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Reliable operation support – Siemens Power Diagnostics™ Service

At your service: Siemens Power Diagnostics

In the last decade and following market developments, the business relationships between customers and original equipment manufacturers (OEMs) of power plants have shifted toward longer-term cooperation. This is particularly due to the rapid development of high-efficiency components, for example gas turbines, using the most advanced technologies and materials. The more sophisticated a power plant component becomes, the more atten-tion is required during operation to avoid the risk of abnormal behavior. This conclusion has led to new forms of cooperation between customers and OEMs. Siemens Power Diagnostics™ Service is one important outcome of this development.

A new level of cooperation With new high-performance equipment being introduced in the market, customers require Operation and Mainte-nance (O&M) programs and Long-Term Programs (LTP). These programs are designed to cover the greater part of the equipment lifetime or the entire combined- cycle plant ‒ occasionally even including some risk-sharing of certain repair costs with an OEM.

With both types of programs, customers are able to better plan operational costs during the service program period. At the same time, the boost in information technology facilitates the secure transfer of large amounts of data over long distances – thus enabling the OEM to use remote monitoring to help customers detect a possible impending operational problem. This can minimize unplanned outages and maximize power generation availability.

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Long-term cooperation between customers and Siemens First monitoring center in Orlando

Services made-to-orderBased on decades of experience in diagnostics, Siemens opened a pilot remote monitoring center in Orlando, Florida in 2000, launching a new quality standard in remote monitoring of advanced gas turbine and combined-cycle plants for long-term service program customers. With the primary focus on these long-term maintenance programs, monitoring on a 24/7 basis was officially introduced in February 2002 as “Power Diagnostics Service” (PDS).

The PDS goal is to detect abnormal operating conditions of power plant equipment like gas turbines, steam turbines, heat recovery boilers, and generators as early as possible in order to subsequently help improve plant availability and operations. To this end, multiple data acquisition tools are used to obtain daily operational data from our customers’ plants.

Aided by advanced diagnostic software, experienced diagnostic engineers can identify issues before they reach conventional alarm levels. If necessary, these engineers can be supported by specialists throughout the entire Siemens Energy organization.

Monitoring and supporting, but not operating As a leading supplier of power plants, we are aware of many of the security challenges concerning the operation of our customers’ plants. Siemens PDS is based on passive

data collection and analysis. In other words, there is no possibility of controlling the site’s instrumentation and control system and engine operation. This means that PDS is not operating customers’ power plants, but helping them run the equipment more efficiently and profitably. This service is backed by field experience gained from more than 400 installations of high-efficiency gas turbines and other equipment, an advantage only the OEM can offer. For this reason, Power Diagnostics is a special service offered to Siemens customers.

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Expert network team

Engineering know-how■■ Interpretation and diagnostics■■ Data assessment■■ Development of recommendations for future operations, repairs, and modernizations

Analysis

Monitoring

Online diagnostics

Offline diagnostics

Your power plantPower Diagnostics

center

Use of advanced diagnostic tools and techniques for■■ Monitoring of machine conditions■■ Collecting and processing of data■■ Analysis of limit values and deviation from normal behavior

Access

Info

Reports

Operation and maintenance by Siemens for a Philippine power plant

Power Diagnostics Service is backed by vast field experience.

Multiple advantages of Power Diagnostics Service

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Winning in competitive markets

Unparalleled experienceSiemens has been at the forefront of power generation for more than 140 years. Therefore, our Power Diagnostics Service is based on experience unrivalled in the industry. With PDS, higher reliability of your power plant is not left to chance, but can be the consequence of a well thought-out process of continuous data acquisition, data analysis, diagnosis and regular documentation of machine condi-tions. PDS is designed to provide a more reliable basis for your management decisions regarding:

■ scheduled outages ■ performance and operating optimizations ■ plant operating support ■ consistent refurbishments ■ timely reinvestments

Better use of scheduled outagesCooperation between the customer and the OEM also means that the units we monitor will be checked against our ever-growing database of similar machines and com-ponents in the field. By doing so, we can help detect many arising issues months before the Instrumentation and Control system (I&C) would generate an alarm or even trip the unit due to equipment protection criteria. With this system in place, many issues can be planned for and addressed proactively during scheduled outages. In addition, with PDS your power plants are monitored using highly advanced computing technology and algorithms designed for the utmost security and quickest response. Early fault detection allows sufficient time for service teams to prepare parts and manpower, turning a potential forced outage into a scheduled event, thus helping to keep downtime to a minimum.

PDS may help you turn a potential forced outage into a scheduled event.

The O&M power plant in Taiwan benefits from PDS and won the 2008 “Best Environmental Plant of the Year” award.

PDS is designed to support your management decisions on consistent refurbishment.

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Higher reliability potential Continued condition monitoring of your power station can help you be an even more reliable partner for your customers. In addition to helping you minimize the risk of unplanned outages, you can use data from our Power Diagnostics Service to optimize the operation of your units, while our regular condition reports can help you assess the demand for future investments. They may also help you to evaluate possible operational alternatives to cover special customer needs.

Opportunity for substantial cost savingsOur regular reviews and performance analyses can help you operate your assets at higher efficiency levels. This may result in substantial savings on fuel, machinery, and enhance environmentally friendly operation.

PDS can also help you make decisions that can potentially extend the lifetime of your power plants. Knowing more about their condition may allow for a more precise risk assessment and a better perspective on their future performance.

Helping you minimize your operational risksIn combination with service programs, PDS can help you minimize the operational risks of your assets. Depending on the service program you select, we can offer a variety of services that enable you to concentrate on your core business while your assets are carefully monitored by our experienced diagnostics and service engineers.

To make use of the full potential of Power Diagnostics Service, you can choose from customized service programs like Operation and Maintenance programs and Long-Term Service Programs. These can be designed to cover the greater part of an engine’s target lifetime or, in the case of an O&M, virtually the entire range of combined-cycle power generation components. While Long-Term Service Programs mainly cover periodic service and maintenance, an O&M program also includes a broader range of Siemens services at your plant. This includes the daily operation of the plant and a wide range of maintenance activities which, based on our global long-term O&M experience and our OEM expertise, can help continuously optimize plant efficiency and availability. With these service offerings featuring PDS, you can find the right combination for your requirements, from a regular monitoring of your power station, to a more detailed monitoring that includes trend analysis, to actions such as assessing threshold deviation from expected unit behavior.

You can choose a service program according to your needs.

PDS allows you to concentrate on your core business while your units are skillfully monitored by our experienced diagnostics and service engineers.

A valuable experience: your success!

Our remote service centers feature expert knowledge for more than 400 gas turbine, steam turbine, and generator installations as well as other power plant components all over the world. These are only a few customer statements that underscore the benefits of Siemens Power Diagnostics Service.

What our customers say about Siemens Power Diagnostics Service:

Siemens fleet knowledge and record database is very helpful and time-saving during an unusual event and defect rectification.

Luckily, we don’t need this service often, but when needed they have responded very quickly.

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Dedicated modules for your success

Monitoring made-to-orderWhile each customer has his or her own service expecta-tion, each power plant has specific requirements. To meet your individual needs, Siemens has developed a system of dedicated modules for diverse tasks. These modules may be adapted and fine-tuned to the application as required, which can help you optimize operational costs.

To date, there are several distinct modules available in the Power Diagnostics product lineup, each of them individu-ally specialized in monitoring, analysis, and diagnosis:

■ Vibration monitoring for steam turbines, gas turbines, and generators

■ Partial-discharge monitors for generators and high- voltage components

■ Diagnosis for water and hydrogen cooling circuits in generators

■ Dedicated rules for automated analysis and diagnosis ■ Thermodynamic process monitoring for entire power plants

Helping you make proactive decisionsFor each module, Siemens can offer regular reporting and information on the components’ status through special, individualized service programs. With this condition monitoring capability, Power Diagnostics Service can offer additional information about your power plant.

This information supports a timely and detailed recognition of many critical tendencies and changes in special operating parameters. These Specialty Monitors can provide:

■ Regular documentation of machine conditions ■ Early detection of many operating issues ■ Reliable information to help you make proactive decisions ■ Fast access to the Siemens expert network

Optimized maintenance strategy Using the results of our modules, you can prioritize and optimize your maintenance resources according to the actual demand. In addition, better knowledge of the machine condition can help you operate your machines more flexibly and may improve the overall efficiency, availability and reliability of your power station.

In combination with a service program, Remote Monitoring and Power Diagnostics Service can also open up new oppor tunities for incentive-based performance sharing between your company and Siemens.

Your access to supportSiemens Power Diagnostics installs and maintains a data acquisition system at your site. The system is connected to the Power Diagnostics Center (PDC) through a secure common Remote Service Platform (cRSP) connection, with a router and phone connection as backup.

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Power Diagnostics Speciality Monitors are available for all components of the energy conversion process.

Modules for Heat Recovery

Steam Generator Gas Turbine Generator Steam Turbine Turbo Train

Take advantage of upcoming planned outages to implement the corrective measures identified remotely.

The PC-based data acquisition system is passively connected to the control system via OPC, receiving data from the I&C system and the Specialty Monitors along a one-way data highway, with no feedback to the site’s I&C system.

At the PDC, the raw data is processed through Power Monitor, an empirical system-modeling tool and an artifi-cial intelligence rule base. Power Monitor is designed to detect even subtle deviations in the analog sensors within the variability of normal operation ‒ and well within the existing control threshold alarm limits ‒ which can aid in early recognition of abnormal equipment behavior. A specific advantage of this generic monitoring technique is that it can be applied to a variety of instrumented equipment. Many out-of-date calibrations, missing or incomplete tag suites, and bad sensors can be accommo-dated with the modeling tool.

If any kind of abnormal equipment behavior is detected, the system is designed to automatically notify Siemens experts to conduct a detailed analysis of the behavior. By using these analyses as the basis for diagnostics, a list of recommendations for immediate actions to avoid operational restrictions can be generated. In the event a shutdown is required to remedy the situation, a planned outage can be used to implement corrective measures. Several customers have already taken advantage of these options supported by Siemens expertise.

Based on the operational data, Siemens can provide regular availability and reliability reports for the customer according to IEEE standard. Using the Siemens Operating Feedback Log (SOFL), the reports could be automatically created, reviewed by Siemens experts, and sent to the customer for release. By providing regular feedback of the operational behavior, customers are able to compare their own units with the Siemens fleet.

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Technical experts using several diagnostic modules help identify, assess, and diagnose abnormal operating conditions and recommend follow-up actions.

We help you optimize your maintenance resources.

Siemens Power Diagnostics features expert knowledge to support your plant operation around the clock

Ready when you need it ‒ around the clock and globally.

Orlando

Berlin

Muelheim

Erlangen

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It’s nice to have a team of smart guys on hand that integrate well with our resources.

It is a good product. It makes you aware of problems that otherwise are very hard to spot. It has saved us from shutdowns in the past. We congratulate Siemens on this product.

Further developmentsToday, Siemens Power Diagnostics Service consists mainly of monitoring and diagnostics. However, with the further development of our tools and modules, even remote services for power plant equipment may become reality in the future. Some of these new services have already been established, such as Remote Balancing, Remote Tuning, and Remote Field Assistance (RFA).

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I simply want to let everyone know that the team at Power Diagnostics Service has provided excellent support to our staff.

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Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.