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Automated forecasting of the resource of powerful electric turbine drives at compressor stations

A.R. Kolganov, O.V. Kryukov, S.E. Stepanov

Vestnik IGEU, 2025 issue 3, pp. 73—79

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Abstract in English: 

Background. Forecasting the technical condition of the main processing installations of compressor stations is one of the priority areas of improvement based on intellectual automation systems. The electric drive of turbochargers with a capacity of 4–25 MW is classified as hazardous production facilities. And in accordance with industry regulatory and technical documents, it is subject to continuous monitoring and resource forecasting in the medium term. The existing systems to monitor technical condition of drive electric motors are based on outdated methods and do not provide reliable and automatic forecast of the resource of high-power electric machines. The domestic electrotechnical market today lacks reliable and adequate technical means and methods of preventive forecast of the condition of electric-driven gas pumping units, which can be used to switch to maintenance according to the actual condition. In this regard, the aim of the study is to provide a theoretically sound methodology to assess the technical condition of an electric drive in on-line mode and automated forecast of its operational parameters.

Materials and methods. The study has been conducted using an empirical method for modeling the aging process of the insulation of the high-voltage stator winding of a synchronous machine. It is based on statistical processing of data on drive failures, a study of operating modes that affect the insulation resource, an assessment of the variation ranges of operational factors and determination of their correlation with the mean time between failures. Forecasting the operating modes of the turbine unit and its adaptive functioning has been carried out using the empirical Montzinger equations and the Saaty paired comparison method for mean time between failures.

Results. The authors have proposed an approach to interactive monitoring of the technical condition of drive machines based on the characteristics of partial discharges in the insulation of electric motors. An integrated system to monitor and forecast the operating modes of electric drives of turbo plants that lead to accelerated aging of the insulation of synchronous motors is developed.

Conclusions. The use of automated systems for predicting the technical condition of the electric drive of a gas pumping unit makes it possible to plan capital and routine repairs based on the actual condition, eliminate the thermal effect of currents and reduce the cost of capital repairs, monitor the operation of the cooling system of powerful machines and maintain optimal modes to increase insulation life. By combining vibration analysis data with FFT power consumption analysis, it is possible to identify the causes of increased vibration levels, thereby reducing overall operating costs.

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Key words in Russian: 
компрессорная станция, газоперекачивающий агрегат, техническое обслуживание и ремонт, электропривод, мониторинг состояния синхронных двигателей, отказы изоляции
Key words in English: 
compressor station, gas pumping unit, maintenance and repair, electric drive, monitoring the condition of synchronous motors, insulation failures
The DOI index: 
10.17588/2072-2672.2025.3.073-079
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