dia tech monitoring and diagnosis system
TRANSCRIPT
Your benefit
DIA TECH Monitoring and Diagnosis System
www.andritz.com
ANDRITZ HYDRO GmbHEibesbrunnergasse 201120 Vienna, Austria Phone: +43 50805 0 Fax: +43 50805 5 1015E-Mail: [email protected]
HP.DIATECH 01.en.01.15
Optimal use by: Ergonomic graphical user interface Powerful hardware and software
Cost reduction by early fault detection: Avoidance of secondary damages Reduction of repair costs and of repair time Maintenance cost reduction Planning of repairs at best time
Increase of proceeds by: Reduction of outage time Optimised energy production Lifetime extension
Top right: indication of actual and historic turbine and pump operating hours; Bottom right: DIA TECH‘s trend chart; Big chart: intro mimic
05
All data, information, statements, photographs, and graphic illustrations in this leaflet are without any obligation and raise no liabilities to or form part of any sales contracts of ANDRITZ HYDRO GmbH or any affiliates for equipment and/or systems referred to herein. © ANDRITZ HYDRO GmbH 2015. All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ HYDRO GmbH or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. ANDRITZ HYDRO GmbH, Eibesbrunnergasse 20, 1120 Vienna, Austria.
DiaTech6pager_EN_.indd 1 12.01.2015 13:40:25
Diagnosis
Knowledge Modules
generating text messages
(Advanced) Condition
Monitoring
Data processing, analysis
& expert visualisation
SCADA (Trending)
Simple Data Display
Protection
Alarm & Trip
A conventional monitoring system delivers
data – our DIA TECH system delivers diag-
nostic results. DIA TECH is an online mo-
nitoring and diagnosis system developed
with our know-how as a designer and man-
ufacturer of main power plant equipment.
You can use it in generating units for all kinds
of power plants. The implemented software
and hardware is based on advanced tech-
nologies. The modularity of software and
hardware makes it possible to add functions
and capabilities to the system to meet cus-
tomer’s specific needs and to add new fea-
tures. The open system architecture allows
easy integration of third party products.
Various diagnosis modules (“Knowledge Mo-
dules”) are available for identifying mechan-
ical, dielectrical and thermal problems. The
quality of online diagnosis is significantly en-
hanced due to consideration of different
operation modes, such as generator normal
operation, turbine normal operation, start up,
shut down, etc.
With this intelligent online monitoring system
it is possible to detect changing condition
of major machine parts earlier and make it
easier to judge degrees of strain, thus sup-
porting a preventive, condition-based main-
tenance strategy. This supports the manage-
ment of the monitored units and at the same
time improves plant availability.
DIA TECH is part of NEPTUN, the integrated common solution for secondary technology
02 03 04
Nowadays all power stations have to maxi-
mise production and minimise costs signifi-
cantly. Even under normal operating condi-
tions all components (turbine, shaft, bear-
ings, generator etc.) are subject to ageing
and damages. Advanced monitoring and
diagnosis systems have to watch indicators
of condition changes, analyse the trend and
provide warnings if alarm levels are exceed-
ed. They should support the fast diagnosis
of deviation causes such as abnormal ageing
and failures, before serious damage occurs.
These analytic and diagnostic results can
then assist plant operators, technical spe-
cialists and plant owners in making decisions.
That way, maintenance costs are reduced
and generation efficiency can be increased.
The early identification of faulty components,
the reduction of unscheduled outages and
shorter repair times are major objectives for
future operational processes. Data is per-
manently sampled and stored upon every
excursion which reduces storage capacity
and yields the data available for „life“. This
unique feature results in accessing data over
longer periods with user friendly graphical
displays. To realise these benefits, the DIA
TECH System, developed by ANDRITZ
HYDRO, incorporating the experiences of
international Electric Generating Utilities.
DIA TECH Monitoring and Diagnosis System
Top left: turbine operation chart and cavitation indication; top right: frequency spectrum and CEPSTRUM for structure borne sound diagnosis; Rotor profile (bottom left) and polar diagram (bottom right) from machine gap monitoring
Monitoring cubicles in PSW Goldisthal
Monitoring and Early Fault Detection
System Architecture
Our Solution Modules
Data Management & VisualisationThe DIA TECH CORE Systemserves as platform for all monitoringand diagnosis modules.
DIA TECH MASTERAcquisition and distribution of various plant data to data base, GUI and knowledge modules
DIA TECH GUIGraphical user interface for mimics, trending, warnings and diagnosis messages, supporting tools
DIA TECH CORE System
Vibration MonitoringProtection – Advanced Condition Monitoring
Changes of shaft alignment Changes of imbalance
(mechanical, magnetically, hydraulic)
Change of bearing clearance & alignment
Shear pin failure Changes of flow characteristics
(changed vane positions, clogging of the grid)
Partial Discharge Analysis (PDA)Measurement – Analysis
Condition changes inside the stator winding insulation
Faulty outer corona protection Ageing of insulation
3rd Party Modules
DIA TECH CAA-HSCooling Air Analysis – Hotspot Detection
Faulty winding connections – break in worst case
DIA TECH CAA-03Cooling Air Analysis – OzoneDiagnosis (surface partial discharge)
Faulty outer corona protection Aging of insulation
DIA TECH SBSStructure Borne Sound Diagnosis
Loosening of stator core Loosening of stator winding
(bars, end winding) Loosening of magnetic wedges
DIA TECH ThMThermal Diagnosis
Loss of cooling air flow Cooling circuit leakage Fouling & clogging of coolers
resp. air ducts in stator core Overheating of stator core and
winding
DIA TECH RTMPRotor Temperature Monitoring(based on calculation)
Overheating of rotor winding
DIA TECH IRDRotor Pole Temperature Monitoring (based on infrared measurement)
Overheating of single poles and Rotor winding
DIA TECH MGMMachine Gap Monitoring
Deformations of stator & rotor Changes of eccentricity &
roundness Changes of turbine clearance
DIA TECH CAVCavitation Monitoring
Increase of cavitation symptoms Reduction of power output
caused by cavitation
DIA TECH MFXMagnetic Field Monitoring of Rotor Winding
Changes of magnetic flux caused by disturbances or imbalances
Interturn faults
DIA TECH TPOTTurbine- and Pump Operation Times
Record and accumulation of different operation modes
Record of Starts and Stops Graphical preparation of
records
Special Solutions & Services Telemetry Fibre Optic Applications Thermal Slipring Monitoring Remote Access Capabilities
DIA TECH Knowledge Modules
Partial DischargeSignals
Air gap. Magnetic field, Infrared
Signals
Temps., Electric, Hydr.
Values etc.
Structure Borne Sound
SignalsCooling Air
SignalsSignal processing
CORE System
Knowledge modules
ANDRITZ HYDRO Modules 3rd Party Modules
MMI
DIA
TE
CH
C
AA
-HS
DIA
TE
CH
C
AA
-O3
DIA
TE
CH
S
BS
DIA
TE
CH
Th
M
DIA
TE
CH
R
TMP
DIA
TE
CH
IR
D
DIA
TE
CH
M
GM
DIA
TE
CH
C
AV
DIA
TE
CH
M
FX
DIA
TE
CH
TP
OT
Vib
ratio
n
PD
A
Sensors / Couplers
Controlsystem
DIA TECH MASTER (Data management + data base) & DIA TECH GUI (Visualization)
Hierarchy of monitoring philosophy
DiaTech6pager_EN_.indd 2 12.01.2015 13:40:29
Diagnosis
Knowledge Modules
generating text messages
(Advanced) Condition
Monitoring
Data processing, analysis
& expert visualisation
SCADA (Trending)
Simple Data Display
Protection
Alarm & Trip
A conventional monitoring system delivers
data – our DIA TECH system delivers diag-
nostic results. DIA TECH is an online mo-
nitoring and diagnosis system developed
with our know-how as a designer and man-
ufacturer of main power plant equipment.
You can use it in generating units for all kinds
of power plants. The implemented software
and hardware is based on advanced tech-
nologies. The modularity of software and
hardware makes it possible to add functions
and capabilities to the system to meet cus-
tomer’s specific needs and to add new fea-
tures. The open system architecture allows
easy integration of third party products.
Various diagnosis modules (“Knowledge Mo-
dules”) are available for identifying mechan-
ical, dielectrical and thermal problems. The
quality of online diagnosis is significantly en-
hanced due to consideration of different
operation modes, such as generator normal
operation, turbine normal operation, start up,
shut down, etc.
With this intelligent online monitoring system
it is possible to detect changing condition
of major machine parts earlier and make it
easier to judge degrees of strain, thus sup-
porting a preventive, condition-based main-
tenance strategy. This supports the manage-
ment of the monitored units and at the same
time improves plant availability.
DIA TECH is part of NEPTUN, the integrated common solution for secondary technology
02 03 04
Nowadays all power stations have to maxi-
mise production and minimise costs signifi-
cantly. Even under normal operating condi-
tions all components (turbine, shaft, bear-
ings, generator etc.) are subject to ageing
and damages. Advanced monitoring and
diagnosis systems have to watch indicators
of condition changes, analyse the trend and
provide warnings if alarm levels are exceed-
ed. They should support the fast diagnosis
of deviation causes such as abnormal ageing
and failures, before serious damage occurs.
These analytic and diagnostic results can
then assist plant operators, technical spe-
cialists and plant owners in making decisions.
That way, maintenance costs are reduced
and generation efficiency can be increased.
The early identification of faulty components,
the reduction of unscheduled outages and
shorter repair times are major objectives for
future operational processes. Data is per-
manently sampled and stored upon every
excursion which reduces storage capacity
and yields the data available for „life“. This
unique feature results in accessing data over
longer periods with user friendly graphical
displays. To realise these benefits, the DIA
TECH System, developed by ANDRITZ
HYDRO, incorporating the experiences of
international Electric Generating Utilities.
DIA TECH Monitoring and Diagnosis System
Top left: turbine operation chart and cavitation indication; top right: frequency spectrum and CEPSTRUM for structure borne sound diagnosis; Rotor profile (bottom left) and polar diagram (bottom right) from machine gap monitoring
Monitoring cubicles in PSW Goldisthal
Monitoring and Early Fault Detection
System Architecture
Our Solution Modules
Data Management & VisualisationThe DIA TECH CORE Systemserves as platform for all monitoringand diagnosis modules.
DIA TECH MASTERAcquisition and distribution of various plant data to data base, GUI and knowledge modules
DIA TECH GUIGraphical user interface for mimics, trending, warnings and diagnosis messages, supporting tools
DIA TECH CORE System
Vibration MonitoringProtection – Advanced Condition Monitoring
Changes of shaft alignment Changes of imbalance
(mechanical, magnetically, hydraulic)
Change of bearing clearance & alignment
Shear pin failure Changes of flow characteristics
(changed vane positions, clogging of the grid)
Partial Discharge Analysis (PDA)Measurement – Analysis
Condition changes inside the stator winding insulation
Faulty outer corona protection Ageing of insulation
3rd Party Modules
DIA TECH CAA-HSCooling Air Analysis – Hotspot Detection
Faulty winding connections – break in worst case
DIA TECH CAA-03Cooling Air Analysis – OzoneDiagnosis (surface partial discharge)
Faulty outer corona protection Aging of insulation
DIA TECH SBSStructure Borne Sound Diagnosis
Loosening of stator core Loosening of stator winding
(bars, end winding) Loosening of magnetic wedges
DIA TECH ThMThermal Diagnosis
Loss of cooling air flow Cooling circuit leakage Fouling & clogging of coolers
resp. air ducts in stator core Overheating of stator core and
winding
DIA TECH RTMPRotor Temperature Monitoring(based on calculation)
Overheating of rotor winding
DIA TECH IRDRotor Pole Temperature Monitoring (based on infrared measurement)
Overheating of single poles and Rotor winding
DIA TECH MGMMachine Gap Monitoring
Deformations of stator & rotor Changes of eccentricity &
roundness Changes of turbine clearance
DIA TECH CAVCavitation Monitoring
Increase of cavitation symptoms Reduction of power output
caused by cavitation
DIA TECH MFXMagnetic Field Monitoring of Rotor Winding
Changes of magnetic flux caused by disturbances or imbalances
Interturn faults
DIA TECH TPOTTurbine- and Pump Operation Times
Record and accumulation of different operation modes
Record of Starts and Stops Graphical preparation of
records
Special Solutions & Services Telemetry Fibre Optic Applications Thermal Slipring Monitoring Remote Access Capabilities
DIA TECH Knowledge Modules
Partial DischargeSignals
Air gap. Magnetic field, Infrared
Signals
Temps., Electric, Hydr.
Values etc.
Structure Borne Sound
SignalsCooling Air
SignalsSignal processing
CORE System
Knowledge modules
ANDRITZ HYDRO Modules 3rd Party Modules
MMI
DIA
TE
CH
C
AA
-HS
DIA
TE
CH
C
AA
-O3
DIA
TE
CH
S
BS
DIA
TE
CH
Th
M
DIA
TE
CH
R
TMP
DIA
TE
CH
IR
D
DIA
TE
CH
M
GM
DIA
TE
CH
C
AV
DIA
TE
CH
M
FX
DIA
TE
CH
TP
OT
Vib
ratio
n
PD
A
Sensors / Couplers
Controlsystem
DIA TECH MASTER (Data management + data base) & DIA TECH GUI (Visualization)
Hierarchy of monitoring philosophy
DiaTech6pager_EN_.indd 2 12.01.2015 13:40:29
Diagnosis
Knowledge Modules
generating text messages
(Advanced) Condition
Monitoring
Data processing, analysis
& expert visualisation
SCADA (Trending)
Simple Data Display
Protection
Alarm & Trip
A conventional monitoring system delivers
data – our DIA TECH system delivers diag-
nostic results. DIA TECH is an online mo-
nitoring and diagnosis system developed
with our know-how as a designer and man-
ufacturer of main power plant equipment.
You can use it in generating units for all kinds
of power plants. The implemented software
and hardware is based on advanced tech-
nologies. The modularity of software and
hardware makes it possible to add functions
and capabilities to the system to meet cus-
tomer’s specific needs and to add new fea-
tures. The open system architecture allows
easy integration of third party products.
Various diagnosis modules (“Knowledge Mo-
dules”) are available for identifying mechan-
ical, dielectrical and thermal problems. The
quality of online diagnosis is significantly en-
hanced due to consideration of different
operation modes, such as generator normal
operation, turbine normal operation, start up,
shut down, etc.
With this intelligent online monitoring system
it is possible to detect changing condition
of major machine parts earlier and make it
easier to judge degrees of strain, thus sup-
porting a preventive, condition-based main-
tenance strategy. This supports the manage-
ment of the monitored units and at the same
time improves plant availability.
DIA TECH is part of NEPTUN, the integrated common solution for secondary technology
02 03 04
Nowadays all power stations have to maxi-
mise production and minimise costs signifi-
cantly. Even under normal operating condi-
tions all components (turbine, shaft, bear-
ings, generator etc.) are subject to ageing
and damages. Advanced monitoring and
diagnosis systems have to watch indicators
of condition changes, analyse the trend and
provide warnings if alarm levels are exceed-
ed. They should support the fast diagnosis
of deviation causes such as abnormal ageing
and failures, before serious damage occurs.
These analytic and diagnostic results can
then assist plant operators, technical spe-
cialists and plant owners in making decisions.
That way, maintenance costs are reduced
and generation efficiency can be increased.
The early identification of faulty components,
the reduction of unscheduled outages and
shorter repair times are major objectives for
future operational processes. Data is per-
manently sampled and stored upon every
excursion which reduces storage capacity
and yields the data available for „life“. This
unique feature results in accessing data over
longer periods with user friendly graphical
displays. To realise these benefits, the DIA
TECH System, developed by ANDRITZ
HYDRO, incorporating the experiences of
international Electric Generating Utilities.
DIA TECH Monitoring and Diagnosis System
Top left: turbine operation chart and cavitation indication; top right: frequency spectrum and CEPSTRUM for structure borne sound diagnosis; Rotor profile (bottom left) and polar diagram (bottom right) from machine gap monitoring
Monitoring cubicles in PSW Goldisthal
Monitoring and Early Fault Detection
System Architecture
Our Solution Modules
Data Management & VisualisationThe DIA TECH CORE Systemserves as platform for all monitoringand diagnosis modules.
DIA TECH MASTERAcquisition and distribution of various plant data to data base, GUI and knowledge modules
DIA TECH GUIGraphical user interface for mimics, trending, warnings and diagnosis messages, supporting tools
DIA TECH CORE System
Vibration MonitoringProtection – Advanced Condition Monitoring
Changes of shaft alignment Changes of imbalance
(mechanical, magnetically, hydraulic)
Change of bearing clearance & alignment
Shear pin failure Changes of flow characteristics
(changed vane positions, clogging of the grid)
Partial Discharge Analysis (PDA)Measurement – Analysis
Condition changes inside the stator winding insulation
Faulty outer corona protection Ageing of insulation
3rd Party Modules
DIA TECH CAA-HSCooling Air Analysis – Hotspot Detection
Faulty winding connections – break in worst case
DIA TECH CAA-03Cooling Air Analysis – OzoneDiagnosis (surface partial discharge)
Faulty outer corona protection Aging of insulation
DIA TECH SBSStructure Borne Sound Diagnosis
Loosening of stator core Loosening of stator winding
(bars, end winding) Loosening of magnetic wedges
DIA TECH ThMThermal Diagnosis
Loss of cooling air flow Cooling circuit leakage Fouling & clogging of coolers
resp. air ducts in stator core Overheating of stator core and
winding
DIA TECH RTMPRotor Temperature Monitoring(based on calculation)
Overheating of rotor winding
DIA TECH IRDRotor Pole Temperature Monitoring (based on infrared measurement)
Overheating of single poles and Rotor winding
DIA TECH MGMMachine Gap Monitoring
Deformations of stator & rotor Changes of eccentricity &
roundness Changes of turbine clearance
DIA TECH CAVCavitation Monitoring
Increase of cavitation symptoms Reduction of power output
caused by cavitation
DIA TECH MFXMagnetic Field Monitoring of Rotor Winding
Changes of magnetic flux caused by disturbances or imbalances
Interturn faults
DIA TECH TPOTTurbine- and Pump Operation Times
Record and accumulation of different operation modes
Record of Starts and Stops Graphical preparation of
records
Special Solutions & Services Telemetry Fibre Optic Applications Thermal Slipring Monitoring Remote Access Capabilities
DIA TECH Knowledge Modules
Partial DischargeSignals
Air gap. Magnetic field, Infrared
Signals
Temps., Electric, Hydr.
Values etc.
Structure Borne Sound
SignalsCooling Air
SignalsSignal processing
CORE System
Knowledge modules
ANDRITZ HYDRO Modules 3rd Party Modules
MMI
DIA
TE
CH
C
AA
-HS
DIA
TE
CH
C
AA
-O3
DIA
TE
CH
S
BS
DIA
TE
CH
Th
M
DIA
TE
CH
R
TMP
DIA
TE
CH
IR
D
DIA
TE
CH
M
GM
DIA
TE
CH
C
AV
DIA
TE
CH
M
FX
DIA
TE
CH
TP
OT
Vib
ratio
n
PD
A
Sensors / Couplers
Controlsystem
DIA TECH MASTER (Data management + data base) & DIA TECH GUI (Visualization)
Hierarchy of monitoring philosophy
DiaTech6pager_EN_.indd 2 12.01.2015 13:40:29
Your benefit
DIA TECH Monitoring and Diagnosis System
www.andritz.com
ANDRITZ HYDRO GmbHEibesbrunnergasse 201120 Vienna, Austria Phone: +43 50805 0 Fax: +43 50805 5 1015E-Mail: [email protected]
HP.DIATECH 01.en.01.15
Optimal use by: Ergonomic graphical user interface Powerful hardware and software
Cost reduction by early fault detection: Avoidance of secondary damages Reduction of repair costs and of repair time Maintenance cost reduction Planning of repairs at best time
Increase of proceeds by: Reduction of outage time Optimised energy production Lifetime extension
Top right: indication of actual and historic turbine and pump operating hours; Bottom right: DIA TECH‘s trend chart; Big chart: intro mimic
05
All data, information, statements, photographs, and graphic illustrations in this leaflet are without any obligation and raise no liabilities to or form part of any sales contracts of ANDRITZ HYDRO GmbH or any affiliates for equipment and/or systems referred to herein. © ANDRITZ HYDRO GmbH 2015. All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ HYDRO GmbH or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. ANDRITZ HYDRO GmbH, Eibesbrunnergasse 20, 1120 Vienna, Austria.
DiaTech6pager_EN_.indd 1 12.01.2015 13:40:25
Your benefit
DIA TECH Monitoring and Diagnosis System
www.andritz.com
ANDRITZ HYDRO GmbHEibesbrunnergasse 201120 Vienna, Austria Phone: +43 50805 0 Fax: +43 50805 5 1015E-Mail: [email protected]
HP.DIATECH 01.en.01.15
Optimal use by: Ergonomic graphical user interface Powerful hardware and software
Cost reduction by early fault detection: Avoidance of secondary damages Reduction of repair costs and of repair time Maintenance cost reduction Planning of repairs at best time
Increase of proceeds by: Reduction of outage time Optimised energy production Lifetime extension
Top right: indication of actual and historic turbine and pump operating hours; Bottom right: DIA TECH‘s trend chart; Big chart: intro mimic
05
All data, information, statements, photographs, and graphic illustrations in this leaflet are without any obligation and raise no liabilities to or form part of any sales contracts of ANDRITZ HYDRO GmbH or any affiliates for equipment and/or systems referred to herein. © ANDRITZ HYDRO GmbH 2015. All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ HYDRO GmbH or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. ANDRITZ HYDRO GmbH, Eibesbrunnergasse 20, 1120 Vienna, Austria.
DiaTech6pager_EN_.indd 1 12.01.2015 13:40:25