combining the pi system and specialist vibration data to manage … · 2018-10-10 · • plant...

#PIWorld ©2018 OSIsoft, LLC

Combining the PI System and Specialist Vibration Data to Manage Asset Risk

Omoruyi Onobhamiukor (Uniper)

Tim Salter (Beran Instruments Ltd)

1

#PIWorld ©2018 OSIsoft, LLC

Contents

.

2

1. Background

2. Beran Instruments Ltd

3. Event

4. Permanent Bend Diagnosis

5. The Journey to Full Speed

6. Staying afloat on Load

7. Conclusion

#PIWorld ©2018 OSIsoft, LLC

We are Uniper

3

Where we operate:

40+ countries around the world

4th largest generator in Europe

Employees: 12,635Our operations:

Power Generation

Commodity Trading

Energy Storage

Energy Sales

Energy Services

Power generation, Storage, Services -

Europe

Power generation - International

Commodity Trading, Energy Sales

€ 2.12 bnEBITDA

100 yearsExperience

38.2 GW Total generation

Main activities:

Gas fired

plants

19.2 GW

Coal fired plants

10.5 GW

Energy storage

Gas: 8.5 bn m3

Gas fields Gas pipelines and

infrastructure

Regasification

Nuclear plants

1.9 GW

Hydroelectric plants

3.6 GW

Trading Energy sales (small to large clients, electricity

and gas)

Services

#PIWorld ©2018 OSIsoft, LLC

Uniper Condition Monitoring

4

On-Line Vibration Monitoring (Critical Rotating Assets)

Advanced Condition Monitoring (All Process Data)

On site Condition Monitoring & Field Balancing

Maintenance Strategy Optimisation

#PIWorld ©2018 OSIsoft, LLC

Beran Instruments Ltd

.

5

Part of the Condition Monitoring Group, founded in 1984 with offices in UK,

USA, Germany and Italy

Diagnostic Monitoring platform for turbines and associated critical plant

Installations in many large power generation companies covering Coal, Gas,

Nuclear and Hydro

Data links to PI since 1998

Full PI partner since Spring 2018

Enhanced PI capability now available

#PIWorld ©2018 OSIsoft, LLC

Beran Plant ProTech™ System

.

6

Analog signals

• Plant ProTech connects to any Protection System

• Connects to vibration / pressure sensors and voltage sources

• Usually via buffered outputs or isolation amplifiers

• Allows powerful vibration diagnostic parameters

#PIWorld ©2018 OSIsoft, LLC

Beran PlantProtech™ System

.

7

Turbines

Pumps

Auxiliary Plant PlantProtech™

Vision Diagnostic

Tools

PlantProtech™

Mimic Dashboard

OSISoft

PI Vision

Other Data

Sources

• DCS

• Temperature

• Pressure

• Environmental

• Performance

• Control Systems

• Web APIs

#PIWorld ©2018 OSIsoft, LLC

Background

8

330 MW CCGT runs on natural gas

General Electric Frame 9FA gas turbine

Stein Industrie heat recovery generator

Steam Turbine

Generator

Single Shaft layout

Combination of Beran and PI used for diagnosis and risk management

#PIWorld ©2018 OSIsoft, LLC

PI ProcessBook™ Mimic

9

#PIWorld ©2018 OSIsoft, LLC

Event

10

Unit fails to start due

to vibration trip!

#PIWorld ©2018 OSIsoft, LLC

Event

11

High Shaft run out

#PIWorld ©2018 OSIsoft, LLC

Event

12

04 - GMB030TE

278.96875

Deg C

04 - GMB031TE

280.86160

Deg C

04 - GMB032TE

261.97144

Deg C

04 - GMB034TE

242.10104

Deg C

04 - GMB035TE

237.35640

Deg C

04 - GMB037TE

240.48303

Deg C

04 - GMB038TE

275.67188

Deg C

04 - GMB039TE

57.30241

Deg C

04 - GMB040TE

210.42310

Deg C

04 - GMB041TE

245.39063

Deg C

U4 - TRE TNH

120.34877

RPM

08/11/2016 13:17:4708/11/2016 06:36:43 6.68 hours

Plot-0

-250

-50

150

350

550

750

950

1005.35714

Sudden decrease in steam

turbine cylinder temperature

#PIWorld ©2018 OSIsoft, LLC

Event

13

Not available for operation!

#PIWorld ©2018 OSIsoft, LLC

Event

14

Change in phase angle!

Damage confirmed (bent rotor)!

#PIWorld ©2018 OSIsoft, LLC

Response

Beran data shows repeatability

in the data and confirm the Bend

is permanent.15

#PIWorld ©2018 OSIsoft, LLC

Event

16

SpheriCAL confirms other

parameters are good

#PIWorld ©2018 OSIsoft, LLC

Situation Recap

The unit has tripped on start-up

No longer available for generation

Beran vibration data has indicated out of balance

PI data has indicated a sudden cooling of the steam turbine

Vibration data confirms the turbine rotor is bent

SpheriCAL confirms all other parameters are good

17

#PIWorld ©2018 OSIsoft, LLC

Response

OEM advised station not to run the machine (lead time on

replacement rotor)

Uniper attempted an in situ trim balance

Keep the unit available during the high demand winter months

Allow for time to plan an outage

Heavy weights required, due to the large imbalance

Heavier nuts on the coupling bolts, tapered bolts added to bolt ends

and steels plates used to replace selected windage plates.

18

#PIWorld ©2018 OSIsoft, LLC

Response

Balancing proved to be a

challenge!19

#PIWorld ©2018 OSIsoft, LLC

Managing The Risk

Once stabilised at minimum load, the machine was run through the

night

Load applied in small stages

Incidents of light impacting, as indicated by the appearance of locked

on ½ speed vibration within the signal

Risk of runaway increase in vibration levels mitigated by setting

vibration alarm and trip limits to provide additional warning to the

control room.

PI data availability to all operators and engineers was excellent

SpheriCAL provided robust anomaly detection

20

#PIWorld ©2018 OSIsoft, LLC

Sense – Think - Act

21

#PIWorld ©2018 OSIsoft, LLC

ACM Smart Hub

22

#PIWorld ©2018 OSIsoft, LLC

Dynamic Operation

23

#PIWorld ©2018 OSIsoft, LLC

Dynamic Operation

24

#PIWorld ©2018 OSIsoft, LLC

Dynamic Operation

25

#PIWorld ©2018 OSIsoft, LLC

Dynamic Operation

26

#PIWorld ©2018 OSIsoft, LLC

RESULTSCHALLENGE SOLUTION

Uniper and Beran

Serious event risked six months loss of generation during peak demand.

Beran vibration data enabled quick and accurate assessment of the issue. PI data enabled investigation into the root cause. Uniper’s SpheriCAL anomaly detection system highlights the problem and gives confidence other process parameters are good

We were able to get the unit back online and generating at a critical demand period. Our approach also gave us some time to plan an outage to repair the bend in the rotor.

• Challenging multi plane in situ trim balancing

• ACM Smart Hub provided effective collaboration tool

• Dynamic operation principles tested in the ‘real world’

• 6 months lost generation saved

• Allowed time to plan an outage

• Permanent shaft bend

• High Vibration

• Can not get unit on to generate electricity

Combining the PI System and Specialist Vibration Data to Manage Asset Risk

27

#PIWorld ©2018 OSIsoft, LLC 28

Omoruyi Onobhamiukor

Technical Lead, Condition Monitoring

Uniper Technologies Ltd

Omoruyi.onobhamiukor@uniper.energy

Tim Salter

Beran Instruments Ltd

Product Manager

tim.salter@beraninstruments.com

#PIWorld ©2018 OSIsoft, LLC

Questions?

Please wait for

the microphone

State your

name & company

Please rate this session

in the mobile app!

Search

“OSIsoft” in

your app store

29

#PIWorld ©2018 OSIsoft, LLC 30