combining the pi system and specialist vibration data to manage … · 2018-10-10 · • plant...
TRANSCRIPT
#PIWorld ©2018 OSIsoft, LLC
Combining the PI System and Specialist Vibration Data to Manage Asset Risk
Omoruyi Onobhamiukor (Uniper)
Tim Salter (Beran Instruments Ltd)
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#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
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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
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Uniper Condition Monitoring
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On-Line Vibration Monitoring (Critical Rotating Assets)
Advanced Condition Monitoring (All Process Data)
On site Condition Monitoring & Field Balancing
Maintenance Strategy Optimisation
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Beran Instruments Ltd
.
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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
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Beran Plant ProTech™ System
.
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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
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Beran PlantProtech™ System
.
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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
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Background
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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
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PI ProcessBook™ Mimic
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Event
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Unit fails to start due
to vibration trip!
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Event
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High Shaft run out
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Event
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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
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Event
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Not available for operation!
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Event
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Change in phase angle!
Damage confirmed (bent rotor)!
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Response
Beran data shows repeatability
in the data and confirm the Bend
is permanent.15
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Event
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SpheriCAL confirms other
parameters are good
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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
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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.
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Response
Balancing proved to be a
challenge!19
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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
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Sense – Think - Act
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ACM Smart Hub
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Dynamic Operation
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Dynamic Operation
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Dynamic Operation
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Dynamic Operation
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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
Tim Salter
Beran Instruments Ltd
Product Manager
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