ALSPA® SHAFT CARE - infaith.kr Brochure-인페이스.pdf · Server (Alspa Care) in different plants via the Intranet or Internet. Authorized visitors may simultaneously and remotely

ALSPA® SHAFT CARE Condition Monitoring and Diagnostic System

POWERwww.power.alstom.com

JEONG JU TAEK

2010로고-청색

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, maintenanceprogrammes 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.

GENERAL

ALSPA® SHAFT CARE

Condition Monitoring and Diagnostic System

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

APPLICATIONS

Industries Served :

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


ALSPA® SHAFT CARE


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

Plots :

Airgap Circle

Airgap Bar

Airgap Wave

Airgap List

Airgap Trand

Air Gap : Diagnose :

Self-Train

1-Plane Balancing

2-Plane Balancing

Decision Support

Case Library

TPH Waveform

Time-Speed

Nyquist

Bode

Waterfall

Cascade

Startup/ Shutdown : Lists :

Vib-Parameter

Process-Parameter

Vib-Alarm

Process-Alarm

System Log

Event List

Factory Report

Machine Report

Machine Status

Figure : Orbit

COMPREHENSIVE ANALYSIS PLOTS


Figure : Waveform Spectrum

ALSPA® SHAFT CARE


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 BALANCING2-Plane Balancing tool is available to machinery engineers or experts to assist in the balancing of machinery.

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.

CASE LIBRARY FOR EASY REPORT GENERATION AND CASE SAVING DOCUMENTATION


ALSPA® SHAFT CARE


UNRIVALED EASE-OF-USE

The S8000 Plus user interface is a Microsoft Windows style application. With the easy to use human interface, minimumtraining 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


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

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 aboutcomplicated machine faults.

REMOTE ACCESS CAPABILITIES

ALSPA® SHAFT CARE


STRUCTURE OF S8000 PLUS LOCAL SETUPS8000 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 InstallData 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 TechnologiesProcess 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 StorageThe 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 RMD8000Optionally, 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.

ALSPA® SHAFT CARE



HIGH-SPEED PARALLEL SYNCHRONOUS FULL-ROTATION DATA ACQUISITION

Applications NET8000 series PWR8000 series HYD8000 series

DAU Mode

Rotating Speed

≥ 36RPM≤ 32000RPM

≥ 36RPM≤ 4000RPM

≥ 12RPM≤ 1000RPM

Industry

Petroleum& Chemical,

Steel & Aluminum

Coal Fired Power, Nuclear Power

Hydro Power

High-Speed Sampling Rate

Number of samples per revolution per channel:

1024

Number of spectrum lines: up to 3200

A/D resolution: 14 bits

Display refresh rate: Up to once per second

If there is no reference mark, key or slot or rotating speed sensor installed on a shaft, the DAUcan 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.

What if there is no reference mark, key or slot or rotating

speed sensor installed?

Calculate rotating speed from a reference vibration channel

Parallel Synchronous Full-Rotation SamplingParallel, 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: 3000RPM，50HzNumber of monitored channels: 16 Number of samples per revolution: 512 (one data group)Size of each sample: 2 BytesMethod 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!

ALSPA® SHAFT CARE



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 month’s 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.

Figure: Automatic statistical calculation of the thresholds

Signal Type Measured ParameterAlarms

Danger WarningThresholds

Amplitude Phase

Vibration

Overall value x x x1X x x2X x x

0.5X xFrequency band 1 xFrequency band 2 x

Residual x

Overall value x x

Overall value Variation by percentage

Process parameters

Load

Figure: Rich and powerful alarms and thresholds

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.

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).

ALSPA® SHAFT CARE



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 real-time. This results in increased asset management capability and efficiency.

The amount of data storage of S8000 Plus for a machine：Rotating speed: 3000RPM，50HzNumber 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


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 user’s 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.

ALSPA® SHAFT CARE



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.

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: Bode

Figure: Nyquist


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

Documents

ALSPA® SHAFT CARE - infaith.kr Brochure-인페이스.pdf · Server (Alspa Care) in different plants via the Intranet or Internet. Authorized visitors may simultaneously and remotely