 determining whether an event has occurred atstep956. Step956 may include comparing the event status, such as a Boolean value, of the most recently received event data with the event status of the event data received in the period prior to the most recently received event data for each tag in the event data. Comparing the event status may include checking for Boolean values in the tags that change from a value that represents an inactive state to a value that represents an active state.
• The method further includes notifying a user when an event occurs at step958. Step958 may also include notifying the user by pushing the notification to amonitoring device800 and displaying the notification on an output display of themonitoring device800, notifying the user by sending the user an email of the notification, notifying the user by sending a user a text message including the notification, or by sending any combination of the three types of notifications. In embodiments, the notification is sent when the Boolean values in the tag for an event changes from an inactive to an active state. Thefleet data system760 may send the event data to themonitoring device800 for at least events that have occurred within the selected timeframe and when the event data includes data related to an active event.
• The method may also include selecting which types of notifications to receive. The method may further include selecting how the notifications will be received. Themonitoring device800 may be used to select which notification types to receive and to select how the notifications are sent to the user. Themonitoring device800 may send those selections to thefleet data system760 and stored in thefleet data store766.
• In some embodiments, the method includes sending service recommendations, maintenance schedules, and reminders to themonitoring device800. These recommendations, schedules and reminders may be initiated byNRMI module780 or by an authorized user, such as a fleet manager or an engineer.
• FIG. 11 is a flowchart of a method for remote management of theturbomachinery systems50 and themonitoring system700 ofFIG. 1. The method includes monitoring theturbomachinery system50 atstep982. Step982 may include monitoring and diagnosing the network connectivity of theturbomachinery system50, such as the connectivity of themonitoring connection system710 to an external network, such as the internet. Step982 may also include monitoring and diagnosing the data acquisition of themonitoring connection system710 from theturbomachinery package60 and the data acquisition of, inter alia, thecontroller610 from the sensors of theturbomachinery system50. Step982 may further include monitoring and diagnosing the performance of themonitoring connection system710, such as the CPU utilization and disk usage of themonitoring connection system710. Step982 may also include monitoring and diagnosing one or more of the systems and subsystems of theturbomachinery system50. Monitoring the systems and subsystems of theturbomachinery system50 may include analysis of the sensor data, the event data, the network connectivity status, and the data acquisition status.
• The method also includes monitoring themonitoring system700 atstep984. Step984 may include monitoring and diagnosing the data posting of the sensor data and the event data at the monitoringsystem data provider720 and thefleet data system760 respectively. Step984 may also include monitoring and diagnosing, inter alia, the operations of the monitoringsystem data provider720, themonitoring system servers740, and thefleet data system760. Step984 may further include monitoring and diagnosing the availability of the service to themonitoring devices800, such as the availability of the sensor data for theliveview module810, the availability of the event data for thedevice events module830, and whether theNN module764 is sending notifications to themonitoring devices800.
• The method further includes managing theturbomachinery system50 atstep992. Step992 may include troubleshooting, updating, and maintaining themonitoring connection system710. Updating themonitoring connection system710 may include pushing an update to themonitoring connection system710 and updating theconnection system module712, such as by onboarding the update from theNRMI module780 to themonitoring connection system710. The update may include, inter alia, an update to the configuration of theconnection system module712 or a software update to theconnection system module712. Step992 may also include the remote initial set up of theconnection system module712. Step992 may also include troubleshooting, updating, and maintaining the data acquisition of themonitoring connection system710 and thecontrol system600. Step992 may further include troubleshooting, updating, and maintaining theturbomachinery system50. Updating and maintaining theturbomachinery system50 and the data acquisition of themonitoring connection system710 and thecontrol system600 may include recommending, scheduling, and performing service on theturbomachinery system50.
• The method yet further includes managing themonitoring system700 atstep994. Step994 may include troubleshooting, updating, and maintaining, inter alia, the monitoringsystem data provider720, themonitoring system servers740, and thefleet data system760. The updates may be provided directly or may be provided by theDRMI module880. Step994 may also include troubleshooting, updating, and maintaining themonitoring devices800. Updating and maintaining themonitoring devices800 may include providing updates of theliveview module810, thedevice events module830, and theDN module850 to each of themonitoring devices800.
• Remote management of themonitoring connection system710 may be limited to preselected authorized users. The method may further include authenticating themonitoring device800 to determine whether the user is authorized to access theconnection system module712 and update theconnection system module712.
• The various methods disclosed herein can each be performed concurrently. Those of skill will appreciate that the various illustrative logical blocks, modules, and algorithm steps described in connection with the embodiments disclosed herein can be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the design constraints imposed on the overall system. Skilled persons can implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the invention. In addition, the grouping of functions within a module, block, or step is for ease of description. Specific functions or steps can be moved from one module or block without departing from the invention.
• The various illustrative logical blocks and modules described in connection with the embodiments disclosed herein can be implemented or performed with a general purpose processor, a digital signal processor (DSP), application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor can be a microprocessor, but in the alternative, the processor can be any processor, controller, or microcontroller. The illustrative logical blocks and modules may include thecontroller610 including thecontrol module612 and themapping module614, theHMI620 including theHSR630, theevent module632, theanalog module634, themonitoring connection system710 including theconnection system module712, theconnection system gateway714, themonitoring system servers740, thefleet data system760, theDRMI module880, themonitoring device800 including theliveview module810, thedevice events module830, theDRMI module880, and the like. A processor can also be implemented as a combination of computing devices, for example, a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
• The steps of a method or algorithm described in connection with the embodiments disclosed herein can be embodied directly in hardware, in a software module executed by a processor (e.g., of a computer), or in a combination of the two. A software module can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium. An exemplary storage medium can be coupled to the processor such that the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium can be integral to the processor. The processor and the storage medium can reside in an ASIC.
• The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art.

Claims (20)

What is claimed is:

1. A system for monitoring a plurality of turbomachinery systems, each including a plurality of sensors and a control system that collects sensor data from the sensors periodically, the system comprising:

a monitoring connection system including a connection system module that periodically receives the sensor data and event data from the control system from one of the turbomachinery systems of the plurality of turbomachinery systems;

a monitoring system data provider that periodically receives the sensor data over a network from the monitoring connection system and stores the sensor data in a monitoring system data store;

a plurality of monitoring system servers connected to the monitoring system data provider and located at a data center with the monitoring system data provider;

a fleet data system located at the data center, the fleet data system periodically receives the event data from the monitoring connection system;

a first monitoring device that receives the sensor data from the monitoring system data provider and the event data from the fleet data system including receiving alerts for predetermined events as the events occur;

a network remote management tools module including

a diagnostic module that monitors the operation of the monitoring connection system, the monitoring system data provider, the plurality of monitoring system servers, the fleet data system, and a plurality of monitoring devices that includes the first monitoring device, and

a management module that updates and maintains the monitoring connection system, the monitoring system data provider, the plurality of monitoring system servers, the fleet data system, and the plurality of monitoring devices; and

a second monitoring device including a device remote management module that manages the monitoring connection system, the monitoring system data provider, the plurality of monitoring system servers, the fleet data system, and the plurality of monitoring devices through the network remote management tools module.

2. The system ofclaim 1, wherein the diagnostic module obtains and monitors status details of the monitoring connection systems of the plurality of turbomachinery systems including the connection system module of each, the monitoring system data provider, and the fleet data system.

3. The system ofclaim 2, wherein the status details of the monitoring connection systems includes a network connectivity status of the monitoring connection systems, a performance status of the monitoring connection systems and a data acquisition status of the monitoring connection systems.

4. The system ofclaim 3, wherein the management module updates the connection system module by onboarding the update from the network remote management tools module to the monitoring connection system.

5. The system ofclaim 4, wherein the update to the connection system module is provided to the network remote management tools module from the device remote management module.

6. The system ofclaim 2, wherein the diagnostic module is configured to monitor and diagnose each turbomachinery system of the plurality of turbomachinery systems.

7. The system ofclaim 6, wherein the fleet data system includes a network notification module that provides notifications to the plurality of monitoring devices, and wherein recommendations related to at least one of the turbomachinery systems of the plurality of turbomachinery systems is provided to at least one of the monitoring devices of the plurality of monitoring devices.

8. A system for monitoring a plurality of turbomachines, each including a plurality of sensors and a control system that collects sensor data from the sensors periodically, the system comprising:

a plurality of monitoring connection systems, each monitoring connection system of the plurality of monitoring connection systems including a connection system module that receives the sensor data and event data from at least the control system that receives the sensor data and the event data for one of the turbomachines of the plurality of turbomachines;

a monitoring system data provider that periodically receives the sensor data over a network from each monitoring connection system of the plurality of monitoring connection systems and stores the sensor data for each of the turbomachines of the plurality of turbomachines in a monitoring system data store;

a plurality of monitoring system servers connected to the monitoring system data provider and located at a data center with the monitoring system data provider, each of the monitoring system servers of the plurality of monitoring system servers is configured to obtain the sensor data for one of the turbomachines of the plurality of turbomachines and provide the sensor data for the one of the turbomachines to at least one monitoring device of a plurality of monitoring devices;

a network remote management tools module including

a diagnostic module that obtains and monitors status details of each monitoring connection system of the plurality of monitoring connection systems including the connection system module of each, the monitoring system data provider, and the fleet data system, and

a management module that updates and maintains the plurality of monitoring connection systems, the monitoring system data provider, the plurality of monitoring system servers, and the fleet data system.

9. The system ofclaim 8, wherein the management module sets up, configures, and updates the plurality of monitoring connection systems.

10. The system ofclaim 8, further comprising a monitoring device of the plurality of monitoring device that includes a device remote management module that manages the plurality of monitoring connection systems, the monitoring system data provider, the plurality of monitoring system servers, and the fleet data system by providing setup information, configuration information, and software updates to the network remote management tools module.

11. The system ofclaim 8, wherein the status details of the plurality of monitoring connection systems includes a network connectivity status of each monitoring connection systems of the plurality of monitoring connection systems, a performance status of each of the monitoring connection systems and a data acquisition status of each of the monitoring connection systems.

12. The system ofclaim 8, wherein the management module updates the connection system module of one of the monitoring connection systems of the plurality of monitoring connection systems by onboarding the update from the network remote management tools module to the monitoring connection system.

13. The system ofclaim 8, wherein the diagnostic module is configured to monitor and diagnose each turbomachine of the plurality of turbomachines.

14. The system ofclaim 13, wherein the fleet data system includes a network notification module that provides notifications to the plurality of monitoring devices, and wherein recommendations related to at least one of the turbomachines of the plurality of turbomachines is provided to at least one of the monitoring devices of the plurality of monitoring devices.

15. A method of monitoring a plurality of turbomachinery systems, each including a control system, the method comprising:

a plurality of monitoring connection systems, each periodically receiving sensor data and event data from the control system of a turbomachinery system of the plurality of turbomachinery systems;

a monitoring system data provider periodically receiving the sensor data from the plurality of monitoring connection systems and providing the sensor data for at least one turbomachinery system to at least one monitoring device of a plurality of monitoring devices;

a fleet data system periodically receiving the event data from the plurality of monitoring connection systems, periodically providing the event data for a predetermined period to at least one monitoring device of the plurality of monitoring devices, and sending an alert to the at least one monitoring device when an event has occurred;

a network remote management module obtaining and monitoring status details of the plurality of monitoring connection systems including a connection system module of each, the monitoring system data provider, and the fleet data system; and

the network remote management module updating and maintaining the plurality of monitoring connection systems, the monitoring system data provider, and the fleet data system.

16. The method ofclaim 15, wherein obtaining and monitoring the status details of the plurality of monitoring connection systems includes monitoring and diagnosing data acquisition including the sensor data and the event data acquisition of the plurality of monitoring connection systems from the from the plurality of turbomachinery systems.

17. The method ofclaim 16, wherein obtaining and monitoring the status details of the monitoring system data provider and the fleet data system includes monitoring and diagnosing the data posting of the sensor data at the monitoring system data provider and the posting of the event data at the fleet data system.

18. The method ofclaim 15, wherein updating and maintaining the plurality of monitoring connection systems includes the network remote management module pushing an update to the plurality of monitoring connection systems.

19. The method ofclaim 15, further comprising the network remote management module monitoring and diagnosing the operation of each turbomachinery system of the plurality of turbomachinery systems.

20. The method ofclaim 19, further comprising the network remote management module providing a recommendation related to at least one of the turbomachinery systems of the plurality of turbomachinery systems to at least one monitoring device of the plurality of monitoring devices.

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