Power Diagnostics Service

Russia Power 2006
14-16 March 2006 ID Number: 61
Moscow, Russia
Power Diagnostics Service for steam turbines and generators
Vanessa Bauch and Michael Killich
Siemens Power Generation Germany
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Siemens AG 2006. All rights reserved.
Russia Power 2006
Moscow, Russia
Abstract Due to market conditions we see a growing demand of flexibility in operating and maintaining power plants. Power plants which were designed for base load operations have to cycle and this has an enormous effect on the availability and reliability of the power plant and the turbo-generator in particular. To keep the risk calculable it is of outmost importance to know the condition of the machines. Another aspect is the necessity of flexibility due to price changes on the electricity markets. During high price periods nobody wants to shut down for a planned overhaul and it might by reasonable to use all the engineering reserves of the machine and to operate it beyond its nominal design limits for some time. These goals can only be reached when the condition of the power plant and its major components can be assessed during normal operation using online diagnostics systems. But online diagnostics does not mean a fully automated software solution, because a real diagnostic can only be achieved using all the engineering capabilities and recourses in the back offices of the turbo-generator manufacturers. Another very important issue is the availability and the avoidance of forced outages using such diagnostics. Used as a watch dog, diagnostics can help to make the business more safe and predictable. Siemens Power Diagnostics therefore is designed as a remote expert centre where we offer engineering support on a long term contractual basis. A software solution which is capable of learning the normal behaviour of the plant prevents the engineers from dealing with trivial occurrences. Using this software and the and the engineering knowledge, it is also possible to decide that a turbo-generator running out of its normal operation limits concerning vibration for example can be operated until the next planned outage evaluating the risk.
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Russia Power 2006
Moscow, Russia
Introduction Liberalization/deregulation of the electricity market continues to expand in many parts of the world. This requires that power producer owners and operators deliver electricity more efficiently and at competitive pricing. In parallel with these market demands, the operation of the complete power plant turbine, generator, boiler and auxiliaries must improve reliability, availability and utilization/efficiency. But even in parts of the world not experiencing liberalization/deregulation the growing demand in some regions for electricity is pushing power producers towards these same improvements. Whatever the market environment, this is poses a special challenge for more mature units, including base-load units that have to cycle and for plants that have not been maintained for optimal performance. To achieve these demands cost reduction and technical innovation programs were implemented in power generation process. Furthermore, a higher flexibility in operating and maintaining the plants is necessary according to the actual market conditions. Older base-load units have to cycle, which creates higher stress on the materials. Planned overhauls are postponed to avoid uneconomic standstill time. Uprating of power output of existing units to the absolute design limits is often used as an additional option to tap maximum profit during peak price periods. In parallel with all these market demands, operation of the complete power plant with the steam turbine set and generator as key components must be enhanced through higher reliability, availability and utilization. The traditional way of handling maintenance business is not aligned to these market requirements. One way to achieve the objective of flexible and short-term outage planning is to use innovative technologies combined with close cooperation with the OEM. There are a variety of solutions to help meet critical customer needs. Siemens Power Generation is in the forefront of providing numerous solutions: proven modernization designs, advanced inspection systems, new maintenance and repair services, and more. A very powerful Siemens tool to improve plant availability is Siemens Power Diagnostics. The system features a modular structure focused on technical function groups of the power plant. It works in combination with the conventional I&C system as an additional diagnostic tool for early detection of condition changes or fault indication and for preventing unexpected malfunctions. The use of comprehensive on-line data acquisition, internet data transmission systems, task-related data analysis, and an expert background knowledge base at the Remote Power Diagnostics Centers enable detailed diagnosis of the actual plant condition.
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Russia Power 2006
Moscow, Russia
With human expert support and engineering solutions from the manufacturer, together with the knowledge-based supervisory diagnostic system, long term condition-based plant operation with enhanced reliability and profitability will be possible. This Power Diagnostic Service enterprise encourages the client to make inspection decisions on turbo set components on a condition- and risk-based maintenance strategy, implement better life-time management under technical and commercial aspects, practice smoother turbo set operation for avoiding frequent overstressing of the machine, resulting in life extension. Condition monitoring with the Power Diagnostic Service leads to effective live cycle asset management. Power Diagnostics Siemens Power Generation is offering Power Diagnostics Services for steam power plants. Today Siemens provides these services globally for more than 200 OEM installations for gas turbines. The expertise on gas units is being applied to the entire steam plant island.
References
Equipment monitored by Power Diagnostics
200 180 160
Number of Units
212 182
94 sites
156 129
140 120 100 80 60 40 20 0

Gas Turbine
9 9
Generator (Gas Turbine) Steam Turbine
11 11
4 1
Generator Balance of (Steam Turbine) Plant
Figure 1: References
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Russia Power 2006
Moscow, Russia
Power Diagnostics is a comprehensive service with modular components designed to monitor, analyze and diagnose the complete turbine island. This advanced service product is a highly sophisticated remote diagnostic system. It combines global engineering experience, sophisticated monitoring, data processing, trending, analysis tools, and security systems. Different Parts work hand in hand and form the backbone of Power Diagnostics Services (see figure 2). Together they enable detailed diagnostics of the plant condition and support development and implementation of condition-based maintenance strategies and the optimization of the plant operations. Power Diagnostics Services performing analysis and diagnostics: Using extensive OEM unit knowledge Using advanced diagnostic tools/techniques Providing trend analysis and problem identification Providing root-cause analysis done by expert teams
Key elements of Power Diagnostics Services
OEM engineering expertise

OEM engin exper eering tise
Onlin e acquis data ition
Comprehensive online data acquisition

Dat proce a ssin analy g / sis
Data processing / analysis
Expe know rt led netwo ge rk
Use of an expert knowledge network
Figure 2: Key Elements of Power Diagnostics Services
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Russia Power 2006
Moscow, Russia
On-line, real-time operating data acquired from customer locations are transmitted to the Power Diagnostics Centers. Data is acquired from sensors attached to customers turbines, generators or auxiliaries. These are supported by PCs and the I&C system. The infrastructure for the data handling process and the intelligent software is provided from one of the Siemens Power Diagnostics Centers (Mlheim, Erlangen and Orlando) supplying the data acquisition, management and event-driven data storage. Data is transmitted to the center and processed through a series of advanced modules and artificial intelligence software to make sure that measured values do not exceed thresholds and operating condition limits, and that the machine and/ or systems are running in a normal mode with a predictable behavior. Skilled Siemens engineers and specialists in various functions, such as thermodynamics, rotor dynamics, fluid mechanics, processes and construction from Siemens departments in Orlando and Mlheim are connected with the Power Diagnostics Centers (see figure 3). This engineering knowledge, combined with the use of advanced diagnostic tools and techniques enable trending and analysis to address a broad range of operating needs that are specific to each customer. The objective is early detection of abnormal operating conditions, assessment by Siemens engineers and specialists and timely recommendations to customers. Any necessary operating adjustments can be made or other actions taken to continue successful performance and avoid unplanned downtime. To summarize, the Power Diagnostics Center performs analyses and diagnostics using highly sophisticated learning software modules, provides trend analyses, problem identification, and root-cause analyses conducted by human experts. The learning software solution helps the experts to avoid spending their time and resources on minor issues. Also, since the pool of information is coming from a large fleet, the experience base grows much faster than it would from only a single plant. Even if no abnormal condition is detected in the turbine-generator our engineering experts are able to generate recommendations on plant operation and/or maintenance actions. These recommendations are designed to maximize the equipments performance, reliability and availability and potentially extend outage intervals.
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Russia Power 2006
Moscow, Russia
Power Diagnostics - Infrastructure for data handling

Online real-time operating data transmission Power Diagnostics Center Expert Network Team
Worldwide network for data exchange
Use of advanced diagnostic tools and techniques for: Reports Monitoring of machine conditions Access Data collection / processing Analysis of limit values and deviation from normal behavior Info Engineering Know-how: Interpretation and diagnosis Data assessment Development of recommendations for future operations, repairs and/or modernization
Your Power Plant
Analysis
14-16 March 2006
Russia Power
Monitoring Offline Diagnosis Power Generation 5 Online Diagnosis Online Diagnosis Vanessa, O263 Bauch
Siemens Power Generation 2004. All Rights Reserved
Figure 3: Data handling There are close to 20 separate diagnostic modules in the Power Diagnostics product line In introducing these services for operating steam turbine-generators, the following diagnostic products are already available, with others to follow: Shaft and bearing vibration Monitoring of turbine generator vibration behavior by measuring shaft and bearing vibration and operating variables over extended period. End winding vibration One of the turbine generator components that is subjected to the most stress are the generator end windings. Despite the precision design and production that goes into these items, the vibration behavior of the end winding nevertheless changes over the course of operation as a result of ageing and thermal influences. Changes in vibration behavior can occur as a result of disturbances in the grid, switching operations and lightning strikes. An analysis of the condition of the end windings can be made by acquiring these vibration (oscillation) levels.
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Russia Power 2006
Moscow, Russia
Torsional Vibration Electrical disturbances in the grid, switching operations and lightning strikes can cause torsional vibration in power plant turbine generators, resulting in the line of shafting being subjected to elevated, sometimes impermissible loading. This is why measurement and evaluation of such events and processes is so important; this also contributes to correct assessment of the condition of the turbine generator with respect to condition-based maintenance. All three types of vibrations can be handled on one hardware and software platform VIBROCAM 5000 RF monitoring: Digital radio frequency measurement system, permits early detection and indication of incipient damage. It is based on the detection of partial discharge that results in short-circuiting across part of the insulation. Krawal: A tool developed for plant design and engineering of the thermodynamic processes integrated into online diagnostics to compare current process data with anticipated values.
Currently 5 modules help collect the data Basis for diagnostic works:
Bearing and Shaft Vibration Measurement
Enables vibration behavior assessment of a turbine island
End Winding Vibration Monitoring

Measures vibration levels at stator end windings to determine changes occurring within the generator
Torsional Vibration Monitor

Monitors vibration levels due to torsional excitation which can cause blade and / or rotor failures
Process engineering Tool (KRAWAL)

Thermodynamic module, which helps compare current process data with expected values
Radio Frequency Measurement System (SIEMON)

Monitors generators and high voltage equipment by partial discharge measurement
Figure 3: Steam Turbine Generator Product Portfolio Figure 4: Overview of available service modules
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Russia Power 2006
Moscow, Russia
Contract The concept of Power Diagnostics is designed to fit in Siemens Strategic Alliances Programs (see figure 5). These long-term service contracts are designed to develop the business from transactional and price-driven models to performance-driven contracts with value-based pricing. Performance-driven, value-based pricing denotes mutually agreed objectives such as availability, reliability or other customer benefits, measured and evaluated in a Score Card. The prices for services ordered within such long-term contracts are therefore fixed prices from a list of specifications plus a bonus / penalty based on the results of the Score Cards. The result is an integrated solution for deregulated markets where Siemens is more or less responsible for all maintenance issues within the turbine island, i.e. the risk sharing level, the level of goal alignment and the value-based pricing. The idea of a value-based pricing and risk sharing is a key element in an Long Term Program contract. One possibility to achieve this is by implementing Score Cards, developed and mutually agreed upon during the negotiation process by the contract partners. This concept of a value-based pricing system is available for Power Diagnostics Service Contract also. In this case the customers benefits have to be identified and fixed in a mutually agreed matrix. These benefits can be in the form of events such as avoidance of a forced outage or early detection of an imminent failure. Early detection, for example, gives the customer additional time for planning and can therefore shorten the outage duration.
Transactional
Expanded Scope / Risk
Performance Driven O&M

Operations & Maintenance
Diagnostic compatible data collection: proactive
Mutual Benefit
Operating Plant Service Agreement
Long Term Program
LTP
Project Managed Maintenance MC Contract
OPSA
e an c i All
Minimum of continous costs TFA

Technical Field Assistance
TMS
Total Maintenance Services
Today: Fire fighting Reactive
Figure 5: Overview Strategic Alliance Programs
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Russia Power 2006
Moscow, Russia
Customer Benefits Increasing cost pressure in power generation forces power plant operators to optimize service and maintenance and to maintain or even improve reliability and availability . This objective can be reached by applying a condition-based maintenance strategy. Siemens Power Diagnostics is a powerful tool to support the power plant operator in achieving this objective But only with the combination of on- and off-line measurements / monitoring can a high degree of assessment quality be attained. The goal of Power Diagnostics Services is to help identify, assess and diagnose plant operating abnormalities that could result in inefficiency and forced outages. Also, the system's condition monitoring capabilities offer more effective life cycle asset management, which is especially important for flexible operation of base-load units. For plant operators, the provision of advance detection of abnormal operating conditions and, ultimately, follow-up actions can result in optimized operation, higher availability and improved turbine island efficiency. For the original equipment manufacturer, information collected through Power Diagnostics can be used to further improve products and services, including improvements in hardware service life and durability, to mitigate collateral equipment damage through early detection, to enhance reliability, and to improve scheduling and optimize the duration of maintenance outages. Results from Power Diagnostics can contribute to development of recommendations for future operations, repairs and/or modernization of customers equipment. This Power Diagnostics Service encourages the customer to: Make inspection decisions on turbo set components in terms of a condition- and riskbased maintenance strategy Improve life-time management through improved data and data analysis Improve turbo set operation to avoid frequent overstressing for potential life extension. The bottom line is this: Siemens Power Diagnostics Services can help identify a problem before it impacts operation, allowing plant personnel to make necessary adjustments for continued operation. In some cases Power Diagnostics can help turn an unplanned shutdown into a scheduled outage with all the personnel and materials needed to help make optimal use of the customers time and money (see figure 6 and case study).
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Russia Power 2006
Moscow, Russia
Limit Value Shut down
Signal progression Start-up Superior limit value Stand still
Identifiable Trend Early detection of an unplanned stand still by diagnostic experts.
t Preparation for the stand still Delta t Economized time in fact of early problem detection and change from an unplanned to a planned stand still.
Figure 6: Benefit of an early damage detection For the short term Power Diagnostics provides the power plant operator with regular documentation of the monitored components on a high quality data basis. In case of recurring problems and/or detected operation abnormalities/trends etc., exclusive access to the engineering network with guaranteed capacities is provided. A Power Diagnostics customer is treated as a preferred customer. Based on continuous monitoring and comparison with the historical data, early detection of problems and damages can be realized. This helps the power plant operator to save costs and to increase sales. But it also offers the possibility to continue plant operation with justifiable risks, for example in phases with high prices on the electricity market. For the long term Power Diagnostics forms the basis for Condition-based maintenance Flexible operation Life-time extension Maintaining optimum efficiency Availability enhancement
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Russia Power 2006
Moscow, Russia
Summary and Outlook Power Diagnostics services

Regular documentation of machine conditions Access to the Siemens Expert Network
can provide
Early detection of many operating issues Information for proactive decision making Condition-based maintenance
are the basis for
Flexible operation Efficiency/ Availability/ Reliability Improvement Risk sharing, extended warranties Performance related payment Cost savings
in combination with long term service contracts
Figure 7: Customer Benefits on short term and long term view
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Russia Power 2006
Moscow, Russia
Case study Online diagnostics does not mean relying exclusively on software solutions. It is the combination of skilled OEM personnel, the operation experience of an entire fleet and the application of advanced diagnostic tools that make for success. The basis for successful diagnostic work is formed by the high quality data pool, combined with a powerful hardware and software system for data processing and an expert team for data assessment. The interaction of an advanced monitoring/ analysis system and experts leads to an established statement about machine behavior, as well as to an observation of problem causes and recommendation for the elimination of the problem. Requirements for a vibration analysis and monitoring system: Diagnosis-oriented data acquisition Diagnosis-oriented data analysis and data reduction to meaningful key parameters with a minimum loss of information Diagnosis-oriented data processing for off-line diagnostics by experts Automatic determining of the machine-model-specific and measuring-point-specific normal conditions and behavior of the key parameters within the excursion for normal operating parameters Diagnosis-oriented monitoring automatic evaluation of key parameters as compared to the values for normal conditions and behavior, with data archiving in the event of deviation from normal conditions. All of these requirements are fulfilled by the Vibrocam5000 hardware and software systems. The following example illustrates the procedure to take in the event that vibration problems arise. Power Diagnostics has demonstrated its abilities already several times as in the following case: 4 weeks ahead of a planned outage in a turbine-generator set all measured vibration values are in normal range, but variations in the generator rotor data were detected. An additional measurement was carried out and the resulting data were analyzed and assessed by the Siemens Power Diagnostics Expert Team. The result of the measurement was the detection of a crack in the axial water guidance in the protection sleeves of the generator rotor. It was recommended to exchange the complete rotor in order to get the power plant back in operation. Through early detection and planning work the rotor was exchanged at the scheduled outage using a pool rotor: Chances of finding the crack during the scheduled outage were very low,
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Russia Power 2006
Moscow, Russia
since the scope did not include the generator. Power Diagnostics Services were significant in preventing a forced outage. The turbine-generator set has one high pressure and two low pressure turbines and a water cooled generator. The turbine and generator side at the low pressure turbine, the turbine and exciter side at the generator, the exciter bearing and the shaft pump were examined by vibration test points (see figure 8).
System configuration
Absolute bearing vibrations (mm/s)
Relative shaft vibrations (m)
Figure 8: System configuration and vibration test points
Examination of the vibration behavior between 10th February 10th March showed changes in the vibration behavior as from 21. February (see figure 9). The measurement values were still under the limit values so the operator was not really alarmed. Concerning vibration issues changes are always indications, even if limit values were not exceeded therefore the situation was seen as a task force issue. In order to get a detailed view of the vibrations the summarized values of the amplitudes as well as the vibration vectors were examined. The vibration vectors showed high changes of the vibration level - about three times higher. The high variations of the vibration level indicate a generator vibration problem (see figure 10).
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Russia Power 2006
Moscow, Russia
Vibration behavior between 10th February 10th March 2005
Change of vibration behavior as from 21.02.05
Figure 9: Vibration behavior between 10th February and 10th March
Comparison 2th February and 30th March 2005
LP2 Bearing Turbine side
LP2 Bearing Generator side
Generator Bearing Turbine side
2th February = dark blue

stable
Generator Bearing Exciter side
Extended changes
Exciter Bearing
30th March = light blue
Shaft Pump
Figure 10: Comparison 2nd February and 30th March
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Russia Power 2006
Moscow, Russia
Experts gather from the significant changes of the vibration levels based on the know-how from development & design and the experience an exciter current depending issue. On this account a correlation vibration behavior versus excitation current was realized. Following distinctive features could be determined No linear correlation between exciter current and vibration level Increased vibrations at higher and lower excitation current Lowest vibration level at 6,8 kA excitation current (see figure 11)
Vibration behavior versus excitation current
Lowest Vibration level at 6,8 kA excitation current Increased vibrations at higher and lower excitation current
Figure 11: Vibration behavior versus excitation current
Based on this results following statements were made: The typical vibration behavior with regard to the exciter current influence has been changed since 21. February There has to be an additional influencing parameter which has a high dependency on the exciter current and causes the vibration One possible reason for this behavior could be the influence of the primary cooling water temperature on the vibration behavior. An additional test was realized to analyze the behavior of the vibration by changing cooling water temperature under constant excitation current. The result of the test showed that the machine had an identical behavior (see figure 12).
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Russia Power 2006
Moscow, Russia
Comparison: changes due to reactive power <> changes due to primary water temperature
Changes of the reactive power
Changes of the primary water temperature
>> the reaction of the machine is identical
Figure 12: Comparison: changes due to reactive power versus changes due to primary water temperature
Based on the generator design a crack in the axial water guidance was assumed (see figure 13). During the standstill a crack in the axial water guidance in the protection sleeves of the generator rotor was detected. About 1,8 liters of water were located in the air gap between water guidance and rotor. The complete rotor was exchanged in order to get the power plant back in operation. The crack was located on one cooling water pipe. Due to the water in the air gaps a better heat transfer could take place which leads to a thermal unbalance within the rotor. Only when the rotor and the cooling water temperature were on the same level there was no heat flow and so far no vibrations. This happened at about 6,8 KA (the point of the lowest vibration level)
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Russia Power 2006
Moscow, Russia
Old generator shaft design Cooling Spare rotor / water guidance (Protective pipe)
cam direction by protection pipe
cam direction by protection pipe
weld
weld
water chamber
R a d i a l pi p e
water chamber
R a d i a l pi p e
relative movement due to shaft bending relative movement due to shaft bending
Axial water guidance Axial water guidance
Compensator Compensator
3mm
12mm
3mm
2120mm
12mm
2120mm
welds
welds
Figure 13: Old generator shaft design Cooling spare roter/ water guidance (protective pipe)
On the sketch in figure 6 you can see the generator cooling design. The rotor is equipped with 4 cooling water pipes (2 water supplies, 2 drain pipes) The cooling pipes are fixed with welded cams. The relative movement due to shaft bending leads can lead to cracks in the weld of the pipe
Based on the above mentioned case study two main points can be pointed out: Continuous monitoring is important to ensure early detection of operation issues in this way time and money can be saved. The know-how from development and design as well as the know-how and experience of specialists are necessary to solve problems in a fast and responsive way.
18/20
Russia Power 2006
Moscow, Russia
Summary Due to the changing market conditions all over the world, the traditional way of dealing with maintenance business no longer fits in with these new environmental requirements. The solution is to achieve a flexible and short-term outage planning process and a reduction of costs. Diagnostics, in particular in combination with Strategic Alliances, can fulfill all these demands, as they are tailor made solutions. Monitoring and diagnostics is a rapidly evolving field in power generation. The combination of available IT technology and on-line expertise provides cost-efficient service and benefits to the customer. In summary: Increasingly more specific analysis and diagnostic technology is now available To maximize the benefits for power plants, the challenge is to employ all requisite technologies via a single platform Global networking of a running fleet enables OEM experts to analyze data quickly and respond rapidly to customer requirements On-line diagnostics - in combination with remote expert knowledge - is the key to condition-based maintenance and provides cost-efficient service for reliable plant operation. For the customer, it is important in any given situation to have access through a diagnostic platform to the knowledge of the people who designed his equipment. For the equipment supplier, the greatest benefit is to have live feedback from his own "running technical systems" that enables him to optimize his own learning process. And last but not least, on-line diagnostics paves the way from scheduled maintenance to condition-based maintenance, thus helping customers operate their units at maximum profitability.
19/20
Russia Power 2006
Moscow, Russia
Literature [1] Taud R.; Scheidel M.: Use and Experience with Gas Turbine On-Line Diagnostics, Power Gen Europe, Barcelona 2004 [2] Bender, K.; Grhn, M.; Rukes, B.; Scheidel, M.: Online Remote Diagnosis of Turbosets and Combined Cycle Power Plants; VDI-Bericht Nr.: 1641, VDI-Verlag, Dsseldorf, 2001 [3] Adam, G.; Bode, A.: Ferndiagnose und Teleservicesystem fr GUD-Kraftwerke; VDI-Bericht Nr.: 1566, VDI-Verlag, Dsseldorf, 2000 [4] Brummel, H.-G.; Scheidel, M.; Thompson, E.: Gut behtet aus der Ferne; Siemens Power Journal, Heft 1/00 [5] Ulbrich, A; Gobrecht E.; Siegel M. R.; Brckner J.: High Steam Turbine Operating Flexibility Coupled with Service Interval Optimization, Power Gen Europe, Barcelona 2004
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Russia Power 2006

14-16 March 2006 ID Number: 61