System
Max Lee
Agenda
1st topic
2nd topic
Condition Monitoring
Current Vibration Analyzer on Market
3rd topic
4th topic
5th topic
6th topic
Diagnostic Plots
ALSTOM 2007. We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
(Efectiveness)
Organization & Availability
Top
Lower
Proactive maintenance
Information
~
Quartile
Quartile
Maintenance Reliability based
Proactive
A2
0%
>65%
Predictive Predictive
Data ~
>45%
~12%
Maintenance Condition based
Preventive
A
B
>20%
>25%
A1
~31%
~55%
Reactive
Wait until it breaks..
Typically 40% reduction Maintenance
Sources:
in maintenance cost
USN
USN
MSP SUBMEPP
1982
2001
Traditional View
Random Failure then a wear out zone
2%
3%
2%
4%
17 %
10 %
5%
3%
17 %
7
%
6
%
9
%
14 %
42 %
56 %
68 %
29 %
6%
B
C
ALSTOM 2007. We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Light
Manufacturing
Light Manufacturing
ng
1st
Top0.2%
1st
% Top
1st
Middle
1st
% Middle
0.7%
Top0.9%
2nd
2nd
% Top
Middle
2nd
2nd
% Middle
1.3%
3rd
% Top1.9%
% Middle
2.5%
3rd
4th
% Top3.2%
%
5.2%
4th $
T $ Middle
STORES
% QUARTILE
Bottom
10.6%
4th
AV)
(%RAV)
1.2%
0.2%
1.2%
0.2%
71.0%
69.0%
2.8%
0.7%
2.8%
0.7%
62.5%
58.1%
3.8%
0.9%
3.8%
0.9%
51.5%
49.2%
4.7%
1.3%
4.7%
1.3%
36.7%
38.9%
6.0%
1.9%
27.6%
31.3%
15.4%
7.8%
19.7%
2.5%
9.8%
3.2%
15.4%
12.9%
5.9%
11.9%$ STORES
1.9%
5.2% $
MAINT
2.0%
15.6%
0.0%
10.6%
(%RAV)
(%RAV)
%
VIB % IR
MECH
Light Manufacturing
71.0%
69.0%
100.0%25.1% 31.0%
31.0% 23.0% 25.1%
25.1%
23.0%
61.0%
71.0%
23.0%
61.0%
100.0% 69.0%
31.0% 100.0%
61.0%
Top
1st
1.2%
0.2%
62.5%
58.1%
92.0%
27.8%
21.9%
25.0%
58.0%
62.5%
58.0%
92.0% 58.1%
27.8% 92.0% 21.9% 27.8% 25.0% 21.9%
58.0%
Middle
1st 25.0%
2.8%
0.7%
51.5%
49.2%
87.0%
22.7%
18.7%
27.0%
54.0%
51.5%
27.0%
54.0%
87.0% 49.2%
22.7% 87.0% 18.7% 22.7% 27.0% 18.7%
54.0%
Top
2nd
3.8%
0.9%
36.7%
38.9%
75.0% 15.1% 19.3%
19.3% 29.0% 15.1%
15.1%
29.0%
52.0%
36.7%
52.0%
75.0% 38.9%
19.3% 75.0%
52.0%
Middle
2nd 29.0%
4.7%
1.3%
27.6%
31.0%
47.0%
68.0% 31.3%
17.5% 68.0% 12.6% 17.5% 31.0% 12.6%
47.0%
Top
3rd
6.0%
1.9%
15.4%
58.0% 19.7%
14.2% 58.0% 7.6% 14.2% 33.0% 7.6%
44.0%
44.0%
Middle
3rd 33.0%
7.8%
2.5%
15.4%
35.0%
35.0%
51.5% 12.9%
10.1% 51.5% 5.4% 10.1% 35.0% 5.4%
35.0%
Top
4th
9.8%
3.2%
5.9%
49.2%
1.9%5.9% 49.2% 2.7% 5.9% 37.0% 2.7%
31.0%
31.0%
Middle
4th 37.0%
11.9%$ STORES
5.2% $
MAINT
2.0%
38.0%
0.0%
1.0%
0.0%
1.0%
0.0%
26.0%
26.0%
Bottom
4th %41.0%
15.6%
10.6%
(%RAV)
%
IR
ELEC
%MECH
OIL
ANAL
OTHER
%41.0%
ON%
PM
% ON
BOM
%
VIB
% IR
% 38.0%
IR%
ELEC
%NDT
OIL
ANAL
OTHER
NDT
ON
PM % (%RAV)
ON
BOM
QUARTILE
Power Generation
%
%
%
%
%
%
%
%
%
1st
Top0.4%
0.9%
1st
Middle
Top1.4%
2nd
2.1%
Middle
2nd
Top
3rd
Top3.5%
3rd
4.9%
Middle
3rd
Middle
3rd
Top
4th
Top6.3%
4th
8.7%
Middle
4th
Middle
4th
12.5%
Bottom
Bottom 4th
4th
95.0%
0.7%
87.0%
1.7%
79.0%
2.7%
62.5%
4.2%
59.8%
6.2%
6.2%
41.7%
8.1%
8.1%
29.8%
10.2%
10.2%
12.8%
13.9%
13.9%
3.8%
18.7%
18.7%
Power Generation
73.0%
0.4%
62.5%
0.9%
54.0%
1.4%
43.9%
2.1%
36.6%
3.5%
3.5%
24.9%
4.9%
4.9%
18.1%
6.3%
6.3%
5.5%
8.7%
8.7%
0.0%
12.5%
12.5%
100.0%
95.0%
92.0%
87.0%
88.1%
79.0%
85.1%
62.5%
79.8%
59.8%
59.8%
74.5%
41.7%
41.7%
68.7%
29.8%
29.8%
60.9%
12.8%
12.8%
52.1%
3.8%
3.8%
85.7%
73.6%
100.0% 73.6%
42.9% 100.0%
Top
1st
1.2%
0.3%
85.7%
Top0.3%
1st
1.2%
0.3%
85.7%
73.6%
100.0%42.2%
0.8%
75.6%
62.8%
91.9% 62.8%
38.6% 91.9% 35.5%
Middle
2.7%
0.8%
75.6%
Middle 1st
1st
2.7%
0.8%
75.6%
62.8%
91.9%
1.3%
64.9%
54.3%
87.4% 54.3%
32.6% 87.4% 30.9%
Top
2nd
3.7%
1.3%
64.9%
Top 2nd
3.7%
1.3%
64.9%
54.3%
87.4%
2.0%
52.7%
44.3%
81.9%
26.7%
Middle 2nd
5.1%
2.0%
52.7%
44.3%
81.9% 25.3%
Middle 2nd
5.1%
2.0%
52.7%
44.3%
81.9%
44.7%
36.9%
76.4% 36.9%
22.3% 76.4% 20.5%
Top3.0%
3rd
6.5%
3.0%
44.7%
Top 3rd
6.5%
3.0%
44.7%
36.9%
76.4%
4.6%
30.9%
25.4%
69.1%and in25.4%
17.6% contained
Middle
3rd 2007.
8.1%
4.6%in this document
30.9%
69.1% 15.6%
ALSTOM
We reserve all
rights
the information
therein.
Reproduction,
use8.1%
or disclosure to4.6%
third parties30.9%
without express
authority is strictly
forbidden.
Middle
3rd
25.4%
69.1%
79.0%
0.4%
72.0%
0.9%
1.4%
68.0%
2.1%
65.0%
3.5%
61.0%
61.0%
4.9%
57.0%
57.0%
6.3%
53.0%
53.0%
8.7%
47.0%
47.0%
12.5%
36.0%
36.0%
1.2%
25.0%
25.0%
2.7%
26.0%
26.0%
3.7%
27.0%
27.0%
5.1%
30.0%
30.0%
6.5%
31.0%
31.0%
8.1%
34.0%
34.0%
0.3%
66.0%
66.0%
0.8%
63.0%
63.0%
1.3%
58.0%
58.0%
2.0%
55.0%
55.0%
3.0%
49.0%
49.0%
4.6%
45.0%
45.0%
Other
Other
Other
%
%
%
%
%
%
20.0%
0.7%
22.0%
1.7%
2.7%
24.0%
4.2%
26.0%
6.2%
28.0%
28.0%
8.1%
31.0%
31.0%
10.2%
33.0%
33.0%
13.9%
34.0%
34.0%
18.7%
38.0%
38.0%
42.9%
42.9%
38.6%
38.6%
32.6%
32.6%
26.7%
26.7%
22.3%
22.3%
17.6%
17.6%
25.0%
26.0%
27.0%
30.0%
31.0%
34.0%
Top
1st
66.0%
42.2%
42.2%
Middle
1st
63.0%
35.5%
35.5%
Top
2nd
58.0%
30.9%
30.9%
Middle
2nd
55.0%
25.3%
25.3%
Top
3rd
49.0%
20.5%
20.5%
Middle
3rd
45.0%
15.6%
15.6%
Point
where
failure
starts to
occur
Changes in
Vibration P-F
interval 1-9
monthsWear Debris in
oil P-F interval 1Quantitative PM
6 months
IR Thermography
P-F Interval 5-8
P-F interval 3-12
weeks
weeks
P1
P2
Audible noise
P3
P-F interval 1-4
weeks
P4
Heat by touch
P = Potential Failure
P5
P6
P6
F = Failure
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Combustion Experience
Event With Vibration
Monitoring
Event
Identified
Escalated
TC
1
TC
TC 2
3
TC
4
TC
5
TC
6
TC
7
TC
8
TC
9
TC
10
TC
11
TC
12
TC
13
TC
14
TC
15
TC 18
16
TC
17
TC
TC
19
TC
20
TC
21
TC
22
TC
23
TC
24
TC
25
TC
TC 26
27
TC
28
TC
TC 29
30
TC
31
40
30
20
10
0
-10
-20
-30
Identify
Alert
Watch
Outage
Criteria
plan
Establishe
Establish
d
ed
Day 3
Crack
Issue Propagates
Starts
Day 4
Crack
Liberate
s
Event Without
Vibration
Monitoring
Unit Restored To
Service After 2 Day
Outage
Unit
Shutdown
And
Inspected
Day 8
Day 9
Collateral
Damage &
Unplanned
Outage
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
$133k In Lost
Revenue
Damag
e
Repaire
d
Day 11
Day 24
Damage
Repaired To
Restored
Unit
Service After
Extensive Outage
$2M In Lost
Revenue
Vibration
Vibration is the oscillating (periodic) motion of an
object caused by an applied force.
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
M/c With
fluid film
bearings
Vibration Measurements
Amplitude
Position
Frequency
Phase
Shape or Form
Basic Motion
Vibration Measurement
horizontal axis
lf
or
ce
time
Ra
di
a
vertical axis
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Displacement
Definition
Typical Application
Measuring rotor position within
the clearance of fluid film
bearings.
Capable of low frequency
response (down to 0 Hz).
Units: microns (m) or
thousandths of an inch (mil)
Eddy-current
proximity
probe
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Relative Vs Seismic
Rotor
Relative
To
Free Space
Rotor to
Bearing
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ACCELEROMETER
ELECTRONICS
COMPONENT
MICA
INSULATOR
CONDUCTIVE
PLATE
ELECTRICAL
INSULATOR
PRELOAD BOLT
MASS
PIEZOELECTRIC
CRYSTAL
BASE
ASSEMBLY
CONDUCTIVE
MATERIAL
Probe
RF SIGNAL
EDDY CURRENTS
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Proximito
r
RF SIGNAL
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RF SIGNAL
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20
CHANGE IN GAP
18
16
CHANGE IN VOLTAGE
OUTPUT IN VOLTS - DC
22
14
12
10
8
6
4
2
0
mils 0
10 20 30 40 50 60 70 80 90 100110120130140
PROBE GAP
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
RF SIGNAL
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Changing Distance
RF SIGNAL
RF SIGNAL
RF SIGNAL
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Demodulator Operation
RF SIGNAL
DEMODULATOR
0
INPUT
PROXIMITOR
OUTPUT
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Vibration AMPLITUDE
pk
pk
rms
pk
Vibration AMPLITUDE
pk
pk
X Probe
rms
0
pk
pk
Y Probe
pk
rms
pk
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
VIBRATION FORM
ORBIT
Shape
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Rotor Shaft
Pad
Thrust Collar
Pad
Pad
Proximit
y Probe
Thrust
Position
Measurement
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Probe Location
Thrust Position Measurement
Thrust Collar
Rotor Shaft
Channel A Probe
Channel B Probe
Install probes within about 30
cm (~12 in) of thrust collar.
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Thermal expansion of
rotor introduces large
errors when
measurements are made
too far away from the
thrust collar.
NOTCH
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PHASE ANGLE
The phase angle is defined as the number of
degrees from the Tacho Phasor pulse to the first
positive peak of vibration.
VIBRATION
SIGNAL
PHASE
LAG
TIME
KEYPHASOR
SIGNAL
DEGREES
OF
ROTATION
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360
Typical Transducer
Configuration Rotating
Machinery
X
Y X Y
Accels
Accel
T13-16
T25-28
Axial
Axial
LM2500
X
T9-10 T11-12
T1-T8
KO
T41-44
KO
Accel
Axial
LP
Compressor
T19-20
Axial
LP
Compressor
T21-22
T29-30
X
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T31-32
T37-38
T39-40
+40
DCS CONTROL
MVC CONTROL
+30
TEMPERATURE
DELTA DEGREES F
+20
+10
0
-10
-20
-30
-40
Protection
Auto
Shutdown
Anti Surge
Overspeed
Condition
Monitorin
g
Plots
Data
Assessment
Decisions
Actions
Machinery
Management
Decision Support
Operation
Advisories
Dynamically
Manage
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Asset
Managemen
t
Process
Hardware
Coordinated
Optimization
Agenda
1st topic
Condition Monitoring
2nd topic
3rd topic
4th topic
5th topic
6th topic
Diagnostic Plots
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
O&E Hub
Shenzhen,
China
Baden, Switzerland
- - P 34
R&D Centre
O&E Hub
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R&D Centre
O&E Hub
- - P 35
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
CC> performance
UK
Poland
Generator
Switzerland
Generator
Spain
Remote Centre
Vibration
Vietnam
Shaft Vibration
GT/CC
Performance
Singapore
Malaysia
CC Performance
All Gas Turbine for
GT24
Argentina
Nigeria
- - P 36
Thailand
Various GT
Various generator
CC>26 Performance
Generato
r
China
Turkey
Brazil
Generator
Italy
Vibration
All Gas Turbine for
GT26
CC Performance
USA:
CC>13E2
Performance
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GT performance
Singapore
Data Transfer
Australia
Data Transfer
(Internet)
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)
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Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
ALSTOM 2007. We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Users
LAN
maintenan
ce
PWR
8000
000
Steam
Turbine &
Generator
accepts
signals
WEB80
00
Local
local
diagno
sis
Server
PWR
8000
Gas
Turbine
PWR
8000
FD/ID
fan
Blower
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Signal Type
Static Signal
Axial Displacement
Eccentricity
Temperature
Pressure
Casing Expansion
Differential Expansion
- - P 48
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Signal from
Sensors
Proximity eddy sensor
Velocity and Acceleration sensor
- - P 49
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Sensitive Monitoring
Y
Main alarm
Total Value
Pre-alarm
1X
Multiply the
monitor target
Total Value Amp.
0.5X
2X
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More focus
80o
Temp
120o
0o
Date/Ti
me
What is Dynamic
Data?
Sine
Wave
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Operating Modes
Steady State vs. Transient
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Steady-State Data
Static vs. Dynamic data
Bargraphs
Orbit-Timebase plots
Spectrum plots
Trend plots
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RulePak Logic
Inputs
Historia
n
RulePak Applications
General Rules
Specific Asset Rules
Mechanical Rules
Instruments Rules
Performance Rules
Asset Statistics (starts,
stops, run time, etc.)
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Actions
Output
aims
Strengthen system stability
Reduce failure probability
- - P 64
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Waveform &
Spectrum
Orbit
Vibration and process
Trend
Waterfall
2-plane
Balancing
Bode
Nyquist
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RMD8000: Structure
Any other
trustful
experts
NET8000
For Vibration
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Alstom PS
Service
Provider
OEMs
Intran
et
Power Plant A
Intern
et
Plant B,C
- - P 71
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Power Plant N
- - P 72
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Plant A
Local User
Local Servers
MODBUS
OPC-UA etc.
Com others
- - P 75
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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-VibTrend
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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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Nyqui
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Waterfal
l
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Multiplots
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