Use and Experience of Gas Turbine On-line Diagnostics · Use and Experience of Gas Turbine On-line ... speed is increased over 3 GHz with ... Figure 3 shows the increase of processor

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Use and Experience ofGas Turbine On-line Diagnostics

Michael Scheidel,

Karlheinz Bender, Dr. Robert Taud

Siemens AG, Power Generation, Germany

0 Abstract

Ten years ago Gas Turbine (GT) Diagnostic Systems were ordered in less then 10 % of new

units. Today this has changed dramatically; almost all newly ordered gas turbines are

equipped with at least a basic Diagnostic System. A main reason is the constantly progressing

gas turbine technology.

To minimize the risk for vendor and customer, diagnostic benefit starts from the beginning of

gas turbine life time with product development and engineering, continues during plant shop

test, commissioning, acceptance test and warranty period and closes the loop with mainte-

nance and service .

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The modular WIN_TS Diagnostic System connected to the I&C System has access to any of

the sensors and obtains between 300 and 1000 signals. Additionally to these signals with the

highest resolution of 1s, a high speed data acquisition for selected signals is included for ana-

logue and for binary signal analysis down to milliseconds. Together with Database, Archive

and Remote Access, these is the basic system frame, on top of which there are various tech-

nology modules.

There are for example thermodynamic, hot gas path, vibration and component life cycle

modules available for analysis and diagnostics.

Through remote access, the system is connected to a Diagnostic Center from which it is

commissioned and to where it sends data via a data container . By means of the Diagnostic

Center, the experts have the possibility to support any critical situation during commissioning

or service. Just some mouse clicks enable them to obtain data from gas turbines all over the

world.

The operating data taken from the Win_TS system are also very important for generation of

availability and reliability figures as well as fleet statistics.

Based on the evaluation of different vibration parameters out of Win_TS it is also possible to

contact engineering for support and remedies. Examples show how engineering advises in-

spections and how the early knowledge of the unit condition can significantly help to im-

prove the unit availability.

For the customer it is important to have access to the knowledge of the developers of his gas

turbine in critical situations through a diagnostic platform.

For the supplier the highest value is live feedback from his own „running technological sys-

tems“ in order to to optimize learning.

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1 Power Plant Market and Role of Advanced Monitoring and Diagnostics Systems

In all world regions, the power generation market has been characterized in recent years by its

orientation towards utilization of gas turbines, both as simple cycle and combined cycle plant

applications. In these plant configuration, both proven or advanced gas turbines represent the

high tech piece of equipment at the core of the plant. Regardless of the overall plant configu-

ration and other extended equipment installed, the Return on Investment ultimately hinges on

the gas turbine. Hence it is essential to focus on this crucial core component.

One lever to do this is to employ advanced Monitoring and Diagnostics Technology. The ap-

proach presented in this paper was fully developed and implemented over recent years, in-

cluding input and feedback both from customers and gas turbine development. The goal is to

maximize investment security and returns throughout the complete plant life cycle. The criti-

cal plant scope for this includes besides the gas turbine the generator, the air intake /exhaust

system and the corresponding auxiliary systems, as shown in Figure. 1. (Siemens name for

this product scope: EconopacTM , derived from Economical Package)

May 2004 © PG G1 4

R: PG2004_Schei, Be,Ta_.ppt

Power-Gen Europe 2004, Barcelona

Monitoring and Diagnostics ofGT Plant Key Components

Econopac� Gas Turbine� Auxiliaries e.g.

- Fuel Gas System - Lube Oil System- Compressor Wash System

� Enclosures� Generator� Air Intake System� Exhaust Gas System� Instrumentation & Control

System� Electrical Package (PCC)� Options

Shell ConceptTurnkey Power Plant

Power IslandEconopac

Air Inlet

Gas Turbine

Generator

Power Control Center

Exhaust Gas System

includingAuxiliary Systems,Enclosures

Fig. 1

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Presented here, Monitoring and Diagnostics applied to the Econopac is the tool to back the

customer’s key generation technology and investment with matching state-of-the-art support

technology and processes. In essence it is advanced life-time support based on a high-tech

platform for monitoring, diagnostics and service, contributing to achieve high reliability.

May 2004 © PG G1 5



Philosophy of GT-Econopac Monitoring and Diagnostics

Function

Time Value

Diagnostics - during all stages of turbine operation and life cycle.

Condition-based maintenance - evaluatedand directed by experts

Better Prevention of forced outages –Detection and resolution of problems

Quality Triangle

Fig. 2

The underlying philosophy of the GT-Econopac Monitoring and Diagnostics concept is de-

scribed within the triangle of Quality Management ( Figure 2):

- focus on function : performance,

- time: response time, and

- value: reliability through prevention of forced outages.

Illustrated in the center of the triangle are the corresponding key elements of the concept and

the benefits of the implementation of Monitoring and Diagnostics:

- Diagnostics during all stages of turbine operation and life cycle

(also channelled into the feedback loop for new product development)

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- Condition-based maintenance evaluated and directed by experts

- Detection and resolution of problems, more effective prevention of forced outages

In the recent years enormous advances were made in the fields of development of computer

power, network technology, as well as specific diagnostic tools. This provided the informa-

tion technology basis (IT) for advanced Monitoring and Diagnostics in an on-line mode, with

remotely , centralized performed interrelated data analysis and diagnostics.

May 2004 © PG G1 6



% of GT (New Apparatus)

GHz ProcessorSpeed

IT innovation supports Gasturbine Diagnostics

Intel 80486 33 MHz

1990 2004

Intel P4 3,4GHz

Diagnostic Installationsfor Gasturbines(New Apparatus)

Processor speed

1990 the transfer of 10 MBdata with a 1200 Baud modem

took one day....

... 2004 it only takes 14 Minwith an dual ISDN line....

.......and 30 seconds with intranet / LAN

100%

Fig. 3

Hence, 10 years ago GT Diagnostics Systems were ordered in less than 10% of new units.

Today this has changed dramatically; almost all newly ordered gas turbines are equipped with

at least a basic Diagnostic System. A main reason is the constantly progressing gas turbine

technology. Correspondingly, IT innovation keeps growing and supporting gas turbine diag-

nostics development. 1990 typically a PC runs with a Intel 486 / 33MHz while today the

speed is increased over 3 GHz with a Pentium 4.

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For example, 1990 the transfer of 10 MB data with a 1200 Baud modem took one day, 2004

it only takes 14 minutes with a dual ISDN line and just 30 seconds with intranet/LAN con-

nection. 10 MB is today a typical day file size for gas turbine data witch is transferred be-

tween fields and offices.

Figure 3 shows the increase of processor speed and Gas turbine Diagnostics installations in

new units.

2 Diagnostic System Platform: Task and Concept

May 2004 © PG G1 8



Evolution Goal : one common platformfor GT,ST and GUD Data Acquisition & Diagnostics

„Gas Turbine Diagnostic Calculators“ and other diagnostic systems in the early 90th

Modern PG Diagnostic Systems „WIN_TS“ today

PC-(USA-Rechner)Flex OS Rel. 6.0

GTD

WIN_OSPC-RI40

Windows 3.1

WIN_OSPC-RI40

Windows 3.1

Alpha-RechnerDEC-UNIX

PC-RI20Rel. 2.X

PC-32MFlex OS Rel. 6.0

Gateway

PC-(USA-Rechner)Flex OS Rel. 6.0

GTDTLR TDY Past

PCWindows NT

GT/TDY

Today

Fig. 4

In the early 90’s, a number of different hard- and software Systems were necessary to perform

the diagnostics tasks in a plant. To reduce the complexity of those configurations the devel-

opment goal was to achieve a common platform for data acquisition and diagnostics.

Figure 4 shows in the upper section a typical example from the early 90’s with the high com-

plexity of different hard- and software installations. These installations were more or less not

compatible and used in separate and stand-alone mode. To do this, diagnostic capabilities

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were limited, time consuming and required a high formal software and hardware competence.

Shown in the lower section is the example for today, with the reached development goal,

while profit could be taken from the information technology evolution. Through one common

platform we can handle these different analysis and diagnostics tasks. In addition new diag-

nostic functions were incorporated in the same manner. One Windows-PC now exceeds the

tasks which were then performed by a number of computer devices.

May 2004 © PG G1 9



Diagnostic System Platform -one host for all Technologies

- Central access to all analysis modules - Integration of 3rd party products- Synergy and cost reduction of equipment and tools- Combination of different data in one database- One evaluation tool for technologists

Fig. 5

In addition to this development, the following goals were achieved (Figure 5):

• Central access to all analysis modules:

Depending on the gas turbine-technology requirements, the customer has access to

more than twenty different analysis and diagnostic modules through Windows Look

and Feel.

• Integration of 3rd party products:

Market available technologies from different companies in combination with the com-

petence of gas turbine producers should compliment the diagnostic platform.

• Synergy and cost reduction of equipment and tools:

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Less hardware and software equipment, along with less administration effort provides

synergy and cost reduction and prevent computer farms around a gas turbine.

• Combination of different data in one database:

Combination of different data in one database allows more complex and interrelated

data conditioning, analysis and diagnostics.

• One evaluation tool for technologists:

There is a common tool used by the technologists for visual evaluation of different

kinds of data. This allows easy handling and focus on the technological evaluation and

interpretation.

May 2004 © PG G1 11



Typical Application GT On-line Monitoring and Diagnostics

GT experience reports

Bearing temperature

max. OTC after ignitionPre event recorder Operation hour counter

Operation logs

Temperature distribution

Step change vibration

Acoustics Analysis

Vibration Analysis

Humming

Thermodynamic GT

Coastdown time

Fig. 6

For example thermodynamic, hot gas path, vibrations and component life cycle modules for

analysis and diagnostics are in use. Latest developments are acoustic analysis to detect foreign

objects in the combustion chamber .

Figure 6 shows the gas turbine monitoring and diagnostics with typical diagnostic tasks.

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May 2004 © PG G1 12



GT experience reports

Bearing temperature

max. OTC after ignitionPre event recorder Operation hour counter

Operation logs

Temperature distribution

Step change vibration

Acoustics Analysis

Vibration Analysis

Humming

Thermodynamic GT

Coastdown time

Windows NT

WIN_TS

Conceptional Goal:Integration off all Diagnostic Technologies

all diagnostic technologies into one

platform.

Fig. 7

Figure 7 shows the integration of all diagnostic technologies into one platform.

May 2004 © PG G1 14



System Functions Determinedthrough Technology Modules

IntegrationintoI&C

AP

AG FAPF

FUM-FSIM-F

H1-AP-RED

Own DataAcquisition Flight

Recorder

Module 6

Module 5

Module 4

Module 3

Module 2

Module 1

Archive

Data Manager ModuleManager

Modem

Central Data Acquisition

Telephone Line

IntegratedRemoteAccess

Modem

ACCOU NTS RECEIVABLE LEDGER

Windows NT

StandardLook & Feel

ACCOU NT NO.SHEE T NO.

DATE INVO ICE NUMBER/DES CRIPTIONCHARG ESC REDITSBALANCEBALANCE FOR WARD

TERMS:

DATEACCO UNT NUMBER

(PLEASE DETACH AND RETU RN WITH YOUR RE MITTANCE)

PAY TH IS AMOUNT

DATE CHAR GES AND CREDITS BALANCEBALAN CE FORWARD

YOUR NAME H ERE123 EASY STRE ETDOWN TOWN, A LT. 00000PHONE 987/123 -4567

AMOUNT ENCLOSED $

Monitor

Printer

Coupling toNetworks

T T

T T

PM

OT TCP / IP

Gas Turbine DiagnosticsWIN TS Diagnostic System

Platform for All Technology Modules9. Econopac Services

Fig. 8

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Figure 8 shows the modular structure of the WIN_TS Diagnostic Platform. The system con-

tains a basic system frame with the interface to Instrumentation and Control, to networks, to

remote access, and the data base and archive infrastructure.

The modular WIN_TS Diagnostic System connected to the I&C System has access to many

of the operational installed sensors and obtains between 300 and 1000 signals. Additionally to

these signals with the highest resolution of 1s, a high speed data acquisition for selected sig-

nals is included for analog and binary signal analysis down to milliseconds. Together with

Database, Archive and Remote Access, this is the basic system frame. The valuables in the

center of the system are the technology modules which can be selected according to the units

task specific requirements.

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3. Diagnostic Network Operation: Configuration and Implementation

of the Feedback Cycle

May 2004 © PG G1 18



Network Configuration

On-Site Data AcquisitionLocal Data ArchiveLocal Diagnostic

Centralized DatabaseAdvanced DiagnosticsTechnical Experts

Vibration

Acoustics

Flugschreiber

Orlando

Erlangen

Periodic TransferEvent Based Notification

Fig. 9

Figure 9 shows the integrated technology platform at the plant site.

An efficient and safe network configuration is the key for reliable remote data acquisition and

diagnostics. Local acquisition, archive and diagnostics combined with periodic and event

based data transfer are the onsite tasks. It continues in the Diagnostics Center with a central-

ized data base. Last but not least, it runs into advanced diagnostics in combination with tech-

nical experts knowledge.

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May 2004 © PG G1 17



PG internal safe Intranet

Global Network Configuration Plant Diagnostics Integration into Siemens Intranet

PG Power DiagnosticsTM Center

WIN_TSWIN_TS WIN_TS

WIN_TS

CompetenceCenter GT

CompetenceCenter GT Competence

Center DTCompetence

Center DTCompetenceCenter GEN

CompetenceCenter GEN

CompetenceCenter -BoP

CompetenceCenter -BoP

Worldwide safe Modem Connections

Fig. 10

The shown global network configuration (Figure 10) gives an idea about the performance of

plant diagnostics integrated into Siemens intranet. In the middle the PG Power Diagnostic

Center is located. Via worldwide safe modem connection the data links to individual plants

and their WIN_TS installations are established. For the qualified assessment of diagnostic

findings the link to the different center of knowledge (competence) like steam turbine, gas

turbine, generator and Balance of plant is established via internal Intranet.

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May 2004 © PG G1 19



Worldwide Implementation of WIN TS Gas Turbine Diagnostics

250 WIN TS Diagnostic Systems Installed for Gas Turbines * including steam turbines

350 WIN TS Diagnostic Systems installed worldwide*

> 120 installed

> 130 installed

60 Hz

50 Hz

Fig. 11

Figure 11 shows the worldwide installation status of the WIN_TS diagnostic systems.

For gas turbines more than 120 installations are in operation in the 60 Hz-region, and over

130 installations in the 50 Hz-region.

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May 2004 © PG G1 21



It is important to receive at early stage continuous life data feedback from „running technological systems“ both for

- immediate Customer support

- product feedback

WIN_TS

SIEMENS PG

Service

Engineering

R&D

Erection/Commisioning

Benefits for Operation,Research and Development

Feedback Loop

Fig. 12

Live data from a running technology system for immediate customer support and product life

cycle feedback is a significant benefit for operation, research and development. As Figure 12

shows, the remote online diagnostic is the feedback loop into customer service, engineering

and research & development after erection and commissioning.

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4. Use and Experience of On-line Diagnostics along the Project Stages

May 2004 © PG G1 23



Global Gas Turbine Diagnostics

ORLANDO ERLANGEN

Lifetime Care for Gas Turbines

Power DiagnosticsTM

Centers

Test Facility CommissioningNew EnginesDevelopment ServiceWarranty

Fig. 13

Through remote access, the local diagnostic systems are connected to Diagnostic Centers in

Orlando and Erlangen, to where they send data via data containers. By means of the Diagnos-

tic Centers, the experts have the possibility to support any situation during commissioning or

service which needs their immediate attention. Just some mouse clicks enable them to obtain

data from gas turbines all over the world (Figure 13).

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May 2004 © PG G1 24



Test Facility

Tesing results and data accessible for technical experts in Competence Centers

Commissioning

• Less effort / replaces test equipment

• Automatic event Documentation with high time resolution for technical experts in Competence Centers

• Documentation of new engines fingerprint

New EnginesDevelopment

• Information about plant status and performance

• Automatic event Documentation for technical experts in Competence Centers

• Remote support for plant operators

Service

• Plants are monitored effectively by Power Diagnostic Centers

• Risk mitigation for LTP, O&M and LTM

• Detailed information of plant history and long term trends

• Conditon based Maintenance

• Fleet data accessible for technical experts in Competence Centers

• optimization of R&D efforts on new engines and upgrades

WarrantyPeriod

New Engines Service

Whole Lifetime Care for Gas Turbine Units

Fig. 14

In Figure 14 advantages of diagnostics in phases are shown.

To minimize the risk for supplier and customer, diagnostic benefit starts from the beginning

of gas turbine life time with product development and engineering, continues by diagnostic

care during plant shop test, commissioning, acceptance test and warranty period and closes

the loop over the entire life cycle with improved maintenance and service.

Further operating data taken from the WIN_TS system are important for generation of reli-

ability and availability figures as well as fleet statistics.

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May 2004 © PG G1 26



Test Facility CommissioningNew EnginesDevelopment

• Information about plant status and performance

• Automatic event Documentation for technical experts in Competence Centers

• Remote support for plant operators

Service

• Plants are monitored effectively by Power Diagnostic Centers


• Detailed information of plant history and long term trends

• Conditon based Maintenance

WarrantyPeriod

New Engines Service

Use and Experiences of On-line Diagnostics

Example:

degradation analysis

Example: RemoteVibration Diagnostics

Fig. 15

Figure 15 shows an example for evaluation of different vibration parameters out of WIN_TS

on basis of which vibration experts in the competence center advise inspections. Thus direct

online knowledge of the unit condition can significantly help to improve the unit reliability.

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May 2004 © PG G1 27



Test Facility

Direct feedbackto engines developpersin G2 and G6

Commissioning

• Documentation of new engines fingerprint, automatically, with high time resolution

New EnginesDevelopment

• Detailed information is available about plant status and performance for warranty items

Service:


• Detailed Information is available about plant status and performance to improve optimization during R&D engineering of new engines and MODs and UPs

WarrantyPeriod:

Ongoing GT / Econopac Development

degradation analysis

from G612

remoteTurbine

Balancingfrom G261 TM

GSW-DataServer

G-wide intranet access for comissioning data

Example:GT Experience

Report GEB

from G611

Fig. 16

Figure 16 shows the gas turbine Experience Report (GEB), basis for consistent reliability and

availability evaluations, which was earlier manually generated by hand and is today per-

formed as an automatic module through the system. It contains detailed information about

availability, status and performance over rolling time periods.

5. Summary, Outlook

Monitoring and Diagnostics is a rapidly evolving field in power generation. The combination

of available IT-technology and on-line ‘expert’-expertise provide cost-efficient service and

benefits to the customer .

Thus it can be summarized:

• More and more specific analysis and diagnostic technology available

• To maximise benefit for power plants, the challenge is to employ alltechnologies needed via one platform

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• Global network to a running fleet allows OEM experts fast data analysisand quick response to customer requirements

• On-line diagnostics - in combination with remote expert knowledge - isthe key to future condition based maintenance and provides cost effi-cient service to reliable plant operation.

For the customer it is important to have access to the knowledge of the developer of his gas

turbine in any situation at hand through a diagnostic platform.

For the equipment supplier it is strong value to have live feedback from his own “running

technological systems” to optimize learning.

And last but not least online diagnostics opens the path from Scheduled Maintenance to Con-

dition based Maintenance thus contributing to customers unit operation for highest profit.

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Literature

[1] Volkmann, H.; Taud, R.: Application and Operating Experience with Econopacs

Equipped with Advanced Gas Turbines;

Power-Gen Europe 2003, Düsseldorf, May 6-8, 2003

[2] Bender, K.; Grühn, M.; Rukes, B.; Scheidel, M.: Online Remote Diagnosis of Tur-

bosets and Combined Cycle Power Plants;

VDI-Bericht Nr.: 1641, VDI-Verlag, Düsseldorf, 2001

[3] Adam, G.; Bode, A.: Ferndiagnose und Teleservicesystem für GUD-Kraftwerke;

VDI-Bericht Nr.: 1566, VDI-Verlag, Düsseldorf, 2000

[4] Brummel, H.-G.; Scheidel, M.; Thompson, E.: Gut behütet aus der Ferne;

Siemens Power Journal, Heft 1/00

Documents

Use and Experience of Gas Turbine On-line Diagnostics · Use and Experience of Gas Turbine On-line ... speed is increased over 3 GHz with ... Figure 3 shows the increase of processor