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Use and Experience of
Gas Turbine On-line Diagnostics
Michael Scheidel,
Karlheinz Bender, Dr. Robert Taud
Siemens AG, Power Generation, Germany
0
Abstract
Ten years ago Gas Turbine (GT) Diagnostic Systems were ordered in less then 10 % of new
units. Today this has changed dramatically; almost all newly ordered gas turbines are
equipped with at least a basic Diagnostic System. A main reason is the constantly progressing
gas turbine technology.
To minimize the risk for vendor and customer, diagnostic benefit starts from the beginning of
gas turbine life time with product development and engineering, continues during plant shop
test, commissioning, acceptance test and warranty period and closes the loop with maintenance and service .
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The modular WIN_TS Diagnostic System connected to the I&C System has access to any of
the sensors and obtains between 300 and 1000 signals. Additionally to these signals with the
highest resolution of 1s, a high speed data acquisition for selected signals is included for analogue and for binary signal analysis down to milliseconds. Together with Database, Archive
and Remote Access, these is the basic system frame, on top of which there are various technology modules.
There are for example thermodynamic, hot gas path, vibration and component life cycle
modules available for analysis and diagnostics.
Through remote access, the system is connected to a Diagnostic Center from which it is
commissioned and to where it sends data via a data container . By means of the Diagnostic
Center, the experts have the possibility to support any critical situation during commissioning
or service. Just some mouse clicks enable them to obtain data from gas turbines all over the
world.
The operating data taken from the Win_TS system are also very important for generation of
availability and reliability figures as well as fleet statistics.
Based on the evaluation of different vibration parameters out of Win_TS it is also possible to
contact engineering for support and remedies. Examples show how engineering advises inspections and how the early knowledge of the unit condition can significantly help to improve the unit availability.
For the customer it is important to have access to the knowledge of the developers of his gas
turbine in critical situations through a diagnostic platform.
For the supplier the highest value is live feedback from his own „running technological systems“ in order to to optimize learning.
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Power Plant Market and Role of Advanced Monitoring and Diagnostics Systems
In all world regions, the power generation market has been characterized in recent years by its
orientation towards utilization of gas turbines, both as simple cycle and combined cycle plant
applications. In these plant configuration, both proven or advanced gas turbines represent the
high tech piece of equipment at the core of the plant. Regardless of the overall plant configuration and other extended equipment installed, the Return on Investment ultimately hinges on
the gas turbine. Hence it is essential to focus on this crucial core component.
One lever to do this is to employ advanced Monitoring and Diagnostics Technology. The approach presented in this paper was fully developed and implemented over recent years, including input and feedback both from customers and gas turbine development. The goal is to
maximize investment security and returns throughout the complete plant life cycle. The critical plant scope for this includes besides the gas turbine the generator, the air intake /exhaust
system and the corresponding auxiliary systems, as shown in Figure. 1. (Siemens name for
this product scope: EconopacTM , derived from Economical Package)
Monitoring and Diagnostics of
GT Plant Key Components
Econopac
Shell Concept
Gas Turbine
Auxiliaries e.g.
- Fuel Gas System
- Lube Oil System
- Compressor Wash System
Enclosures
Generator
Air Intake System
Exhaust Gas System
Instrumentation & Control
System
Electrical Package (PCC)
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Turnkey Power Plant
Power Island
Econopac
Air Inlet
Generator
Exhaust Gas System
Gas Turbine
including
Auxiliary Systems,
Enclosures
Power Control Center
May 2004
© PG G1
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Fig. 1
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Presented here, Monitoring and Diagnostics applied to the Econopac is the tool to back the
customer’s key generation technology and investment with matching state-of-the-art support
technology and processes. In essence it is advanced life-time support based on a high-tech
platform for monitoring, diagnostics and service, contributing to achieve high reliability.
Philosophy of GT-Econopac
Monitoring and Diagnostics
Function
Quality Triangle
Diagnostics - during all stages of
turbine operation and life cycle.
Condition-based maintenance - evaluated
and directed by experts
Better Prevention of forced outages –
Detection and resolution of problems
Time
May 2004
Value
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Fig. 2
The underlying philosophy of the GT-Econopac Monitoring and Diagnostics concept is described within the triangle of Quality Management ( Figure 2):
-
focus on function : performance,
-
time: response time, and
-
value: reliability through prevention of forced outages.
Illustrated in the center of the triangle are the corresponding key elements of the concept and
the benefits of the implementation of Monitoring and Diagnostics:
-
Diagnostics during all stages of turbine operation and life cycle
(also channelled into the feedback loop for new product development)
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Condition-based maintenance evaluated and directed by experts
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Detection and resolution of problems, more effective prevention of forced outages
In the recent years enormous advances were made in the fields of development of computer
power, network technology, as well as specific diagnostic tools. This provided the information technology basis (IT) for advanced Monitoring and Diagnostics in an on-line mode, with
remotely , centralized performed interrelated data analysis and diagnostics.
IT innovation supports Gasturbine Diagnostics
1990 the transfer of 10 MB
data with a 1200 Baud modem
took one day....
GHz
% of GT
Processor
(New Apparatus)
Speed it only takes
2004
14 Min
...
with an dual ISDN line....
.......and 30 seconds with
intranet / LAN
Processor speed
Diagnostic
Installations
for Gasturbines
(New Apparatus)
Intel 80486 33 MHz
1990
May 2004
100%
Intel P4 3,4GHz
2004
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Fig. 3
Hence, 10 years ago GT Diagnostics Systems were ordered in less than 10% of new units.
Today this has changed dramatically; almost all newly ordered gas turbines are equipped with
at least a basic Diagnostic System. A main reason is the constantly progressing gas turbine
technology. Correspondingly, IT innovation keeps growing and supporting gas turbine diagnostics development. 1990 typically a PC runs with a Intel 486 / 33MHz while today the
speed is increased over 3 GHz with a Pentium 4.
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For example, 1990 the transfer of 10 MB data with a 1200 Baud modem took one day, 2004
it only takes 14 minutes with a dual ISDN line and just 30 seconds with intranet/LAN connection. 10 MB is today a typical day file size for gas turbine data witch is transferred between fields and offices.
Figure 3 shows the increase of processor speed and Gas turbine Diagnostics installations in
new units.
2
Diagnostic System Platform: Task and Concept
Evolution Goal : one common platform
for GT,ST and GUD Data Acquisition & Diagnostics
„Gas Turbine Diagnostic Calculators“ and other diagnostic systems in the early 90th
PC-RI20
Rel. 2.X
PC-(USA-Rechner)
Flex OS Rel. 6.0
PC-(USA-Rechner)
Flex OS Rel. 6.0
Alpha-Rechner
DEC-UNIX
TLR
GTD
GTD
TDY
Past
PC-32M
Flex OS Rel. 6.0
Gateway
WIN_OS
WIN_OS
PC-RI40
Windows 3.1
PC-RI40
Windows 3.1
Modern PG Diagnostic Systems „WIN_TS“ today
Today
GT/TDY
PC
Windows NT
May 2004
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Fig. 4
In the early 90’s, a number of different hard- and software Systems were necessary to perform
the diagnostics tasks in a plant. To reduce the complexity of those configurations the development goal was to achieve a common platform for data acquisition and diagnostics.
Figure 4 shows in the upper section a typical example from the early 90’s with the high complexity of different hard- and software installations. These installations were more or less not
compatible and used in separate and stand-alone mode. To do this, diagnostic capabilities
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were limited, time consuming and required a high formal software and hardware competence.
Shown in the lower section is the example for today, with the reached development goal,
while profit could be taken from the information technology evolution. Through one common
platform we can handle these different analysis and diagnostics tasks. In addition new diagnostic functions were incorporated in the same manner. One Windows-PC now exceeds the
tasks which were then performed by a number of computer devices.
Diagnostic System Platform one host for all Technologies
- Central access to all analysis modules
- Integration of 3rd party products
- Synergy and cost reduction of equipment and tools
- Combination of different data in one database
- One evaluation tool for technologists
May 2004
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Fig. 5
In addition to this development, the following goals were achieved (Figure 5):
•
Central access to all analysis modules:
Depending on the gas turbine-technology requirements, the customer has access to
more than twenty different analysis and diagnostic modules through Windows Look
and Feel.
•
Integration of 3rd party products:
Market available technologies from different companies in combination with the competence of gas turbine producers should compliment the diagnostic platform.
•
Synergy and cost reduction of equipment and tools:
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Less hardware and software equipment, along with less administration effort provides
synergy and cost reduction and prevent computer farms around a gas turbine.
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Combination of different data in one database:
Combination of different data in one database allows more complex and interrelated
data conditioning, analysis and diagnostics.
•
One evaluation tool for technologists:
There is a common tool used by the technologists for visual evaluation of different
kinds of data. This allows easy handling and focus on the technological evaluation and
interpretation.
Typical Application GT On-line
Monitoring and Diagnostics
GT experience reports
Pre event recorder
Thermodynamic GT
Operation logs
Operation hour counter
max. OTC after ignition
Temperature distribution
Vibration Analysis
Step change vibration
Acoustics Analysis
Bearing temperature
Coastdown time
May 2004
Humming
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Fig. 6
For example thermodynamic, hot gas path, vibrations and component life cycle modules for
analysis and diagnostics are in use. Latest developments are acoustic analysis to detect foreign
objects in the combustion chamber .
Figure 6 shows the gas turbine monitoring and diagnostics with typical diagnostic tasks.
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Conceptional Goal:
Integration off all Diagnostic Technologies
Thermodynamic GT
GT experience reports
Operation logs
Operation hour counter
Pre event recorder
max. OTC after ignition
Temperature distribution
Vibration Analysis
Step change vibration
Acoustics Analysis
Bearing temperature
Coastdown time
Humming
all diagnostic
technologies into one
platform.
Windows NT
WIN_TS
May 2004
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Fig. 7
Figure 7 shows the integration of all diagnostic technologies into one platform.
Gas Turbine Diagnostics
WIN TS Diagnostic System
9. Econopac
Services
Platform for All Technology Modules
Coupling to
Networks
T
T
Data Manager
M
P
T
T
TCP
/ IP
OT
YOUR
NAME
H ERE
123
EASY
STRE
ET
DOWN
PHONETOWN,
987/123
A-4567
L T. 00000
Module
Manager
TERMS:
DATE
DATE
ACCO UNT NUMBER
AMOUNT ENCLOSED $
(PLEASE DETACHAND RETU RN WITH YOUR RE MITTANCE)
CHAR GES AND CREDITS
BALANCE
BALAN CE FORWARD
PAY TH IS AMOUNT
ACCOU NTS RECEIVABLE LEDGER
ACCOU NT NO.
SHEE T NO.
DATE INVO ICE NUMBER/DES
CHARG
CCRIPTION
ES
REDITS
BALANCE
BALANCE FOR WARD
Archive
Printer
Standard
Look & Feel
Module 1
Own Data
Acquisition
Flight
Recorder
Windows NT
Module 2
Monitor
Module 3
Integration
into
I&C
Module 4
AP
H1APRED
Module 5
Modem
Central Data Acquisition
APF AG F
FUM-F
S IM-F
Module 6
Telephone
Line
Modem
Integrated
Remote
Access
System Functions Determined
through Technology Modules
May 2004
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Fig. 8
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Figure 8 shows the modular structure of the WIN_TS Diagnostic Platform. The system contains a basic system frame with the interface to Instrumentation and Control, to networks, to
remote access, and the data base and archive infrastructure.
The modular WIN_TS Diagnostic System connected to the I&C System has access to many
of the operational installed sensors and obtains between 300 and 1000 signals. Additionally to
these signals with the highest resolution of 1s, a high speed data acquisition for selected signals is included for analog and binary signal analysis down to milliseconds. Together with
Database, Archive and Remote Access, this is the basic system frame. The valuables in the
center of the system are the technology modules which can be selected according to the units
task specific requirements.
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3. Diagnostic Network Operation: Configuration and Implementation
of the Feedback Cycle
Network Configuration
Orlando
Flugschreiber
Periodic Transfer
Event Based Notification
Centralized Database
Advanced Diagnostics
Technical Experts
Acoustics
On-Site Data Acquisition
Local Data Archive
Local Diagnostic
May 2004
Vibration
Erlangen
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Fig. 9
Figure 9 shows the integrated technology platform at the plant site.
An efficient and safe network configuration is the key for reliable remote data acquisition and
diagnostics. Local acquisition, archive and diagnostics combined with periodic and event
based data transfer are the onsite tasks. It continues in the Diagnostics Center with a centralized data base. Last but not least, it runs into advanced diagnostics in combination with technical experts knowledge.
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Global Network Configuration
Plant Diagnostics Integration into Siemens Intranet
WIN_TS
WIN_TS
WIN_TS
WIN_TS
Worldwide safe Modem Connections
PG Power DiagnosticsTM Center
PG internal safe Intranet
Competence
Competence
Center
CenterGT
GT
May 2004
Competence
Competence
Center
CenterDT
DT
Competence
Competence
Center
CenterGEN
GEN
Competence
Competence
Center
Center-BoP
-BoP
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Fig. 10
The shown global network configuration (Figure 10) gives an idea about the performance of
plant diagnostics integrated into Siemens intranet. In the middle the PG Power Diagnostic
Center is located. Via worldwide safe modem connection the data links to individual plants
and their WIN_TS installations are established. For the qualified assessment of diagnostic
findings the link to the different center of knowledge (competence) like steam turbine, gas
turbine, generator and Balance of plant is established via internal Intranet.
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Worldwide Implementation of
WIN TS Gas Turbine Diagnostics
350 WIN TS Diagnostic Systems installed worldwide*
250 WIN TS Diagnostic Systems Installed for Gas Turbines
60 Hz
> 120 installed
> 130 installed
50 Hz
May 2004
* including
steam turbines
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Fig. 11
Figure 11 shows the worldwide installation status of the WIN_TS diagnostic systems.
For gas turbines more than 120 installations are in operation 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 at early stage continuous life data
feedback from „running technological systems“ both for
- immediate Customer support
- product feedback
Service
SIEMENS PG
Erection/Commisioning
Engineering
WIN_TS
R&D
Feedback Loop
May 2004
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Fig. 12
Live data from a running technology system for immediate customer support and product life
cycle feedback is a significant benefit for operation, research and development. As Figure 12
shows, the remote online diagnostic is the feedback loop into customer service, engineering
and research & development after erection and commissioning.
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4. Use and Experience of On-line Diagnostics along the Project Stages
Global Gas Turbine Diagnostics
Power
DiagnosticsTM
Centers
Lifetime Care
for Gas
Turbines
ORLANDO
New Engines
Development
May 2004
ERLANGEN
Test Facility
Commissioning
Warranty
Service
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Fig. 13
Through remote access, the local diagnostic systems are connected to Diagnostic Centers in
Orlando and Erlangen, to where they send data via data containers. By means of the Diagnostic Centers, the experts have the possibility to support any situation during commissioning or
service which needs their immediate attention. Just some mouse clicks enable them to obtain
data from gas turbines all over the world (Figure 13).
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Whole Lifetime Care for Gas Turbine Units
New Engines
Development
• Fleet data
accessible for
technical experts in
Competence
Centers
• optimization of R&D
efforts on new
engines and
upgrades
Test Facility
Tesing results
and data
accessible for
technical
experts in
Competence
Centers
Commissioning
• Less effort /
replaces test
equipment
Warranty
Period
• Information about
plant status and
performance
• Automatic event
Documentation with • Automatic event
high time resolution
Documentation for
for technical experts
technical experts in
in Competence
Competence
Centers
Centers
• Documentation of
new engines
fingerprint
• Remote support for
plant operators
New Engines
May 2004
Service
• Plants are monitored
effectively by Power
Diagnostic Centers
• Risk mitigation for
LTP, O&M and LTM
• Detailed information
of plant history and
long term trends
• Conditon based
Maintenance
Service
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Fig. 14
In Figure 14 advantages of diagnostics in phases are shown.
To minimize the risk for supplier and customer, diagnostic benefit starts from the beginning
of gas turbine life time with product development and engineering, continues by diagnostic
care during plant shop test, commissioning, acceptance test and warranty period and closes
the loop over the entire life cycle with improved maintenance and service.
Further operating data taken from the WIN_TS system are important for generation of reliability and availability figures as well as fleet statistics.
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Use and Experiences of On-line Diagnostics
New Engines
Development
Test Facility
Commissioning
Warranty
Period
Example:
degradation
analysis
• Information about
plant status and
performance
• Plants are monitored
effectively by Power
Diagnostic Centers
• Automatic event
Documentation for
technical experts in
Competence
Centers
• Risk mitigation for
LTP, O&M and LTM
• Remote support for
plant operators
New Engines
May 2004
Service
Example: Remote
Vibration Diagnostics
• Detailed information
of plant history and
long term trends
• Conditon based
Maintenance
Service
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Fig. 15
Figure 15 shows an example for evaluation of different vibration parameters out of WIN_TS
on basis of which vibration experts in the competence center advise inspections. Thus direct
online knowledge of the unit condition can significantly help to improve the unit reliability.
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Ongoing GT / Econopac Development
New Engines
Development
• Detailed Information is
available about plant
status and performance
to improve optimization
during R&D engineering
of new engines and
MODs and UPs
degradation
analysis
from G612
Test Facility
Direct feedback
to engines
developpers
in G2 and G6
Commissioning
• Documentation of new
engines fingerprint,
automatically, with high
time resolution
remote
GSWTurbine
DataServer
Balancing
from G261 TM
Warranty
Period:
• Detailed information is
available about plant
status and
performance for
warranty items
Service:
• Risk mitigation for LTP,
O&M and LTM
Example:
GT Experience
Report
GEB
from G611
G-wide intranet access
for comissioning data
May 2004
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Fig. 16
Figure 16 shows the gas turbine Experience Report (GEB), basis for consistent reliability and
availability evaluations, which was earlier manually generated by hand and is today performed as an automatic module through the system. It contains detailed information about
availability, status and performance over rolling time periods.
5.
Summary, Outlook
Monitoring and Diagnostics is a rapidly evolving field in power generation. The combination
of available IT-technology and on-line ‘expert’-expertise provide cost-efficient service and
benefits to the customer .
Thus it can be summarized:
•
More and more specific analysis and diagnostic technology available
•
To maximise benefit for power plants, the challenge is to employ all
technologies needed via one platform
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Global network to a running fleet allows OEM experts fast data analysis
and quick response to customer requirements
•
On-line diagnostics - in combination with remote expert knowledge - is
the key to future condition based maintenance and provides cost efficient service to reliable plant operation.
For the customer it is important to have access to the knowledge of the developer of his gas
turbine in any situation at hand through a diagnostic platform.
For the equipment supplier it is strong value to have live feedback from his own “running
technological systems” to optimize learning.
And last but not least online diagnostics opens the path from Scheduled Maintenance to Condition based Maintenance thus contributing to customers unit operation for highest profit.
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Literature
[1]
Volkmann, H.; Taud, R.: Application and Operating Experience with Econopacs
Equipped with Advanced Gas Turbines;
Power-Gen Europe 2003, Düsseldorf, May 6-8, 2003
[2]
Bender, K.; Grühn, M.; Rukes, B.; Scheidel, M.: Online Remote Diagnosis of Turbosets and Combined Cycle Power Plants;
VDI-Bericht Nr.: 1641, VDI-Verlag, Düsseldorf, 2001
[3]
Adam, G.; Bode, A.: Ferndiagnose und Teleservicesystem für GUD-Kraftwerke;
VDI-Bericht Nr.: 1566, VDI-Verlag, Düsseldorf, 2000
[4]
Brummel, H.-G.; Scheidel, M.; Thompson, E.: Gut behütet aus der Ferne;
Siemens Power Journal, Heft 1/00
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