Reliable operation support –
Siemens Power Diagnostics™ Service
www.siemens.com/energy
Answers for energy.
Long-term cooperation between customers and Siemens
First monitoring center in Orlando
At your service:
Siemens Power Diagnostics
In the last decade and following market developments, the business relationships between
customers and original equipment manufacturers (OEMs) of power plants have shifted
­toward longer-term cooperation. This is particularly due to the rapid development of highefficiency components, for example gas turbines, using the most advanced technologies
and materials. The more sophisticated a power plant component becomes, the more attention is required during operation to avoid the risk of abnormal behavior. This conclusion has
led to new forms of cooperation between customers and OEMs. Siemens Power Diagnostics™
Service is one important outcome of this development.
A new level of cooperation
With new high-performance equipment being introduced
in the market, customers require Operation and Maintenance (O&M) programs and Long-Term Programs (LTP).
These programs are designed to cover the greater part of
the equipment lifetime or the entire combined-­cycle plant
‒ occasionally even including some risk-sharing of certain
repair costs with an OEM.
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With both types of programs, customers are able to better
plan operational costs during the service program period.
At the same time, the boost in information technology
­facilitates the secure transfer of large amounts of data
over long distances – thus enabling the OEM to use
­remote monitoring to help customers detect a possible
­impending operational problem. This can minimize
­unplanned outages and maximize power generation
­availability.
Your power plant
Power Diagnostics
center
Expert
network team
Use of advanced
diagnostic tools and
techniques for
■■ Monitoring of
­machine conditions
■■ Collecting and
­processing of data
■■ Analysis of limit
values and ­deviation
from normal
behavior
Engineering
­know-how
■■ Interpretation and
diagnostics
■■ Data assessment
■■ Development of
recommendations
for future operations,
repairs, and
­modernizations
Reports
Access
Info
Analysis
Monitoring
Offline diagnostics
Online diagnostics
Power Diagnostics Service is backed
by vast field experience.
Multiple advantages of Power Diagnostics Service
Services made-to-order
Based on decades of experience in ­diagnostics, Siemens
opened a pilot remote monitoring center in Orlando, Florida
in 2000, launching a new ­quality standard in remote
­monitoring of advanced gas turbine and combined-cycle
plants for long-term service program customers. With the
primary focus on these long-term maintenance programs,
monitoring on a 24/7 basis was officially introduced in
February 2002 as “Power Diagnostics Service” (PDS).
The PDS goal is to detect abnormal operating conditions
of power plant equipment like gas turbines, steam
­turbines, heat recovery boilers, and generators as early
as possible in order to subsequently help improve plant
availability and operations. To this end, multiple data
­acquisition tools are used to obtain daily operational data
from our customers’ plants.
data collection and analysis. In other words, there is no
possibility of controlling the site’s instrumentation and
­control system and engine operation. This means that PDS
is not operating customers’ power plants, but helping
them run the equipment more efficiently and profitably.
This service is backed by field experience gained from
more than 400 installations of high-efficiency gas turbines
and other equipment, an advantage only the OEM can
­offer. For this reason, Power Diagnostics is a special
­service offered to Siemens customers.
Aided by advanced diagnostic software, experienced
­diagnostic engineers can identify issues before they reach
conventional alarm levels. If necessary, these engineers
can be supported by specialists throughout the entire
­Siemens Energy organization.
Monitoring and supporting, but not operating
As a leading supplier of power plants, we are aware of
many of the s­ ecurity challenges concerning the operation
of our c­ ustomers’ plants. Siemens PDS is based on passive
Operation and maintenance by Siemens for a Philippine power plant
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PDS may help you turn a potential forced
outage into a scheduled event.
PDS is designed to support your management
­decisions on consistent refurbishment.
The O&M power plant in Taiwan benefits
from PDS and won the 2008
­“Best ­Environmental Plant of the Year” award.
Winning in competitive markets
Unparalleled experience
Siemens has been at the forefront of power generation
for more than 140 years. Therefore, our Power Diagnostics
Service is based on experience unrivalled in the industry.
With PDS, higher reliability of your power plant is not left
to chance, but can be the consequence of a well thoughtout process of continuous data acquisition, data analysis,
diagnosis and regular documentation of machine conditions. PDS is designed to provide a more reliable basis for
your management decisions regarding:
■■ scheduled outages
■■ performance and operating optimizations
■■ plant operating support
■■ consistent refurbishments
■■ timely reinvestments
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Better use of scheduled outages
Cooperation between the customer and the OEM also
means that the units we monitor will be checked against
our ever-growing database of similar machines and components in the field. By doing so, we can help detect many
arising issues months before the Instrumentation and
Control system (I&C) would generate an alarm or even trip
the unit due to equipment protection criteria. With this
system in place, many issues can be planned for and
­addressed proactively during scheduled outages. In
­addition, with PDS your power plants are monitored using
highly advanced computing technology and algorithms
designed for the utmost security and quickest response.
Early fault detection allows sufficient time for service teams
to prepare parts and manpower, turning a potential forced
outage into a scheduled event, thus helping to keep
downtime to a minimum.
Higher reliability potential
Continued condition monitoring of your power station
can help you be an even more reliable partner for
your customers. In addition to helping you minimize the
risk of unplanned outages, you can use data from our
­Power Diagnostics Service to optimize the operation of
your units, while our regular condition reports can help
you assess the demand for future investments. They
may also help you to evaluate possible operational
­alternatives to cover special customer needs.
Opportunity for substantial cost savings
Our regular reviews and performance analyses can help
you operate your assets at higher efficiency levels. This
may result in substantial savings on fuel, machinery, and
enhance environmentally friendly operation.
PDS can also help you make decisions that can potentially
extend the lifetime of your power plants. Knowing more
about their condition may allow for a more precise risk
­assessment and a better perspective on their future
­performance.
You can choose a service program
­according to your needs.
Helping you minimize your operational risks
In combination with service programs, PDS can help you
minimize the operational risks of your assets. Depending
on the service program you select, we can offer a variety
of services that enable you to concentrate on your core
business while your assets are carefully monitored by our
experienced diagnostics and service engineers.
To make use of the full potential of Power Diagnostics
­Service, you can choose from customized service programs
like Operation and Maintenance programs and Long-Term
Service Programs. These can be designed to cover the
greater part of an engine’s target lifetime or, in the case
of an O&M, virtually the entire range of combined-cycle
power generation components. While Long-Term Service
Programs mainly cover periodic service and maintenance,
an O&M program also includes a broader range of S
­ iemens
services at your plant. This includes the daily operation of
the plant and a wide range of maintenance activities
which, based on our global long-term O&M experience
and our OEM expertise, can help continuously optimize
plant efficiency and availability. With these service offerings
featuring PDS, you can find the right combination for your
requirements, from a regular monitoring of your power
station, to a more detailed monitoring that includes trend
analysis, to actions such as assessing threshold deviation
from expected unit behavior.
PDS allows you to concentrate on your core business while your units are skillfully
monitored by our experienced diagnostics and service engineers.
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A valuable experience: your success!
Our remote service centers feature expert knowledge for more than 400 gas turbine, steam turbine,
and generator installations as well as other power plant components all over the world. These are only
a few customer statements that underscore the benefits of Siemens Power Diagnostics Service.
What our customers say about Siemens Power Diagnostics Service:
»
»
Siemens fleet knowledge and
­record ­database is very helpful
and time-saving during an ­unusual
event and defect ­rectification.
«
Luckily, we don’t need this service often, but
when needed they have responded very quickly.
«
Modules for
Heat Recovery
Steam Generator
Gas Turbine
Generator
Steam Turbine
Turbo Train
Power Diagnostics Speciality Monitors are available
for all ­components of the energy conversion process.
Take advantage of upcoming planned outages to
implement the corrective measures identified remotely.
Dedicated modules for your success
Monitoring made-to-order
While each customer has his or her own service expectation, each power plant has specific requirements. To meet
your individual needs, Siemens has developed a system of
­dedicated modules for diverse tasks. These modules may
be adapted and fine-tuned to the application as required,
which can help you optimize operational costs.
To date, there are several distinct modules available in the
Power Diagnostics product lineup, each of them individually specialized in monitoring, analysis, and diagnosis:
■■ Vibration monitoring for steam turbines, gas turbines,
and generators
■■ Partial-discharge monitors for generators and
­high-­voltage components
■■ Diagnosis for water and hydrogen cooling circuits
in generators
■■ Dedicated rules for automated analysis and diagnosis
■■ Thermodynamic process monitoring
for ­entire ­power plants
Helping you make proactive decisions
For each module, Siemens can offer regular reporting and
information on the components’ status through special,
individualized service programs. With this condition
­monitoring capability, Power Diagnostics Service can offer
­additional information about your power plant.
This information supports a timely and detailed recognition
of many critical tendencies and changes in special operating
parameters. These Specialty Monitors can provide:
■■ Regular documentation of machine conditions
■■ Early detection of many operating issues
■■ Reliable information to help you make proactive decisions
■■ Fast access to the Siemens expert network
Optimized maintenance strategy
Using the results of our modules, you can prioritize and
optimize your maintenance resources according to the
­actual demand. In addition, better knowledge of the
­machine condition can help you operate your machines
more flexibly and may improve the overall efficiency,
availability and reliability of your power station.
In combination with a service program, Remote Monitoring
and Power Diagnostics Service can also open up new
oppor­tunities for incentive-based performance sharing
­between your company and Siemens.
Your access to support
Siemens Power Diagnostics installs and maintains a data
acquisition system at your site. The system is connected
to the Power Diagnostics Center (PDC) through a secure
common Remote Service Platform (cRSP) connection,
with a router and phone connection as backup.
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Siemens Power Diagnostics features expert knowledge to support your plant operation around the clock
Berlin
Muelheim
Orlando
Erlangen
Ready when you need it ‒ around the clock and globally.
The PC-based data acquisition system is passively connected
to the control system via OPC, receiving data from the
I&C system and the Specialty Monitors along a one-way
data highway, with no feedback to the site’s I&C system.
At the PDC, the raw data is processed through Power
Monitor, an empirical ­system-modeling tool and an artificial ­intelligence rule base. Power Monitor is designed to
detect even subtle deviations in the analog sensors within
the variability of normal operation ‒ and well within the
existing control threshold alarm limits ‒ which can aid
in early recognition of ­abnormal equipment behavior.
A specific advantage of this generic monitoring technique
is that it can be applied to a variety of instrumented
equipment. Many ­out-of-date calibrations, missing or
­incomplete tag suites, and bad sensors can be accommodated with the modeling tool.
If any kind of abnormal equipment behavior is ­detected,
the ­system is designed to automatically notify Siemens
­experts to conduct a detailed analysis of the behavior.
By using these analyses as the basis for diagnostics, a
list of recommendations for immediate actions to avoid
operational restrictions can be generated. In the event
a shutdown is required to remedy the situation, a planned
outage can be used to implement corrective measures.
Several customers have already taken advantage of these
options supported by Siemens expertise.
Based on the operational data, Siemens can provide
­regular availability and reliability reports for the customer
according to IEEE standard. Using the Siemens Operating
Feedback Log (SOFL), the reports could be automatically
created, reviewed by Siemens experts, and sent to the
customer for release. By providing regular feedback of
the operational behavior, customers are able to compare
their own units with the Siemens fleet.
Technical experts using several diagnostic modules help identify, assess, and diagnose abnormal
operating conditions and recommend follow-up actions.
We help you optimize your maintenance
­resources.
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Further developments
Today, Siemens Power Diagnostics Service consists
mainly of monitoring and diagnostics. However,
with the further d
­ evelopment of our tools and
modules, even remote services for power plant
equipment may become reality in the future.
Some of these new services have already been
­established, such as Remote Balancing, Remote
Tuning, and Remote Field Assistance (RFA).
»
»
»
I simply want to let everyone
know that the team at Power
­Diagnostics Service has provided
excellent s­ upport to our staff.
«
It is a good product. It makes you
aware of problems that otherwise
are very hard to spot. It has saved
us from shutdowns in the past.
We congratulate ­Siemens on this
product.
«
It’s nice to have a team of
smart guys on hand that ­integrate
well with our resources.
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«
Published by and copyright © 2011:
Siemens AG
Energy Sector
Freyeslebenstrasse 1
91058 Erlangen, Germany
Siemens Energy, Inc.
4400 Alafaya Trail
Orlando, FL 32826-2399, USA
For more information, please contact
our Customer Support Center.
Phone:+49 180 524 70 00
Fax: +49 180 524 24 71
(Charges depending on provider)
E-mail:support.energy@siemens.com
Energy Service Division
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