Overview

A 450 MW combined cycle gas turbine operating at a spark spread of approximately $25/MWh generates more than $270,000 in value per day, but an undiagnosed fault runs the cost of lost generation and a premium rate for emergency response until the plant is back online.

The challenge

When the plant's 9FB combined cycle gas turbine didn’t synchronize during a start sequence, the operations team faced a potential unplanned outage.

With the potential for losses running from $270,000 to over $1 million depending on duration, they called the operations team called GE Vernova's Remote Diagnostic Services (RDS) for remote support to diagnose the fault in near real-time.

The solution

The RDS team connected within 20 minutes of the call and the engineer pulled up the Exciter Process Alarms and the Sequence of Events log. Within two hours, the data pointed to a communication loss between the EX2100* exciter controller's core and both the M1 and M2 cores. The RDS engineer identified a faulty DSPX card as the root cause and the unit returned to service in under four hours.

*EX2100 is a trademark of GE Vernova and/or its affiliates.

Outcomes

Quick return to operation

20 minutes

RDS connection established

< 2 hours

Root cause identified

< 4 hours

Unit returned to service

$270K/event**

Estimated return-to-service savings

** Based on 450 MW at $25/MWh spark spread.

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A fault that could have triggered a multi-day forced outage was resolved in a single shift. Access to live alarm data and sequence of events logs gave the site team a precise repair action, rather than a list of possibilities to work through.

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