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Instrumentation & Controls
Instrumentation & Controls
SPPA-D3000 Machinery Analysis
• Technical Description
The diagnostic monitoring solution for optimizing the
availability of turbomachinery
March 2008
VIBROCAM 5000
is renamed to
SPPA-D3000 Machinery Analysis
(Siemens Power Plant Automation)
Answers for energy.
© Siemens AG 2008. All rights reserved
Siemens Energy Sector
Instrumentation & Controls
Contents
Contents .............................................................................................................................................................................................2
Increased availability...........................................................................................................................................................................3
Avoidance of unscheduled outages ................................................................................................................................................3
Reduction of scheduled downtimes by limiting the extent of maintenance work to what is actually required .................................3
Diagnosis of anomalies...................................................................................................................................................................4
The modules of SPPA-D3000 Machinery Analysis .............................................................................................................................5
Overview.........................................................................................................................................................................................5
The VD5000 data acquisition unit...................................................................................................................................................5
Modular software package CM500 .................................................................................................................................................6
The diagnostic computer ................................................................................................................................................................9
Applications in steam turbine power plants ....................................................................................................................................... 10
Applications in combined-cycle power plants (CCPPs)..................................................................................................................... 12
Applications in pumped-storage and run-of-the-river power plants ................................................................................................... 14
Applications of SPPA-D3000 Machinery Analysis portable............................................................................................................... 16
Rapid fault recognition using SPPA-D3000 Machinery Analysis portable .................................................................................... 16
Technical data................................................................................................................................................................................... 18
SPPA-D3000 module: VD5000 data acquisition unit .................................................................................................................... 18
SPPA-D3000 module: CM500 software ....................................................................................................................................... 18
SPPA-D3000 module: Diagnostic computer ................................................................................................................................. 19
Abbreviations .................................................................................................................................................................................... 19
Note:
VIBROCAM 5000
has been renamed
Siemens Power Plant Automation "SPPA -D3000 Machinery Analysis“
VIBRODAU 5000
has been renamed
VD5000 as a module for the solution SPPA -D3000 Machinery Analysis
VIBROEXPERT CM-500
has been renamed
CM500 as a module for the solution SPPA -D3000 Machinery Analysis
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Increased availability
The consistent implementation of condition-oriented maintenance strategies requires in-depth knowledge of the machine
condition.
SPPA-D3000 Machinery Analysis provides this information for turbomachinery
such as:
„
Steam turbine generators
„
Gas turbines
„
Pumped-storage sets
„
Compressors
„
Turbine feedwater pumps
Condition-oriented maintenance is the strategy for optimizing the availability of production machinery.
This is possible through:
„
Avoiding unscheduled outages
„
Reduction of scheduled downtimes by limiting the extent of maintenance work to what is actually required
„
Diagnosis of anomalies
Avoidance of unscheduled outages
Continued operation of machinery exhibiting anomalies accompanied by automatic diagnosis-oriented observation of the
anomalies until the next scheduled shutdown avoids production losses. Insurance companies approve of this method of
procedure provided suitably qualified diagnostic systems are deployed.
Reduction of scheduled downtimes by limiting the extent of maintenance work to what is actually required
Plant components are only subjected to inspection and overhaul
when measured characteristic values deviate from setpoints. Detailed
knowledge of the machine condition can therefore reduce inspection
periods to a minimum.
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Information about the machine condition permits technicians and engineers to increase the availability of machinery. Powerful
diagnostic tools are required for this purpose.
Sensitive diagnosis-oriented monitoring of the machine condition ensures that even incipient changes in machine behavior
can be reliably detected. The earliest possible detection of an incipient fault maximizes the reaction time for determining the
most economic solution to the problem.
Even continued emergency operation of machinery which is already damaged or scheduled for inspection and overhaul is
supported by the prompt supply of information about development of the fault.
Diagnosis of anomalies
Reliable information about actual faults and their causes is a prerequisite for finding an economic solution to any problem.
Through the multitude of functions and diagrams available for fault recognition, SPPA-D3000 Machinery Analysis provides
both standard and innovative tools to support the implementation of condition-oriented maintenance strategies for
turbomachinery.
„
Unbalances
„
Alignment faults
„
Rubbing
„
Open circuits
„
Incipient cracks
„
Looseness
„
Blade fractures
„
Foundation changes
and many more problems can be reliably detected.
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The modules of SPPA-D3000 Machinery Analysis
Overview
SPPA-D3000 Machinery Analysis is one of the solutions in the portfolio Siemens Power Plant Automation SPPA-D3000
Diagnostic Suite.
SPPA-D3000 Machinery Analysis comprises three modules:
„
The VD5000 data acquisition unit
„
The CM500 software package and
„
The diagnostic computer
The VD5000 data acquisition unit
VD 5000 was specifically developed for the diagnostic monitoring of
turbomachinery. Dedicated system features include:
„
Parallel, rotor-triggered data acquisition, which is a prerequisite for fault
analysis and enables the correlation of all measured values
„
A data acquisition cycle time of approx. 1 second ensures extremely
fast reaction times in the event of abnormal machine behavior.
„
With up to 64 vibration measuring channels, distributed between up to 3
shafts, and 112 channels for measuring process variables, as well as
three speed inputs, data can be acquired from any turbomachine
combination.
„
The acquisition of total vibration, of four harmonics for both amplitude
and phase and of a residual vibration value guarantees reliable fault
analysis.
„
Automatically acquired time functions, spectra and shaft orbits provide
further information for determining the cause of the fault.
The operator can detect deviations from normal machine behavior at a glance.
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Modular software package CM500
CM500 is also perfectly tailored for the analytical monitoring of turbomachinery. It fulfils the following tasks:
„
Monitoring
„
Archiving
„
Analysis
The normal behavior of the machine is determined automatically and archived as the reference condition.
Monitoring
Up to 1000 automatically calculated limit and reference values for every vibration measuring point guarantee highly sensitive
monitoring of the machine condition during normal operation for changes in relation to reference conditions.
Deviations of individual values from reference values can be linked to fault-typical event patterns and monitored. If an event
pattern occurs, preprogrammed actions can be initiated automatically.
Startup and run-down procedures can be monitored by comparing every measured vibration value with the corresponding
value from a statistically determined reference procedure.
Historical events are accurately reproduced with a resolution of up to one second for the purposes of analysis.
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The combination of high-quality diagrams greatly facilitates
the analysis of an event.
Current event patterns are automatically compared
with stored patterns. If there is a match, an appropriate
message can be output, for example.
Archiving
If any individual measured value deviates from the learned reference condition, a complete data set is stored for the entire
machine. As long as all measured values remain within acceptable tolerance ranges, complete data sets are only archived at
specified intervals, or in the case of startup and run-down procedures, in specified speed increments.
This means that the original measured data for every event remain available for many years and can be accessed with a view
to interpreting current processes.
Important startup and run-down procedures are automatically detected and stored.
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Analysis
Almost all diagnostic diagrams are interactive and permit the simultaneous display of data for several measurement points,
thus permitting correlations between causes and effects to be identified.
The modular, password-protected CM500 software enables maintenance personnel and diagnostic engineers to evaluate a
wide range of diagrams with a view to assessing the machine condition.
Instances of loosening and incipient cracks become evident in the altered resonance behavior of the machine structure.
This can be seen from the diagrams.
The startup behavior is monitored automatically based on statistically determined reference procedures.
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The diagnostic computer
The latest generation of commercially available personal computers with a Windows operating system can be used.
Diagnostic computers can be integrated in the in-house LAN (local area network) using Ethernet cards. This enables access
to any data acquisition unit from any workplace.
Password-protected connection of the diagnostic computer to a telephone network via modem makes access possible for
specialists from around the world, which means that fast and reasonably priced support can be provided for diagnostics.
Time functions, frequency spectra and orbits, and their positions with respect to each other, are powerful analytical tools.
Special events, such as the effects of load rejection, are examined with the aid of the transient recorder.
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Applications in steam turbine power plants
Most steam turbines are used in base or middle-load power plants. Sensitive
monitoring of normal operation and the analysis of startup and run-down
procedures are of special importance in these applications.
Monitoring of normal operation relative to operating conditions enables
abnormal deviations in machine behavior to be recognized at an early stage.
During normal operation, all machines equipped with SPPA-D3000 Machinery
Analysis are monitored by comparing current measured values with reference
values relative to the given operating condition.
Up to 64 individual operating conditions for normal operation can be defined based on
parameters such as power, exciter current and condenser pressure.
The system can calculate up to 1000 limit and reference values for each individual
vibration measuring point.
Continuous comparison of actual measured values with these reference values
permits sudden or incipient changes, as well as any deviations from the normal
machine condition, to be detected automatically.
The level of sensitivity attained is independent of machine type or design.
The measured vibration values for different power classes are displayed in color. Individual limit values and reference values
are automatically determined for each power class.
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Event-driven system reactions make it possible to automate troubleshooting procedures.
Fault-typical limit value violation patterns, also known as event patterns, can be stored in SPPA-D3000 Machinery Analysis.
When such an event pattern is recognized, preprogrammed actions can be performed, e.g.
„
Activation of a relay
„
Measurement of time functions, spectra or orbits
„
Output of messages
„
Freezing of short term ring memory
„
Automatic startup of software programs, e.g. to send a fax or e-mail
This automatic data interpretation provides immediate information about the necessary operational procedures when an event
occurs.
Repeated startup and run-down operations often put a considerable load on machines.
The analytical examination of startup and run-down procedures is of great importance for this reason. SPPA-D3000 Machinery
Analysis can provide a solution to this problem simply by comparing every startup and run-down procedure with a reference
procedure.
This enables incipient cracks, rubbing or looseness to be recognized reliably during startup and run-down procedures.
Event patterns are stored.
The measured vibration value should move within the
automatically determined tolerance range during startup.
SPPA-D3000 Machinery Analysis determines reference procedures through the statistical evaluation of normal startup and
run-down procedures from stored data.
The above-mentioned faults can readily be recognized based on the automatic comparison of the current startup or run-down
procedure with a previously determined reference procedure.
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Applications in combined-cycle power plants (CCPPs)
These power plant variants are very common due to relatively
low capital investment costs, high efficiency and flexible
operation. Different machine combinations are possible
depending on the application targets.
Thanks to its modular structure, SPPA-D3000 Machinery
Analysis is suitable for use with any machine combination in a
combined-cycle power plant.
SPPA-D3000 Machinery Analysis monitors every machine
individually, irrespective of the operating condition or mode of
the coupled machines and independently of
„
the number of gas and steam turbines that are
mechanically coupled to the generator
„
the combination of machines in the energy cycle.
The flexibly configurable data acquisition unit VD 5000
makes it possible to monitor any combination of gas and
steam turbines.
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An important aspect in the monitoring of combined-cycle power plants is the method by which the steam turbine is coupled
with the generator during operation. The coupling engagement angle can produce different vibration conditions which
influence the entire machine train and which may subject the machine to increased loading.
SPPA-D3000 Machinery Analysis provides immediate feedback in such cases, making it possible to repeat the engagement
procedure so as to minimize the load imposed on the machine.
Monitoring the gear mesh frequencies
Monitoring the gear mesh frequencies of important gearboxes is another of the many possible applications of SPPA-D3000
Machinery Analysis.
Vibration acceleration signals can be demodulated, converted into gear-specific characteristic values and incorporated in the
monitoring function.
Gearboxes can also be incorporated in diagnostic monitoring by
means of intelligent characteristic value formation.
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Applications in pumped-storage and run-of-the-river
power plants
Unlike run-of-the-river power plants, pumped-storage plants used as peak-load power plants have special requirements
relating to the monitoring system.
These requirements result from the different operating regimes in
which they are used:
„
Turbine operation
„
Pumping operation
„
Phase correction operation in pumping mode and
„
Phase correction operation in turbine mode
A different vibration pattern occurs in each of these operating
regimes relative to the operating condition. SPPA-D3000 Machinery
Analysis acquires the relevant binary signals in each case and
incorporates the operating regime in diagnostic monitoring.
The system can identify up to 16 operating conditions within the
various operating regimes based on operating variables such as
power, head height and inlet guide vane position.
SPPA-D3000 Machinery Analysis defines sets of limit and reference
values corresponding to sudden or incipient changes for every
operating condition within every operating regime. These are used for
monitoring deviations from the learned normal condition.
This method guarantees extreme monitoring sensitivity even
with a wide spectrum of different operating conditions.
The relationship between vibration
amplitudes and power becomes
clearly visible.
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The greatest machine loading occurs during transient operating conditions
For this reason these conditions are of great interest for an analysis of the machine condition. With the help of binary
signals or manual controls, SPPA-D3000 Machinery Analysis acquires the raw signals from the vibration sensors during
transient operating conditions and makes them available for evaluation.
Operating mode changeovers, e.g. from pump
operation to turbine operation, can be examined
using the transient recorder, which visualizes the
forces acting on the machine.
„
Alignment errors are visualized
Another software module customized for use with this machine type is available in addition to the functions of
SPPA-D3000 Machinery Analysis which we have already described.
The "stacked orbit" diagram displays the shaft orbits of the machine, which are generally measured on three measuring
planes, one on top of the other, thus facilitating the visualization of alignment errors.
The graphical combination of orbits measured in
different planes permits conclusions to be drawn
with respect to alignment.
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Applications of SPPA-D3000 Machinery Analysis
portable
Rapid fault recognition using SPPA-D3000 Machinery Analysis portable
When a fault is detected, it is seldom immediately clear what type of analyzers will be required for identifying the fault.
32 vibration measuring channels and 8 channels for the acquisition of process variables make the portable version of
SPPA-D3000 Machinery Analysis the ideal fault recognition tool. When it is equipped with all the functions described above
(all functions can be backfitted as modules), this solution can function as any of the following:
„
Event-driven data collector
that can automatically archive events in detail, even over a period of months, without operator supervision
„
Automatic messaging system
which can reliably signal minute changes in the machine condition and, if required, send a fax or e-mail to any address
„
32-channel frequency analyzer
for fault analysis on the basis of frequency spectrums
„
32.channel orbit analyzer
which presents the shaft orbits of up to 8 planes for evaluation. Differential displays permit run-out compensation.
„
32-channel storage oscilloscope
for selective analysis of individual sensor signals
„
32-channel transient recorder
with the help of which special rapidly occurring events, such as operating regime transitions and sudden load rejection,
can be stored and analyzed.
These characteristics make SPPA-D3000 Machinery Analysis
portable an ideal solution, especially for the service engineer who
is frequently on the road. It means that a large number of different
analyzers do not need to be transported and it avoids the
time-intensive installation of several items of equipment.
The many features of SPPA-D3000 Machinery Analysis mean that
it is also more than capable of meeting the requirements of
commissioning or test bay applications. The ease with which the
system can quickly be configured to suit a specific machine or
measurement task is especially worthy of note.
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The raw signal from the sensor is compared with a
signal from the archive.
Changes in the orbit are clearly visible when compared
with a reference measurement.
The raw signals are archived and subsequently
analyzed in the case of special transient events.
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Technical data
SPPA-D3000 module: VD5000 data acquisition unit
Different variants of the VD5000 data acquisition unit exist. These vary with respect to the maximum number of channels and
whether or not they contain an integrated computer with a hard disk.
Measuring channels for vibration measurement:
Up to 64
Measuring channels for acquisition of process variables:
Up to 112 by analog means or via OPC
Measuring channels for acquisition of reference signals (1 pulse per revolution)
Up to 4
Measuring channels for acquisition of binary signals:
Up to 32
Relay outputs:
Up to 32
Data acquisition cycle time
approx. 1 second
Data acquisition
Parallel on all measuring channels
SPPA-D3000 module: CM500 software
The CM500 software is modular in design, thus making it possible to produce a customized solution for each individual
application.
Modules exist for the following applications:
Diagnostic monitoring
„
Statistical evaluation of data to determine normal behavior of machine during power operation
„
Statistical evaluation of data to determine normal behavior of machine during startup or run-down
„
Definition of rules for monitoring
„
Monitoring of machine for deviations from normal behavior during power operation
„
Monitoring of machine for deviations from normal behavior during startup and run-down
„
Monitoring of machine during turning gear operation (shaft distortion)
„
Display of data in the form of bar diagrams or tables which change color when an event occurs
„
Display of tolerance ranges during power operation
„
Display of tolerance ranges during startup and run-down (tolerance range)
„
Cyclic or event-driven archiving of data
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Tools for analysis of machine condition
„
Statistical evaluation of data
„
Trend evaluation, polar diagrams, XY diagrams
„
Spectral analysis (for one or all measuring points)
„
Analysis of time signal (for one or all measuring points)
„
Orbit analysis (dynamic signal component) incl. position of orbit in plain bearing (static signal component)
„
Bode and Nyquist diagrams for analysis of startup and run-down behavior
„
Run-down curves
„
Orbit vs. speed diagram
„
Transient recorder
„
and many more
SPPA-D3000 module: Diagnostic computer
If there is no computer integrated in the VD5000 data acquisition unit, the visualization computer also performs diagnostic
monitoring for the machine.
„
Standard PCs with a Windows XP operating system are used for this purpose.
„
No special requirements are specified with respect to computer performance.
„
The technical data correspond to those of the latest office PC class.
„
The screen should be as large as possible. 21" or more is recommended.
Abbreviations
OPC
OLE for process control
SPPA
Siemens Power Plant Automation
SPPA-D3000
Siemens Diagnostic Suite
VD5000
Module data acquisition unit for the SPPA-D3000 Machinery Analysis solution
VC500
Software module for the SPPA-D3000 Machinery Analysis solution
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© Siemens AG 2008. All rights reserved
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Published by and Copyright © 2008:
Siemens AG
Energy Sector
Freyeslebenstraße 1
D-91058 Erlangen
Siemens AG
Energy Sector
Fossil Power Generation
Instrumentation & Controls
Siemensallee 84
D-76187 Karlsruhe
sppa-d3000.pg@siemens.com
www.siemens.com/sppa-d3000
D3MMA_DT1_MachAnalys_TechDescr_e_V1-0
All rights reserved.
Subject to change without
prior notice
Printed on chlorine-free paper.
The trademarks and brand names
used in this document are the
property of Siemens AG or their
associated companies or the
individual holder.
The information in this document
contains general descriptions
of the technical options available, which
are not necessarily implemented in all
Individual cases. The required features
should therefore be specified in each
individual case at the time of closing
the contract.
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