ALSPA SHAFT CARE

Condition Monitoring and Diagnostic System

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Condition Monitoring and Diagnostic System

GENERAL
As competition in today's market increases, the need to reduce costs whilst maximizing output is paramount. An important area where operating costs can be reduced is through implementing a preventative maintenance strategy. Condition monitoring of rotating machinery is an extremely valuable tool to industry. Access to continuous data assists in identifying faults, allowing remedial action to be carried out before a costly breakdown occurs. Consequently, maintenance programmes can be scheduled according to need, maximizing plant availability. Alspa Shaft Care is an advanced on-line condition monitoring and diagnostic system, an open new generation condition monitoring platform specifically designed for rotating machinery managing. It collects, stores and displays through advanced diagnostic tool parameters, allows to combine data from many different sources into one common platform, providing plant with a total solution.

APPLICATIONS
Industries Served : Power Generation Oil & Gas Petroleum and Chemical Hydro Power Generation Nuclear Power Generation Natural Gas Pipeline Steel and Aluminum Pulp and Paper Wastewater Treatment Others Monitored Machines: Steam Turbines Gas Turbines Water Turbines Generators Centrifugal and Axial Compressors Blowers/Fans Electric Motors Expanders Gearboxes Pumps Others Input signals : Rotating Speed Vibration Axial Displacement Temperature Pressure Pressure Pulsation (Hydro Power) Air Gap (Hydro Power) Noise (Hydro Power) Eccentricity Differential Expansion Process Parameter via MODBUS, PI or OPC Communication Others

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Condition Monitoring and Diagnostic System

COMPREHENSIVE ANALYSIS PLOTS

Plots : Overview Multi-Plots Single-Bar Waveform Spectrum Spectrum Multi-Spectrum Vib-Trend Process-Vib-Trend Orbit Multi-Orbit Holo-Graph 3D-Holo-Graph Full Spectrum Shaft Centerline Polar Process Waterwall Transition Waveform Axial-Orbits Performance Curve Noise Spectrum Time-Speed Nyquist Bode Waterfall Cascade Vib-Parameter Process-Parameter Vib-Alarm Process-Alarm System Log Event List Factory Report Machine Report Machine Status Startup/ Shutdown : Lists : Air Gap : Airgap Circle Airgap Bar Airgap Wave Airgap List Airgap Trand Diagnose : Self-Train 1-Plane Balancing 2-Plane Balancing Decision Support Case Library TPH Waveform

Figure : Orbit

Figure : Waveform Spectrum

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Condition Monitoring and Diagnostic System

CUSTOMIZABLE DECISION SUPPORT

Decision support functionality allows machinery engineers or other personnel to easily analyze machinery condition and diagnose faults by intelligent diagnostics or interactive diagnostics through the use of a Knowledge Management Database (KMB). The KMB is engineered, designed, and built by our experts with a flexible and highly intuitive rule-building utility. This allows users to embed their unique diagnostic knowledge of equipment and processes into a powerful and fully customized knowledge base reflecting the specific characteristics of each asset, process, and plant. Rules derived from the experience of plant engineers and operators can be used to continuously evaluate equipment condition. Utilizing Decision Support enables machinery engineers to spend more of their time resolving problems and optimizing the operation of assets.

2-PLANE BALANCING
2-Plane Balancing tool is available to machinery engineers or experts to assist in the balancing of machinery.

CASE LIBRARY FOR EASY REPORT GENERATION AND CASE SAVING DOCUMENTATION
The Case Library enables machinery engineers and analysts to generate reports easily by documenting the fault and inserting selected fault diagrams in the form. The report can be saved to Word for further editing or saved in the server of Alspa Care as a case for future maintenance and diagnostic reference.

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Condition Monitoring and Diagnostic System

UNRIVALED EASE-OF-USE
The S8000 Plus user interface is a Microsoft Windows style application. With the easy to use human interface, minimum training is required to access and display data. Navigator Powerful right-key-click function Zoom In/Out user-selected data display area Spread/conceal information display area Peak pick Selection of channel or data type Tile or cascade data display windows Simultaneous view of historic and real-time data User configurable tool bar, default multi-plot, overview, etc. Automatic generation of multi-level reports

REMOTE ACCESS CAPABILITIES

RMD8000 is a remote monitoring and diagnostic center used to enhance accessibility. It is mostly used by group corporations, service providers or manufactures. It can receive, store and display the data uploaded from Local Server (Alspa Care) in different plants via the Intranet or Internet. Authorized visitors may simultaneously and remotely access both the real-time and historic data anytime, anywhere on any PC connected to the Intranet or Internet by visiting RMD8000. With the Remote Diagnostic Consultation System and by visiting RMD8000, analysts may consult with each other about complicated machine faults.

BROWSER/ SERVER STRUCTURE

The S8000 Plus system is based on a Browser / Server architecture. Multiple users can have simultaneous access to the machine operating data at high speed using IE via the Intranet or Internet. This allows plant condition information to be truly distributed to all relevant plant departments, i.e. Operations, Performance, Efficiency, Maintenance, Control and Instrumentation Departments. Advantage and Benefit No client software requirement No license restriction for browser No maintenance requirement at the client terminals Supports simultaneous viewing by more than 50 peoples at high speed

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Condition Monitoring and Diagnostic System

STRUCTURE OF S8000 PLUS LOCAL SETUP

S8000 Plus local setup consists of a Local Server (WEB8000 Plus) and several Data Acquisition Units (DAU). The Data Acquisition Units sample signal inputs such as rotating speed, vibration and process variables, convert them from analog to digital, and transfer the data to the WEB8000 Plus. The Local Server (WEB8000 Plus) stores and manages historical and real-time data transferred from Data Acquisition Units, generates analytical plots and other data display formats and publishes them to web browsers. In additional the WEB8000 Plus is used to set up and manage all Data Acquisition Units.

Figure: Structure of S8000 Plus local setup

Easy to Install Data Acquisition Unit is a 19" inches rack-mount unit. It can be installed in the control room or operations office. WEB8000 Plus can be installed anywhere with LAN coverage. Open, Industry-Standard Technologies Process parameters can be acquired directly by each Data Acquisition Unit via hard wire connection. Alternatively, a connection to the plant DCS via serial communications or process server via TCP/IP may be utilized to acquire process parameters via an electronic data link, including (but not limited to), MODBUS, PI, and OPC. Exporting data from S8000 Plus to DCS or PI/OPC database is also available.

Reliable Data Storage The DAU has its own 512M memory. Even the data transfers between DAU and WEB8000 Plus failed because of the disabled LAN, data can be automatically temporarily stored in this memory until the transfers recovered. This ensures data against losing. Optional remote access via RMD8000 Optionally, machine operating data stored in the WEB8000 Plus can be uploaded to a Remote Monitoring & Diagnostic Center (RMD8000) via Intranet or Internet in real-time. The RMD8000 can be located at corporate headquarters, an ALSTOM or OEM office, or at a service provider facility. Authorized visitors may remotely and simultaneously access both the real-time and historic data anywhere, anytime on any PC via the Intranet or Internet by visiting RMD8000. POWER

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Condition Monitoring and Diagnostic System

HIGH-SPEED PARALLEL SYNCHRONOUS FULLROTATION DATA ACQUISITION

The Data Acquisition Unit (DAU) is part of the S800 Plus System. It samples the signal inputs such as rotating speed, vibration, process variables, converts them from analog to digital and transfers the data to WEB8000 Plus. It supports the TCP/IP protocol based on the Ethernet (10M/100M) standard, and transmits data via the enterprise network. In addition it is characterized by high speed, high accuracy, high reliability, easy installation and connection, maintenance-free. Meanwhile, the DAU is the first field acquisition station in the world with a WEB function. From a computer on the same network with the DAU, a user can view spectrum and other data from the DAU with IE browser.

DAU Mode Applications Rotating Speed NET8000 series 36RPM 32000RPM Petroleum& Chemical, Steel & Aluminum PWR8000 series 36RPM 4000RPM Coal Fired Power, Nuclear Power HYD8000 series 12RPM 1000RPM Hydro Power

Industry

Number of Inputs of the DAU Signal Type NET8000 Plus PWR8000 Plus HYD8000 Plus 4 24 24 NET8000 Dual PWR8000 Dual HYD8000 Dual 8 48 48

Rotating Speed Vibration Hard-Wired Process

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What if there is no reference mark, key or slot or rotating speed sensor installed?

High-Speed Sampling Rate Number of samples per revolution per channel: 4096 Number of spectrum lines: up to 3200 A/D resolution: 14 bits Display refresh rate: Up to once per second

Calculate rotating speed from a reference vibration channel

If there is no reference mark, key or slot or rotating speed sensor installed on a shaft, the DAU can calculate rotating speed from a reference vibration channel. Based on the calculated rotating speed, during each revolution of the shaft, the DAU samples the vibration and hardwired process signals parallel and synchronously, The number of samples for each channel per revolution is determined by user defined setup. The starting point of each sampling cycle is determined by the reference vibration channel. This also ensures that each sampled signal has the same starting phase.

Parallel Synchronous Full-Rotation Sampling Parallel, synchronous full-rotation sampling is based on rotating speed. According to the machine rotating speed, during each revolution of the rotor, the system acquires a fixed configured number of samples for each vibration or process channel. The starting point of each sampling cycle is determined by a reference mark, key or slot on the shaft. This ensures that each sampled signal has the same starting phase. The amount of data storage for a machine Rotating speed: 3000RPM50Hz Number of monitored channels: 16 Number of samples per revolution: 512 (one data group) Size of each sample: 2 Bytes Method of data storage: store each group of data to ensure the entire storage of useful data. Size of stored data: 3000RPM * 24h/day * 60m/h * 512 * 2B * 16 ~ 69G/day This amount of data storage is excessive!

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OUR SOLUTION: SENSITIVE MONITORING- SOPHISTICATED DATA STORAGE SOLUTION

A comprehensive suit for thresholds are provided with the S8000 Plus system except for danger alarm and warning alarm, ensuring complete monitoring and data storage for machine unsteady-state running. This is known as sensitive monitoring technology Thresholds for measured parameters include: overall value, 1X, 2X, 0.5X, optional frequency bands, residual, amplitude and/or phase Automatic statistical calculation of the thresholds Thresholds may be statistically calculated with respect to the machine historical running condition. For example, based on the data of last months normal steady-state running, the WEB8000 Plus can automatically calculate the range for overall value, 1X, 2X, 0.5X, frequency bands, residual, amplitude and/or phase during this period. Applying a scaling factor can increase or reduce these ranges to be the thresholds during steady-state running. Automatic event-driven data storage Fully annotated data storage Real-time event notification During machine steady-state running, WEB8000 Plus data storage is time-driven, i.e. it can store one group of machine data on a fixed user defined time interval, the time interval can be 5 /10 /20 minutes. When any vibration channel exceeds the threshold for overall value/1X/2X, or when any hardwired process parameter exceeds the danger/warning alarm, the WEB8000 Plus will automatically speed up the storage rate and store the two groups of data before and after this event. When any vibration channel exceeds its danger/ warning alarm, the WEB8000 Plus will automatically trigger black box. Black box can store up to 600 groups of data before and after the event. www.alstom.com POWER When load variation by percentage exceeds a fixed value set by the user, the WEB8000 Plus will also speed up the storage rate to store that group of data after the event. During event-driven data storage, the WEB8000 Plus will automatically store the corresponding data for all vibration channels and hardwired process parameters for convenient fault analysis. The entire data is called sensitive monitoring data (SM data).

Figure: Automatic statistical calculation of the thresholds

Signal Type

Measured Parameter Overall value 1X 2X 0.5X Frequency band 1 Frequency band 2 Residual Overall value Overall value

Danger x

Alarms Warning x

Vibration

Thresholds Amplitude Phase x x x x x x x x x Variation by percentage

Process parameters Load

Figure: Rich and powerful alarms and thresholds

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Condition Monitoring and Diagnostic System

Sensitive monitoring data is marked in the database, and through a specialized software interface it is listed for easy identification and analysis. Also, through a variety of notification mechanisms such as cell phone, email, pop-up window or sound, these events can be consistently delivered to personnel in realtime. This results in increased asset management capability and efficiency.

Advantage and Benefit Optimum amount of information stored with all useful data before and after an event, which provides comprehensive data for fault diagnosis and predictive maintenance. Fully annotated data storage Easy identification of event-driven data increases the users asset management capability and efficiency. Solved the problem of too much useless data stored during machine steady-stage running, which increases the system storage capability.

The amount of data storage of S8000 Plus for a machine Rotating speed: 3000RPM50Hz Number of monitored channels: 16 Number of samples per revolution: 512 (one data group) Size of each sample: 2 Bytes Time interval of data storage (time-driven): 5 minutes

Size of stored data: (24h/day) * (60m/h) / 5m * 512 * 2B * 16 + SM data/day~ 4.6M/day + SM data/day

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DATA STORAGE DURING STARTUP / SHUTDOWN OR OFF-LOAD

Automatic identification and rapid switch The WEB8000 Plus will automatically identify a machine startup, shutdown or off-load condition and switch the data storage method with high speed. The switch only takes 0.01 to 0.1 seconds.

Full waveform capturing and data storage solution in both rotating speed interval and time interval During a startup, shutdown or off-load event, the WEB8000 Plus captures the waveform data via a user defined rotating speed interval. The rotating speed interval can be 5~500RPM. When there is not an obvious variation in the rotating speed, the WEB8000 Plus will automatically trigger time-driven data storage via a user defined time interval. The time interval can be 3~180 seconds.
Figure: Bode

Real-time displays During a startup, shutdown or off-load event, the S8000 Plus can simultaneously display machine real-time data and relevant analysis plots.
Figure: Nyquist

Advantage and Benefit Ensures timely and comprehensive storage of data during startup, shutdown or off-load events. Provision of real-time data and relevant analysis plots remotely or on-site during a startup, shutdown or off-load event may be invaluable to maintenance and operations personnel.

Figure: Cascade

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Condition Monitoring and Diagnostic System

MALAYSIA

Information Asia ALSTOM Power Asia Pacific Sdn Bhd 5th Floor, Chulan Tower 3 Jalan Conlay 50450 Kuala Lumpur Malaysia +603 2055 6000

PSE/BPROB/GTCRMN09/eng/PS3/04.09/CH/6892 - - 2009. ALSTOM, the ALSTOMlogo and any alternative version thereof are trademarks and service marks of ALSTOM. The other names mentioned, registered or not, are the property of their respective companies. The technical and other data contained in this document is provided for information only. Neither ALSTOM, nor its officers or employees accept responsibility for or should be taken as making any representation or warranty (whether express or implied) as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. ALSTOMreserves the right to revise or change this data at any time without further notice.

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