ALSPA Care

Web-based Condition Monitoring & Diagnosis

PRADYUMNA DIXIT
SEPTEMBER 2010

POWER SERVICE
 Agenda

1st topic Introduction to ALSTOM

2nd topic PIS and ALSPA Care Platform

3rd topic ALSPA Shaft Vib. Care – S8000 System

4th topic ALSPA Care Centre

5th topic Diagnostic Plots

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ALSTOM: Two Main Activities, Three
Sectors

Equipment & services for power generation

 Alstom
Transport

 Alstom Power

 Alstom Grid
Equipment & services for
rail transport
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ALSTOM: Two Main Activities, Three
Sectors

Power Transport
Service 21. 28.4%
6% 5.4 €
4.1 € bn bn

Power
50% Systems
9.5 € bn

Total orders 2006/07 :

€19 bn
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ALSTOM : Present in All Power Markets

Technologies adapted to all major energy

sources
Gas Coal

Hydro Nuclear Wind (*)

(conventional
part)

(*) subject to finalisation of acquisition of Ecotecnia, Spanish wind turbine company (agreement signed in June 07)
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 Agenda

1st topic Introduction to ALSTOM

2nd topic PIS and ALSPA Care Platform

3rd topic ALSPA Vib. Care - S8000 Plus System

4th topic ALSPA Care Center

5th topic Diagnostic Plots

Vibration
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 ALSTOM PIS, Power Automation &
Control

Richmond, USA

Shenzhen,
China

Baden,
Switzerland
(Former ATC)

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 Alstom M&D References

Spain: UK Poland Switzerland

 CC&GT performance  Generator  Generator  Generator

Spain Italy China

 Vibration  Generat  Remote Centre
 All Gas Turbine or
for GT26 India
 CC Performance  Vib &
Turkey Generat Vietnam
or  GT/CC
USA:  Vibrati
Thailand Performance
 Various GT on
 Shaft Vibration Singapore
 Various generator
 GT
performance
Malaysia
Brazil  All Gas Turbine Singapore
 CC Performance for GT13E2  Data Transfer
 All Gas Turbine  CC performance
for GT24  Shaft Vibration
 Generator
 Transformer
Argentina
 CC&GT26 Australia
Performance
Nigeria  Data Transfer
 CC&GT13E2 (Internet)
Performance
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 Alstom M&D System
– One Monitoring For Your Complete
Plant

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 Structure of the CareCentre platform
GenCare GTCare STCare BoilerCare HydroCare WindCare PlantCare

Shaft, Main
Shaft Shaft Shaft Performanc Shaft
Gearbox equipment
Vibration Vibration Vibration e Vibration
Vibration` vibration

End Wind. Exhaust Cycle Intelliget

Auxilary Auxilary
Emmissions Performance Sootblowing
Vibration

Fast Trans. Exhaust Performanc Performanc

Partial Combustor
Data Emmissions e e
Discharge Pulsation
Recorder
Boiler/HRS Partial
Modules Thermal Thermal Maintenanc
Rotor Flux G Life Discharge
Performance Efficency e
counter
Rotor Transformer
Water Wall
Condition Performance Bearings Rotor Flux PD
Temperature
ROMON
Transformer
Bearings Bearings Pulverizer AirGap Condition
TRAMON

Platform CareCentre: Unique Platform at Plant Level and at Remote Level

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 Information circle

Plant A

HQ Remote Centre

Local O&M HQ management

Plant B
DB WEB Servers Firewall

In-house
Diagnosti
cs Team

Local O&M
External OEM
Experts Experts

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 Agenda

1st topic Introduction to ALSTOM & PIS

2nd topic PIS and ALSPA Care Platform

3rd topic ALSPA Vib. Care - S8000 Plus System

4th topic ALSPA Care Center

5th topic Diagnostic Plots

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Current Products on market

• Portable Instrument
- No continuous data accessing and storage
(information is not sufficient for the analysis by
experts if something really happens)
- Traveling and timing costs increased for going into
the plant to take out the data
- The data is hard to be shared with pool of
experts (physical constraints)
• Online Condition Vibration Analyzer
- “Remote Access” (client terminal restrictions – one
to one point)
- Dedicated line is required for data accessing
- Client software required for data accessing (extra
costs required for software license – limited access
to the data)
- The data from different plants cannot be
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ALSTOM
centralized in a specific location where the
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Key Drawbacks of the Both Vibration
Analyzer

To maximally utilize the expertise

resources, we shall provide the experts
with both real-time and historical data
right away WHENEVER the problems occur
and WHEREVER the experts are

YET, both of the vibration analyzer

products did not build up the linkage
between the data and the experts

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 ALSPA Shaft Vib. Care – S8000 System

Introduced by ALSTOM PIS Division

• Condition Monitoring (CoMo) – Vibration Module

− ALSPA Care Center (Remote set-up): Remote

Monitoring Center for utility group with multi-
plants

− S8000 Plus (local set-up): Large rotating machine

online monitoring and diagnostic system

• GT, Wind turbines, water-wheel turbine,

Generators, Compressors, Blowers, etc.
• Auxiliaries such as pumps, cooling tower fans,
air blower, coal grinding machine, Agitator
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 S8000 Plus – Local setup: System
Architecture
WEB8000
Local Local local
Server diagno
maintenan
ce
sis
User’s
LAN

PWR PWR PWR

8000 8000 8000

Steam Gas FD/ID Blower

Turbine & Turbine fan
epts signals either direct,
Generator via signal conditioner
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 S8000 Plus’ Key Feature - 1

• Easy Data Accessibility

− B/S structure, which is web-based

− Support both on-site diagnosis and remote

diagnosis through INTERNET/INTRANET

− Benefits:
 No client software set-up restrictions, by
which means: anybody, any computers have an
access to internet are capable of browsing
into the system for REAL-TIME & HISTORICAL
TIME DATA viewing at the same time at
anywhere
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 S8000 Plus’ Key Feature -2

Sensitive Monitoring
 Store all the useful data

- data when operating state changes

- data when abnormal operating status
occurs
- startup and shutdown data

Benefits
 Optimum amount of information stored
with all useful data before and after an
event, which provides comprehensive data
for fault diagnosis and predictive
maintenance

 Huge amount of hard disk storage

reduction
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 Sensitive Monitoring
Y
Main alarm

Total Value Pre-alarm

•Multiply
1X
the monitor
target
•Total Value
X
Amp.
0.5X
•1X, 2X, 0.5X…
2X Vector

•More focus

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 Statistical Learning

Main alarm
amplitude
Pre-alarm

threshold

phase

time axis
learning time

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Does Sensitive Monitoring tech only
stores the useful data?

Time-
driven

Event-
driven

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 S8000 Plus: Data Acquisition

• Tachophasor Signal
• Dynamic Signal
− Displacement
− Velocity
− Acceleration
• Static Signal
− Axial Displacement
− Eccentricity
− Temperature
− Pressure
− Casing Expansion
− Differential Expansion
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 Compatibility with any brands of
sensors and TSI

 Sensors
 Proximity eddy sensor
 Velocity sensor
 Acceleration sensor
 Protection Meter
 Bently® 7200
 Bently® 3300
 Bently® 3500-20
 Shinkawa VM-7
 Epro/Philips® RMS700& MMS6000
 Vibro-Meter® VM600
 Schenck® Vibracontrol 4000
 Entek® 6600
 METRIX® Transmitter

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 Capacity of DAU-NET8000

Static
Vib. Static
Signals Tacho
Dynamic Signals
(Hard phasor
Signals (Modbus)
connection)

NET8000 Plus 24 12 255 4

NET8000 Dual 48 24 255 8

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 Agenda

1st topic Introduction to ALSTOM & PIS

2nd topic PIS and ALSPA Care Platform

3rd topic ALSPA Vib. Care - S8000 Plus System

4th topic ALSPA Care Centre

5th topic Diagnostic Plots

Vibration
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 Alstom ALSPA Care Centre -
Architecture
HQ Remote Centre
Training
Web Clients And Support

In House Remote
Monitoring Center

DB WEB Servers Firewall Internet / Intranet

Plant A Plant B Plant N

Local User Local User Local Servers
Local Servers
MODBUS Local
MODBUS
OPC-UA etc. M&D Server
OPC-UA etc.
Com others Com others

Shaft Vibration, PD ,RFM,VIC, ROMON WIND FAS

M&D Modules

Sensors
Sensors

Gas Turbine, ST, Generator, Boiler

Wind Turbine Equipments

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 Additional Functions of ALSPA Care
Center

• Access real-time units operational and

alarm status on machine list
• Automatically or customized generate
multi level reports
− Region level report
− Factory level report
− Machine level report
• Rich professional diagnosis plots
• Long-term operation data storage
• Maintenance, overhaul and outage archive
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 Benefits to multi-plant utilities

• Achieve predictive maintenance

• To effectively use internal experts
experience inside group
• Collecting the raw operational data to
improve equipment operation
• Centralize the operational date from
subsidiaries to
− Comparison of operation and maintenance
quality and improvement

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 Case study - multi-plant
utility ..Huaneng

• Total capacity: 25,057 MW up to 2008

• 11,400 MW under construction
• 33 plants
• Main fleet: 300 MW, 350MW and 600 MW
• 2*1000 MW in Yuhuan Power Plant

• Remote center set-up in Dec. 2006

• 1st phase: covering 25 units in 11 plants
• 2nd phase: has been commenced in July, 2007
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 Remote Center for Huaneng
HQ Remote Centre

DB WEB Servers Firewall

Plant A
Local User
Local Servers
MODBUS
OPC-UA etc.
Com others

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 Agenda

1st topic Introduction to ALSTOM & PIS

2nd topic PIS and ALSPA Care Platform

3rd topic ALSPA Vib. Care - S8000 Plus System

4th topic ALSPA Care Centre

5th topic Diagnostic Plots

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 Overvie
w

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 Rich
Plots

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 Waveform Spectrum

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 Rich
Vib-
Trend
Plots

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 Single
Bar

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 Multi-
Bar

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 Process-Vib-
Trend

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 Orbit

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 2-Plane Balancing

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 Polar

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 Shaft Centerline

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 Bode

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 Nyquis
t

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 Waterfal
l

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 Multi-
plots

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Thanks for your
attention

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