Altbach/Deizisau CHP plant:
Integrating early fault detection
minimizes consequential damages
Reference – Diagnosis
Instrumentation, Controls & Electrical
SPPA-D3000 Plant Monitor
detects faults in the Altbach/Deizisau combined
heat and power plant (CHP) early, thus avoiding
machine failures and high repair costs.
The Plant
The Result
■ Early identification of
abnormal plant behavior
using online monitoring
which is integrated into
the control system
■ Minimization of consequential damage, costs
and downtime through
faster and more effective
early warning
The Altbach/Deizisau CHP plant ensures reliable,
economical and environmentally-friendly power
supply. EnBW operates several plants at the site
with a total output of around 1,200 MW, including
the 476 MW coal-fired block HKW 1. The district
heating generated supplies a considerable
proportion of the industrial enterprises in
Esslingen and Stuttgart, as well as private
households in the surrounding area.
The Task
In 2010, a sudden drop in shaft vibrations
on the generator in HKW 1 remained undetected.
When running a machine train, significant
increased resonance vibrations occurred, resulting in extensive analyses over several months.
Although the cause was traced to a short circuit
from a lightning strike, it was not possible
to explain the remaining impact in full. To avoid
lengthy analyses of this type in future, a reliable
system for early identification of faults should
have been installed. This system identifies
discrepancies in system behavior at an early
stage and triggers more detailed analyses of them.
Our Solution
An SPPA-D3000 Plant Monitor is now used at
HKW 1 to identify damage at an early stage.
Status monitoring is fully integrated into the
existing SPPA-T3000 Control System. Based on
the archived data, Plant Monitor learns the
normal behavior of the power plant in various
operating states and automatically creates
corresponding models for all system components.
In this way, regularly comparing current values
with the learned normal values allows
deviations to be identified early – long before
absolute limit values are reached.
Unlike traditional monitoring systems, the
analyses do not require intensive searching
of historic archive data. Plant Monitor uses
real-time data and the root cause analysis
is based on actual deviations in the running
of the plant.
Preventive maintenance measures can also
be better planned, and consequential damage
and resulting costs minimized.
A subsequent review showed that in the case
described, SPPA-D3000 Plant Monitor would
have identified the short circuit early. Through
fast and effective analysis would have issued
a prompt warning, thereby dispensing with
the need for laborious follow-up analysis.
"Plant Monitor can be used
in all operating states – even
transient ones. Values which
deviate from normal behavior
are identified early, allowing
us to make sound decisions
on the basis of foresight."
Andreas Mühlig, Head of Technology/Maintenance
EnBW AG, Altbach/Deizisau Power Plant
siemens.com/sppa
Published by and copyright © 2015:
Siemens AG
Power and Gas Division
Freyeslebenstrasse 1
91058 Erlangen, Germany
For more information contact
sppa-d3000.energy@siemens.com
www.siemens.com/energy/sppa-d3000
Siemens Energy, Inc.
Instrumentation, Controls, & Electrical
1345 Ridgeland Parkway, Suite 116
Alpharetta, GA 30004, USA
D3PPM_FR_Altbach-PlantMon_e_V1-0
Order no. E50001-G230-A415-X-4A00
Printed in Germany
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Subject to change without prior notice.
The information in this document contains
general descriptions of the technical options
available, which may not apply in all cases.
The required technical options should
therefore be specified in the contract.