Power Gen Europe 2006 Cologne, Ref. No.

306

2006-03-07

Operational Flexibility for Steam Turbines based on Service Contracts with Diagnostics Tools
Michael Killich, Siemens Power Generation, Germany Power Gen Europe 2006 Cologne,

Abstract

The world wide liberalization of the electricity market forced the utilities to deliver electrical energy with high efficiency and at a competitive price. To achieve these demands cost reduction and technical innovation programs were implemented in power generation process. Furthermore according to the actual market conditions a higher flexibility in operating and maintaining the plants is necessary. Older base load units have to cycle, which creates higher stresses to the materials. Planned overhauls will be 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 catch maximum profit during high price periods. In parallel with all these market demands the operation of the complete power plant with the steam turbine set and generator as key components need to be enhanced by higher reliability, availability and utilization.
-1 Siemens AG 2006. All rights reserved.

The traditional way of handling the maintenance business is not aligned to these market requirements, because it is based on transactional and price oriented business models. The contractual parties are focusing unilateral objectives, which normally are different from each other, and trying to reach them separately. As a result, a lot of resources are necessary for the awarding process. Orders has to be prepared and evaluated for different work scopes and the packages has to be negotiated by the parties. All this leads to high transactional costs and long, inflexible outage planning processes which are a handicap for the operator to remain or become competitive and successful.

One way to achieve the objective of a flexible and short termed outage planning and to reduce the transactional costs is to establish Strategic Alliances between the utilities on the one side and the manufacturers on the other. These tailor made contracts should be the basis to leave the transactional business behind and to enter value based and success depending business models or contracts. Critical factors for the success were the alignment of the objectives and the definition of benchmark matrices (Score Cards) to measure the level of success. The range of this Strategic Alliances can vary from simple parts availability programs or Operating Plant Service Agreements (OPSA) to Long Term Programs (LTP) with risk sharing elements and the value based payment mentioned above. In addition these aims could be achieved more efficiently by using intelligent condition monitoring strategies for the power plant and its key components using a supervisory on-line diagnostic system. The use of comprehensive on-line data acquisition, internet data transmission systems, task-related data analysis and an expert background knowledge base at newly founded Remote Diagnostic Center enable detailed diagnosis of the actual plant condition.

With human expert support and engineering solutions from the manufacturer together with the knowledge based supervisory diagnostic system a long term condition based plant operation with enhanced reliability and profitableness will be possible. This Power Diagnostic enterprise promotes the client to make inspection decisions on turbo set components on a condition and risk based maintenance strategy, better life time management under technical and commercial aspects,

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more smooth turbo set operation to avoid frequent overstressing the machine which will result in life extension. Together with our Strategic Alliances Programs like LTPs risk sharing models and extended warranties could be implemented.

Condition monitoring with the Power Diagnostic tool leads to effective live cycle asset management.

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Deregulation of the markets

Like in other regions of the world, the power generation market in the Asian-Pacific region has in recent years been characterized by its orientation towards deregulation. The use of gas turbines in simple-cycle and combined-cycle plant applications grew rapidly. But also the mature fleet has to be operated more cost efficient. Market trends in the last years could be summarized as follows:

Privatization & deregulation of global energy markets Entering on Independent Power Producers (IPPs) New market purchasing new and existing plants Rising operational cost no longer a pass through to rate payers Aging conventional steam units requiring modernization to remain competitive Increasing stringent environmental requirements Asset value optimization driving all customer decisions

The privatization and deregulation trend is an international movement, which has already taken place in the American market. In Asia, Europe and Australia the movement strongly depends on the different country markets and political strategies. For the year 2008 there will be a market liberalization of 40% in the non-American markets. This trends leads to changes in the behavior of power producers. Increasing competition has caused power plants to switch from traditional time-based maintenance strategies to those based on a plants operating condition. As deregulation becomes a reality for the power generation industry and as competitive power production becomes standard operation procedure, the quality of power a company produces becomes the measure of its success. This requires the utility, independent power producer (IPP) and/or industrial power producers (IND) to bid power competitively at current market rates. The power producer that operates at the lowest cost per kilowatt-hour will thrive in this challenging environment. In a regulated environment electricity prices are typically calculated using the average costs of generation plus a recovery fee for the investment and a multiplier for the return of the investment. In a deregulated market this costs are no longer a pass trough to the customer and plant operation (the plant dispatch) depends on the marginal costs for the electricity production (Figure 1). If the actual market price is lower than the marginal costs, the plant cannot be operated in a cost-effective manner. A recovery of capital, return of investment and

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recovery of sustaining costs is achieved only during periods with spot prices higher than the marginal costs. Therefore the operating requirements can be summarized as follows:

Reliability and Availability is the Key Maximum Flexibility needed for Cycling Operation Reliable and Quick Start Up and Shut Down capabilities Ability to effectively take advantage of the high price phases in the Market - 80% of Annual Sales is earned during 20% of the time Optimize component life usage Extension of the maintenance intervals Adequate and proactive maintenance to reduce forced outage rate Reduction of overhaul durations

Figure. 1a. (Simplified Dispatch Curve Example taken from German electricity market)

Deregulation / Cost Reduction

market price marginal costs

NPP STPP (coal) STPP (oil) CCPP GTPP grid demand

cumulated capacity
Power Generation PG O26

Fig. 1a

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Figure. 1b. (Simplified Dispatch Curve Example taken from German electricity market)

Deregulation / Cost Reduction

Dispatch rate 100 % Reduction of marginal costs NPP Competitive Advantage STPP (coal) STPP (oil) 50 % CCPP GTPP grid demand 0% cumulated capacity
Power Generation PG O26

Fig. 1b

The market situation and the different areas of competitive position can be abstracted in a strategic gameboard shown in Figure 2. Power producers or power plants with high marginal costs in power production and inflexible processes concerning operations and / or maintenance are in a zone of competitive disadvantage (danger zone). Therefore it is of outrageous importance to bring or keep your assets in such a position. Even for older plants the reduction of transactional costs, the reduction of fuel costs (availability, efficiency) or the reduction of spare parts in the warehouse could be key factors to enter this success area (lower right). We see plants in this area only to be the successful ones in the long term.

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Figure. 2. (Strategic Gameboard)

Strategic Game Board

high

Danger Zone
Increasing Competition
low

Increasing Competition Competitive Advantage

high
Power Generation PG O26

Marginal costs low

Flexibility

Fig. 2

2.

Traditional Maintenance Concepts

Basis for all Strategic Alliances is the traditional maintenance business with its variety of services from Technical Field Assistance (TFA) to Turn Key Outages. As shown in Figure 3 the Total Maintenance Service (TMS) concept could be implemented for all contracts or business models. TMS is a cyclic planning process to make sure that all necessary personnel, spare parts and tools are at site at the right time. This objective is been achieved by several meetings with the customers for planning and checking purposes. The complete TMS process is installed for Customers with alliances contracts in particular.

For high quality engineered components there are repair opportunities in our workshops all over the world. In more and more cases it is possible to have an on site or even in-situ repair using advanced on site tools.

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A consolidated outage management is available for all turn key outages and strategic alliances.

Figure. 3. (Traditional Maintenance Concepts)

Traditional Maintenance Concepts

Total Maintenance Services (TMS) Technical Field Assistance (TFA)

High Quality Engineered Components Component Repairs Consolidated Outage Management Advanced Technology Specialty Inspection & On-site Repairs

Maintenance Contract (MC)

Turn-key Inspections and Outages
Power Generation
PM O26 Marketing October 2003

Portfolio of Service Programs

Fig. 3

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3.

Strategic Alliances Programs

Strategic Alliances are linking advantages and work scopes of the traditional business to a single long term maintenance contract. This process of integration is shown in Figure 4. The result is an integrated solutions for deregulated markets where Siemens is more or less responsible for all maintenance issues in the turbine island. The risk sharing level, the level of goal alignment and the value based pricing is increasing from our Operating Plant Service Agreement (OPSA) over the Long Term Programs (LTP) to Operation & Maintenance (O&M). The OPSA agreement is designed for customers with own experiences and / or capacities regarding maintenance issues who are interested in long term budgeting and new, more competitive business models. These business models are the basis for online diagnostics, up grades and condition based maintenance also. The OPSA contract is actually the most preferred contract type for the turbo generator performance maintenance business, but it is limited in its risk sharing level. Customers who are interested in value based risk sharing models prefer the LTP contract. The interconnection between scope flexibility and risk sharing level is shown in Figure 5.

Figure. 4. (Philosophy of Strategic Alliances -Contract Portfolio)

Contract Portfolio
Transactional Expanded Scope / Risk Performance Driven Operations & Maintenance

O&M

Long Term Program Operating Plant Service Agreement Project Managed Maintenance Contract Technical Field Assistant Total Maintenance Services

LTP Mutual Benefit MC TFA TMS Commitment OPSA

es c ian l l A

Power Generation PG O26

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Fig. 4 Figure. 5. (Philosophy of Strategic Alliances)

Deregulation / Cost Reduction

Flexible scope

OPSA

Fixed scope

Turnkey Outage

LTP / O&M

Transactional Individual Goals Price Driven

Performance driven Mutual Benefit Risk Sharing

Power Generation PG O26

Fig. 5

3.1

Availability Parts Program (APP)

The scope of the APP program is defined as follows: 3.2 Perform unit configuration & interchangeability study Parts modification to improve unit reliability Provide outage parts as kits Identification of critical spares Parts Catalogue Inventory Reduction Program Operating Plant Service Agreement (OPSA)

The scope of the OPSA program is defined as follows: Same as APP with addition of Component repair and refurbishment Turnkey inspections / outages / overhauls Consolidated project management (optional) and back-office support
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Alignment to outage duration needs / goals Performance of unit configuration & interchangeability study Parts modification to improve unit reliability Forced Outage Protection

The OPSA is more or less a master agreement to purchase exclusively from Siemens for 6-12 years. Based on the order values (per year) there is a certain discount level on field services and spare parts. (see Figure 6)

Figure. 6. (Discount OPSA)

Contract Structure
Discount Matrices
Operation Plant Service Agreement (OPSA)

Discount Trends Maximal Discount

Discount %

Different contracts

Basic Discount

Order Value

Power Generation PG O26

Fig. 6

3.3

Long Term Program (LTP)

The scope of the OPSA program is defined as follows: Same as APP & OPSA Goal Alignment, plant assessment, mutual agreed Score Cards Unit condition assessment Determine Long Term Maintenance Requirements

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Modernization & Refurbishment (implementation of TMs Technische Mitteilung) Performance based payment Risk sharing models Dedicated Program Manager

There are the following key roles in an LTP contract: Executive Management Contact partner at Siemens PG Leads commitment for the process Vision philosophy Periodic review (Goals and objectives, Progress metrics) Assure resource commitments Strategic Alliance Core Team (Alliance Managers) Facilitator / Coordinator / Catalyst Full vertical & horizontal span Identify initiatives & report performance Implement corrective actions Manage Alliance Process Implementation Teams Each group has unique functions and tasks that contribute value to the LTP

The typical organization Structure of an LTP is shown in Figure 7.

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Figure. 7. ( LTP Organization Structure)

Organization Structure
Implementation Teams

Long Term Program (LTP)

Executive Management

Customer

Strategic Alliance Core Team (Implementation Teams) Unit / Fleet Performance Evaluation LT Strategic Planning: Maintenance & Perf. Enhance

Outage Implementation

Performance Enhancement Implementation

Alliance Performance Metrics

Power Generation PG O26

Fig. 7

As mentioned in chapter 3, the idea of a value based pricing and risk sharing is a key element in an LTP contract. One possibility to achieve this is the implementation of Score Cards, developed and mutually agreed upon, during the negotiation process by the contract partners. This Score Cards should contain all important issues and results coming out of the agreed work scope (critical to quality (CTQ) outputs). Depending on the degree of success, each issue is evaluated and scored separately. Because the listed issues are not all of the same importance typically, there is the possibility of a weighting factor. An example of such a Score Card is shown in Figure 8.

The sum of all scored points in comparison with the maximal accessible number of points is basis for the bonus / penalty calculation shown in Figure 9.

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Figure. 8. (Example of a Score Card)

Financial Advantage
Score Card (Example)
Safety / Human Performance Record able Injuries per OSHA Other Weight 0,4 0,6 1,0
Penalty Bonus

2, 5

AWP*

Long Term Program (LTP)

MTP*

Schedule Compliance Key Milestones completed on time Startup, in number of runs

5

Weight 0,3 0,3 0,4

Actual Schedule/ Target Schedule MTP*

Quality / Reliability

E L P M A X E
1,0 Weight 0,5 0,5 1,0 0

1 0

AWP*

7, 5

1 5

AWP*

Any post-outage TG work performed by Contractor. Occurrences of MWhr curtailments due to TG work by Contractor MTP*
AWP: Actual Weighted Points

MTP: Maximum Total Points

Power Generation PG O26

Fig. 8 Figure. 9. ( Financial Advantage: Bonus / Penalty System)

Financial Advantage
Bonus / Penalty System

Max Target Price

Long Term Program (LTP)

Bonus
Target Price

Performance weighted points

Penalty
Target Price 5%

Bonus/Penalty = Target Price x 5% x[2x (AWP / MTP)-1]

AWP: Actual Weighted Points MTP: Maximum Total Points

Power Generation PG O26

Fig 9.
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3.4

Program Implementation Process

The implementation process is shown in Figure 10. First of all the program objectives have to be defined and a plant assessment has to be performed in the case of a risk sharing model. The following list of project objectives should be basis for the negotiations: Reliability and Availability Goals Maximum Flexibility needed for Cycling Operation Reliable and Quick Start Up and Shut Down capabilities Optimize component life usage Extend intervals between inspections Predictive maintenance to reduce Forced Outage Rate Reduced outage durations Flexible outage schedules

The definition of the work scope and the contract structure are linked to the different program types defined in chapter 3.1 3.3. The contract structure could contain: Organizational Structure Execution Process Identify Strength / Weakness (Customer/Siemens) Task, Function, Process, Responsibility Commercial Conditions Master Terms and Conditions Enhanced Guaranties Share Risk Definition of Condition Based Payment

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Figure. 10. (Implementation Process)

Strategic Alliance Programs

Program Implementation Process

Program Objectives

Definition of Work scope

Contract Structure

Execution, Monitoring, Measurement & Change

Driven by Executive Steering Committee

Power Generation
PM 026 Marketing November 2002

17

Fig. 10

After Execution and order implementation the results are monitored and analysed to improve the process and the performance. This issue is handled by a dedicated program manager. Last but not least the financial results are measured and are input to the implementation loop again (Figure 11.).

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Figure. 11 (Measurement Improvement Loop)

Strategic Alliance Programs

Program Objectives

Definition Of Work scope

Contract Structure

Execution, Monitoring, Measurement & Change

Managed by Program Manager Alter Process as necessary Measurement of Objective Financial Goals Met

Power Generation
PM 026 Marketing November 2002

22

Fig. 11

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4. Remote Diagnostics as Building Block for Optimized Plant Operation

Power DiagnosticsTM is a modular built system to monitor, analyze and diagnose the complete turbine island. The advanced service product is a high sophisticated remote expert diagnostic system which is the basis for condition based maintenance strategies and optimization of the plant operations. The results of Power DiagnosticsTM can be recommendations for further operations, repairs and/or modernization of customers equipment. Power DiagnosticsTM not limited to Siemens units but is applicable to all kind of steam turbines and generators. The goal of Power DiagnosticsTM is to diagnose the operation of the turbine island for purpose of early detection of abnormal operating conditions. Hardware failures, instrumentations malfunctions may lead to abnormal conditions. Detection of these conditions results in optimized operation, higher availability, and improved turbine island efficiency. This service can benefit operations by mitigating running off nominal conditions. It also provides the original manufacturers key information that can be used to further improve products and services such as increases in hardware life and durability, mitigation of collateral equipment damage through early detection, improvement in reliability, and optimization of maintenance durations. Skilled OEM engineers and technicians, enabling them to make timely recommendations to customers, who can be used to help assess future actions, will analyze this information. is

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Figure. 12. (Diagnostics Basics , Monitoring, Analysis vs. Diagnostics)

Terms and Definitions

Monitoring
Data Measurement Data Compression

Analysis
Data Processing

Diagnostic
Data Interpretation

Operation Data Logging Signal Analysis Limit Value Check Alarm Trip Data Base Visualization

Operation Data Logging

Operation Learning Phase Normal Behavior Deviation from Normal Behavior Online Diagnostics Offline Expert Diagnostics

Signal Analysis

Data Base Visualization

Power Generation PG O26

Fig. 12 To reach the objective not only to monitor the different measured values but to implement a real diagnostics system, a global network of high sophisticated experts is needed and the raw data of the turbo generator, process factors and state variables have to be collected and have to be correlated and analyzed. There is no software solution for this in depth diagnostics available and will not be in near future. This data evaluation has to be done by engineers. But the software is capable of learning the normal behavior of a machine or a system and to detect deviations from this normal behavior. Therefore it is possible to set alarm and trip thresholds and to create intelligent and event driven data management systems. The software is operating more or less like a watchdog or a filter, to make sure human experts are dealing with complex diagnostics issues only.

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The differentiation between monitoring, analysis und diagnostics is shown in Figure 12 and defined as follows: Monitoring: Simple stand-alone-monitoring-systems offer the possibility of visualization of all measured values and a simple comparison against defined thresholds. A detailed knowledge to define the alarm and/or trip level is needed even here. The System consists of:

Sensors (temperature, vibration, magnetic flux, data from I&C, a.s.o.) Data processing System Visualization Equipment (could be part of the I&C System)

Analysis: The analysis system is based on the data coming out of the monitoring system and is characterized by complex data calculation of interacting parameters. The software is capable to create reference values which are the basis for comparison of expected and actual values to the machine conditions. The System consists of:

Sensors Processing of measured values Personal PC Software (Analysis Function)

Diagnostic The advanced product solution represents the diagnostic system setting up on the results of the analysis and contains the measurement values and parameters, the identification of failures, disturbances and recommendations from an remote expert center. The software is capable of learning the normal behavior of a machine or a system during a period of time which should contain all different load factors and start up and shut down procedures. Data which cannot be explained by the process model will be passed through to the human experts only. The System consists of:

Sensors Processing of measured values

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Personal PC Software (Analysis Function) Remote Expert Center

Due to the fast growing market of new sensor technology Power DiagnosticsTM is built up on a modular basis. In this way a high flexibility and a fast adoption to new developments can be achieved. The critical factor of Power DiagnosticsTM is the data processing:

On-site data acquisition and monitoring system Data infrastructure and collection Measurement and analysis of equipment conditions and performance Comparison of conditions to fleet equipment baselines, design specification and experiences, communication of relevant data

Technical advice Identification and isolation of problems Root-cause analysis and experience-based learning Data archiving and unit/machine analysis Remote Expert Center Problem reporting and corrective action recommendation Identification and isolation of problems

The focus of Power DiagnosticsTM is to bring together the core business of the operator and the manufacturer to use their overlapping fields of experience (Figure 13) to establish real condition based maintenance based on a relevant data basis. Modern computer software allows to have access to all data by the experts in our global network but privacy protection is a must and is a key function of our system.

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Figure. 13. (Power DiagnosticsTM, Concept of overlapping know-how areas)

Diagnostics Concept
Power Power Plant Plant Diagnostics Diagnostics with with Remote Remote Control Control & & Smart Smart Sensors Sensors Assessment using overlapping areas of know-how & Diagnostics
BOP

Global network of engineers

Know How Width

Customer

Know-how from design and manufacturing

I&C

Siemens

Recommendations for optimized power plant operation Find and implement measurements in cooperation with the customer oriented on customer benefits Conditioned based maintenance Performance based payments Extended warranties and risk sharing in combination with LTPs
Power Generation PG O263 Michael Killich

Boiler

Turbine Generat or

Operation

Assess ment

Design

Develop ment

Know How Depth

Fig. 13 The underlying philosophy of the monitoring and diagnostics concept is described within the know-how range and depth:
-

focus on core competencies, data privacy, communication time: short response times due to global resources value: access to Siemens engineering, condition based maintenance, prevention of forced outages.

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4.1 Diagnostics System Platform: Task and Concept

Global Network of Experts

Data supply Data supply Data supply

Worldwide network for online service data exchange

Power Diagnostics Center

Data Handling Hardware Hardware // Software Software Plant Power PlantTechnology Access

Global Expert Network Engineering Know-how

End User

Monitoring Analyse Offline Diagnose Online Diagnose

Power Generation PG O26

Figure. 14. (Data handling concept, decentralized network of engineering experts) The infrastructure for the data handling process and the intelligent software is provided from one of the Siemens Power DiagnosticsTM Centers. They offer the data acquisition, management and event driven data storage. The data will be transmitted, processed through a series of advanced modules and artificial intelligence software to make sure that measured values dont exceed thresholds and the operating conditions and the machine and/or systems are running in a normal mode with a predictable behavior.

Experts of different departments like thermodynamics, rotor dynamics, fluid mechanics, processes and construction from our engineering departments in Orlando and Mlheim are the backbone of the network of experts. This network is organized in a decentralized manner and located at different places. In the case of a more complex event there is a demand of coordination between the different engineers. For that purpose we have installed a full time project management.. If it comes to a multidisciplinary problem not limited to the turbogenerator, the coordinator will contact other departments (I&C, BoP, boiler etc.), to elaborate an overall solution. The Project Managers will distribute the results of diagnostics in form of
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reports or recommendations to the product line marketing and to the sales service. In urgent cases the customer will be informed immediately. Summarizing the Power DiagnosticsTM Center is performing analysis and diagnostics using high sophisticated learning software modules, is providing trend analysis, problem identification and root-cause analysis done by human experts. The learning software solution prevents them from dealing with trivial problems. The engineers in the remote expert center are comparing and analyzing the incoming data from the whole fleet connected to the diagnostics center. Because of the pool of information coming from a huge fleet, the experience is growing much faster than it would be possible for a single operator.

Even if there is no problem the engineering experts are able to generate recommendations on plant operations and/or maintenance actions. The recommendations are designed to maximize the equipments performance, reliability and availability and potentially, extend outage interval cycles. The organization structure and the process flow is shown in Figure 15 below.

Network Process Data Flow

Power Plant Data
Engineering Coordinator

Turbine Generator I&C E-Technic BoP Boiler Process

Specifications

Thermodynamic Processes Mechanics Fluid mechanic Rotor dynamics Commissioning Construction

Diagnostic Center Deviation of normal behaviour Storage of historic machine data Data security Tools

Power Generation PG O26

Fig. 15

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The following diagnostic modules are available today, but the technology is proceeding fast. In addition to the more general development of faster computer networks, there is a fast development of new sensor technologies. (Figure 16):

Vibration Diagnostics: Shaft vibration, bearing vibration, end-winding vibration using fiber optic accelerometers.

Thermodynamics Diagnostics KRAWAL: A tool developed for plant design and engineering of the thermodynamic processes integrated in the online diagnostic to compare current process data with expected values.

Turbine Operability Enhancement TOE: Historically steam turbine operation were designed for a market that was typically either base load or intermediate duty load operation. Applying the historical steam turbine start-up philosophy either limits the operating flexibility or exceeds steam turbine allowable stresses increasing service consumption.

The demand for flexible operation leads to the development of innovative concepts to reduce start-up times of steam turbines while minimizing service time consumption thereby improving availability. This new concepts include plant operability enhancements, such as e.g.
-

steam turbine stress controller and stress monitoring system high level of plant automation plant systems designed to provide steam conditions necessary for a pre-selected start-up mode

remote online monitoring and diagnostics

Online Life Consumption Calculation: Basis for TOE.

RF Monitoring: In high-voltage equipment such as Generators, Terminal lead area, transformers and motors faults occur. To avoid repair costs or even loss of revenue due to unscheduled outages, it is necessary to identify these faults and rectify them in time

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Faults in electrical equipment do not occur suddenly but, in most cases, are announced in advance by telltale partial discharges. They short-circuit across part of the highvoltage insulation and can be detected by radio frequency (RF) measurement methods because of their radio-frequency character. Suitable selection of RF measuring points allows detection of partial discharge sources over the entire high-voltage range. To avoid intervention in the insulation system of the components itself, natural coupling points are preferred. By digital unmasking of the partial discharge signals from the usually noisy complex mixture of RF signals it is possible to determine the causes of the discharge. With simultaneous measured data acquisition and different measuring points it is possible to locate possible source of faults.

Other modules as shown in Figure 6

Figure 16 (Available Diagnostic Modules).

Diagnostics Module Portfolio

Generator Steam turbine
Generator Temperature Analysis End winding Vibration Monitoring

Auxiliaries/ Balance of Plant

Humity Ingress Monitoring Online Life Consumption calculation

HF-Monitoring Shaft/Bearing Vibration Monitoring H2 Leakage Detection Measurement of internal efficiency

Operating hours Counter Coast down Time TOE

Torsional Vibration Monitoring

KRAWAL Bearing Temperature Turbine stress Evaluator

Stator bars Temperature Monitor

Power Generation PG O26

Fig. 16

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4.2 Diagnostic : Contractual Models Partnership Solutions The concept of Power DiagnosticsTM is designed to fit in our Strategic Alliances Programs. These long term service contracts (OPSA, LTP, O&M) 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 means mutual agreed objectives like 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. This concept of a value based pricing system is available for Power DiagnosticsTM Service Contract also. In this case the customers benefits have to be identified and written down in a mutual agreed matrix. Events like avoidance of an forced outage or early detection of an developing failure could be those benefits. The early detecting for example gives the customer additional time for planning and can therefore shorten the outage duration. The different service packages coming with a diagnostics service contract are clustered in the following packages / modules (Figure 17):

Service Package 0 The service package 0 is a fingerprint of the actual behavior of the plant or machines at different (normal) operating / load conditions. All the incoming data from the different measurement chains are identified and interpreted to be the normal status of the system. Extreme variations from the expected conditions can be determined by comparison with the design data of the engineering details. Service package 0 is based on a fixed work scope. Service Package 1 All measured values are within normal ranges (experience from service package 0) and no extreme variations or trends could be found in the data. The package includes cyclique human expertise also (online weekly / offline quarterly). The results are stored and added to the databases. An quarterly report is issued.

Service package 1 is based on a fixed work scope.

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Service Package 2 All measured values are in normal ranges (below alarm levels) , but there a trend is identified which needs a more detailed examination to make sure that no generic problem is upcoming that might result in values (e.g. vibrations) over the alarm or trip level. The measures which can be taken are defined in co-operation with the customer. proactive activities.

The work scope depends on the single accuracy and cannot be fixed or predicted.

Service Package 3 One or more measured values are higher than the corresponding alarm levels. Based on a root case analysis a recommendation is provided which may result in a allowance of a risk operation by the manufacturer or the insurance company for a limited time period. In the mean time all data are evaluated by human experts.

Definition of Service Packages

Fingerprint Service-Package 0
Documentation of normal conditions Machine lifetime documentation

Detailed monitoring Continuous monitoring

(based on deviations from normal conditions/behaviour)

Monitoring and additional measurements

(based on findings in Package 1 or 2)

Service- Package 1
Trend tracing (fixed monitoring schedule) Actualisation of the lifetime documentation Customer visit

Service- Package 2
Detail. Trend Tracing (Control of deviations) evil. Offline measurements on site) Analysis of actual machine condition Estimation of continuing operation Recommendations to operating mode Finding based cause studies Actualisation of lifetime documentation

Service- Package 3
Detail. Trend Tracing
Analysis of actual machine condition Documentation Estimation of continuing operation (Risk operation) Recommendations to operating mode Finding based cause studies Recommendations for the preparation and implementation of measurements Control of measurements Actualisation of lifetime documentation Power Generation PG O26

Figure 17 (Available Diagnostic Modules).

The range of the diagnostic packages / modules and the scope of the different service packages are not fixed and can be adopted to the customers needs. The boundaries between the different services packages are results of customer interviews so far.

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For customers who have already signed an long term program the costs for the service packages 0 and 1 including the regarding recommendations coming with a quarterly report (Figure 8) will integrated in the existing contract. Hard- and software costs will be charged separately and all costs from service modules 2 and 3 will be charged on time and material bases or on the above mentioned value based pricing models.

Sales estimation
Transactional Expanded Scope / Risk Performance Driven O&M

Diagnostic compatible

Long Term Alliances

Data collection proactiv

LTP OPSA

Mutual Benefit

MC

TFA TMS

Today: fire fighting reactiv

Minimum of contineous costs

Power DiagnosticsTM

Commitment Power Generation

Performance Maintenance Marketing O263

Figure 18 (Market Drivers Transactional business vs. performance driven business ).

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The customer benefits and the corresponding investment for the different packages is shown in Figure 19. The benefits related to the Service Package can be summarized as follows:

Service Package 1:

Access to the Siemens expert network and the Siemens service hotline (the expert network consists of Siemens engineers of all main power plant disciplines like steam turbine engineering, gas turbine engineering, generator engineering, I&C, E-Technics, Process Engineering, Balance of Plant, Boiler)

Documentation and reporting of the plant / machine conditions on a regular basis Early detection of changes because of good and reliable data bases

Service packages 2 and 3:

Risk operation Early problem (damage) detection Additional time for planning

All in all the Power DiagnosticsTM System is basis for

Condition based maintenance Flexible operations Lifetime extension Efficiency improvement Availability increase

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Customer Benefits
Benefit
Condition based maintenance Flexible operation Lifetime extension Efficiency improvement Availability increase

Power DiagnosticsTM is basis for...

Access to Expert Network regular documentation Early detection of problems

Risk operation Early damage detection Continuing operation

Hard/Software Investment Basic Investment

Service Package 0
One off costs

Service Package 1
Base amount

Service Package 2

Service Package 3

Time and material or performance based charging

Marginal costs Fixed Price

Costs
Power Generation PG O26

Figure 19 Customer Benefits and Partner Solutions.

4.3

Data Acquisition, Network Operation and Feedback Cycle

An efficient and safe network configuration is the key to reliable remote data acquisition and diagnostics. Local acquisition, archiving and diagnostics combined with periodic and eventbased data transfer are the on-site tasks. The system infrastructure for the data handling have to fulfill high safety requirements to make sure that the data flow is secure (Figure 20).

Operative measuring, the evaluation of troubles and the periodic measurement for trend and state assessments in the past came to the conclusion that the information content is often used insufficiently by measuring signals for the assessment of the machine condition. E.g. on the one hand the traditional supervision carries out a low evaluation of the information content of the signals and on the other hand all periodic measurements with transportable measuring and analyzing equipment have only the character of sample measuring, despite an extensive signal analysis.

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In both cases the knowledge over the time and the temporal course of the changed, often very complex behavior of a machine, inclusive of all accompanying boundary conditions is insufficient.

Power Diagnostics TM Center

SAP

Remote Service Center

HQ Region Remote Clarification Reports Diagnostics

User Accounts

Expert Network
Diagnose
Experten, Engineering Know-how

Intranet

Installed Base Data

Remote Service Platform

DMZ
Access Server

Extended Platform Services

Basic Software Components Data Services (temp)

ISDN, POTS

Internet

VPN

Customer Site

Remote Access Client

RS-Agent Remote enabled equipment

Customer Network

On Site Server

RS-Agent

Local Services

Power Generation

Figure 20 Secure Data Handling. With Power DiagnosticsTM comprehensive diagnostic statements concerning the assessments of the turbo machines and its operation mode and therefore requirements and decisions with regard to further operation shall get possible. Prerequisite for the diagnostics is the comprehensive usage of the information content of signals to the plant assessment.

Data acquisition suitable for diagnostic: The data acquisition requires the measuring of signals, which contain adequate information about the condition and condition changes of the respective machine. The data acquisition has to be carried out in a way that a considerable information loss doesnt already occur in the measuring phase:

Continuous signal recording

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Recording of the operation regime as well as of the relevant measures of the process technology.

Data analysis and data reduction to informative code numbers suitable for diagnostic at minimal information loss: The objective is a to reduce the data to informative characteristic quantities. The large amount of data has to concentrate on few representatives and qualitatively clear characteristic quantities.

Data preparation suitable for diagnostic for off-line diagnostic by experts. Manual assessment of machine conditions. In the context of a diagnostic computer in on-line operation or of stored data a variety of representations have to be selectable or over printer/plotter displayable.

Determination of the machine type and measuring place specific normal condition and normal behavior of the characteristic quantities in the fluctuation area of normal operation parameters for the operation condition.

Supervision suitable for diagnostic, i.e. automatic data assessment in the comparison with the values of the normal condition and normal behavior with data storage at deviation of the normal condition as well as qualified machine protection: The tasks of supervision suitable for diagnostic consist in the comparison of the characteristic quantities with the characteristic quantities of the normal condition or the normal behavior among the respective operation regime of the plant with following two functional aim positions in the variation area of the normal operation parameters.

Plant protection: Condition changes of characteristic quantities which signal the plant endangering of the operational safety must be recognized in the interest of the quickest possible triggering of the machine protection.

Control of the data storage: Condition changes of single characteristic quantities, which don't lie in the area of its normal behavior, must be subjected to event-driven data storage.

Automatic on line diagnostic at deviation of the normal condition: Automatic determination of the machine type and measuring place specific behavior of characteristic quantities. The full effectiveness of the diagnostic is achieved if machines and measuring place specific limit and reference values which take into

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account the constructive unusual features of the machines and their operation are defined for the characteristic quantities.

The global network configuration shown (Figure 14) gives an idea of the performance of the plant diagnostics integrated into the Siemens intranet. The PG Power Diagnostics Center is located in the middle. Worldwide secure modem connections establish the data links to the individual plants and their WIN_TS installations. For qualified assessment of diagnostic findings, links to the various centers of knowledge (competence) for say steam turbines, gas turbines, generators and the balance of plant are established via the in-house Intranet.

Worldwide Implementation of WIN TS Gas Turbine Diagnostics

350 WIN TS Diagnostic Systems installed worldwide*
250 WIN TS Diagnostic Systems Installed for Gas Turbines
* including steam turbines

60 Hz

> 120 installed

50 Hz

> 130 installed

October 2004

Power-Gen Asia 2004, Bangkok

PG G1

17

R: PG2004_Schei, Be,Ta_.ppt

Fig. 21 Figure 21 shows the installation status of WIN_TS diagnostic systems worldwide. More than 120 installations for gas turbines are in service in the 60 Hz region, and over 130 installations in the 50 Hz region.

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Benefits for Operation, Research and Development

It is important to receive continuous live data feedback from "running technological systems" at early stage, both for - immediate customer support - product feedback
Service

Erection/Commisioning

SIEMENS PG

Engineering

R&D

WIN_TS

Feedback Loop

October 2004

Power-Gen Asia 2004, Bangkok

PG G1

18

R: PG2004_Schei, Be,Ta_.ppt

Fig. 22 Live data from a running technology system for immediate customer support and product lifecycle feedback provides a significant benefit for operation, research and development. As Figure 22 shows, remote online diagnostics serves as the feedback loop into customer service, engineering and research & development after erection and commissioning. Through remote access, the local diagnostic systems are connected to Diagnostics Centers in Orlando and Erlangen, to where they send data via data containers. From the Diagnostic Centers, the experts are able to assist in any critical situation which needs their immediate attention during commissioning or service. Just a few mouse clicks and they have access to data from gas turbines all over the world 5. Summary, Outlook Due to the changing market conditions all over the world the traditional way of handling the maintenance business does no longer fit these new environmental requirements. The solution is to achieve a flexible and short termed outage planning process and a reduction of marginal and transactional costs. Strategic Alliances in combination with Remote Diagnostics can fulfil all these demands because they are tailor made solutions based on contracts designed to leave the transactional business behind. The range of this Strategic Alliances varies from Operating Plant Service Agreements (OPSA) to Long Term Programs (LTP) and Operation and
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Maintenance Contracts (O&M) with risk sharing elements and the possibility of complete outsourcing of the maintenance tasks. Value based and success oriented payment makes sure that both partners will benefit from a good performance. Monitoring and diagnostics is a rapidly evolving field in power generation. The combination of available on-line expertise and Strategic Alliances provides cost-efficient service and benefits to the customer. In summary: Risk sharing and value based pricing based on assessment using diagnostics Extended Warranties More and more specific analysis and diagnostic technology is now available To maximize the benefit for power plants, the challenge is to employ all technologies needed 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 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 technological systems" that enables him to optimize his own learning.. And last but not least, on-line diagnostics and Strategic Alliances paves the way from scheduled maintenance to condition-based maintenance, thus helping customers to operate their units at maximum profit.

Literature [1] [2] Taud R.; Scheidel M.: Use and Experience with Gas Turbine On-Line Diagnostics, Power Gen Europe, Barcelona 2004 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 Adam, G.; Bode, A.: Ferndiagnose und Teleservicesystem fr GUD-Kraftwerke; VDI-Bericht Nr.: 1566, VDI-Verlag, Dsseldorf, 2000 Brummel, H.-G.; Scheidel, M.; Thompson, E.: Gut behtet aus der Ferne; Siemens Power Journal, Heft 1/00

[3] [4]

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Biographical Information Speaker: Michael Killich Position: Marketing Manager Steam Plant Services Company: Siemens Power Generation Country: Germany ____________________________________________________________________ Michael Killich is head of the marketing group within the O26 Performance Maintenance product line, responsible for Europe, Africa, Asia-Pacific He is holding a Master of Science Degree in Power Engineering of Aachen Technical University. After some years as project manager for Von Roll AG in Switzerland for waste fired cogeneration power plants he joined a privately owned operating company for a waste incineration in Germany as head of the technical department during erection phase and as a maintenance manager after PAC. In 2001 he entered Siemens AG to work for the Performance Maintenance O26 product line in Mlheim, Germany. 2003 he became head of the marketing group.

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