ProvibTech s Power Generation Solution

Transcription

1 ProvibTech s Power Generation Solution Application_200MW Steam Turbine With years of experiences on vibration protection and condition monitoring, ProvibTech obtained more and more reputation in power generation. Steam Turbine is playing an important role in power generation, hereunder we d like to lead a standard 200MW steam turbine for reference. ProvibTech is able to supply a complete solution for vibration protection and online condition monitoring including making diverse proposals, engineering, installation, commissioning and training. Application Layout This layout is to have a clear but simple introduction about the main measurement points for Steam Turbine. ProvibTech is able to make a complete engineering work before deliver the materials to customer. Not only saves customer a large number of of installation & commissioning cost, but also takes 1 / 25

2 customer great convenience. Please refer to below picture. Below diagram is to introduce how ProvibTech s rack system PT2060 running with PCM360 system. 2 / 25

3 TSI Monitoring & Condition Monitoring System HP IP LP G E Sensor System Relay Output PLC/DCS 4-20mA PT2060 Data Acquisition Module PT2060 Process Signals Transient/Dynamic Signals Ethernet PCM360 SERVER SMS User 1 User 2 User 3 PCM360 Condition Monitoring System 3 / 25

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5 ProvibTech Products Transducers TM0180 The TM0180 (8mm) is designed for long life cycles and are suitable for harsh environments. ProvibTech realizes one of the most significant problems in proximity probe installations are ground loops and loss of isolation due to damaged cable jackets. ProvibTech s custom rugged cable jacket prevents the probe cable from breaking and tearing and is highly resistive to corrosive environments. The TM0180 probe and TM0181(extension cable) are equipped with a standard protective rubber boot, which covers the connectors and prevents oil and dirt penetration. The TM0180 series probes come in 0.5m and 1.0m cable lengths, as well as, special lengths of 5.0m and 9.0m with an integrated probe and extension cable design. The probe may be selected in English or metric units, as well as, reverse mounting options. Reverse mount probes are used with TM0393X probe housings for hazardous areas. With up to 2mm(80mil) linear range,tm0180 is generally applied for radial vibration, thrust position, rotation speed,eccentricity and phase reference. It is frequently used with ProvibTech s extension cable TM0181 and driver TM0182 and reverse probe housing TM0393X. TM0110 The 11mm probe has up to 4mm (160mil) linear range. The TM0110 probe is recommended when a longer linear range is required. The TM0110 proximity probe system is designed to meet API 670 industrial standard. TM0110 is generally applied for thrust position. It is frequently used with ProvibTech s extension cable TM0181 and driver TM / 25

6 TM0120 The 25mm probe has up to 12mm (470mil) linear range. The probe is designed for measuring differential expansion. The TM0120 integrates the probe, extension cable and the driver into one unit. This integral proximity probe is designed for easy field installation. The TM0120 probe comes in lengths of 1m, 5m and 9m standard cable (2 conductor shielded cable). TM0793V/TM0782A TM0793V is with sensitivity 4.0mV/mm/sec (100mV/in/sec). TM0782A is with sensitivity 100mV/g. TM0782A and TM0793V are piezoelectric accelerometer/velocity transducer directly interfaces with ProvibTech s signal conditioners PT2060, DTMs, DM200 or TR1101. TM0602 For steam turbine applications, the relative case expansion due to thermal effect should be monitored. Case expansion is the thermal growth of the machine case as it expands during machine start up and on line operations. The TM0602 is typically mounted on the foundation at the opposite end from where the turbine casing is attached to the foundation. The case expansion transducer system provides information on the growth of the machine case relative to the foundation. LVDTs (linear variable differential transformers) are used to measure the case expansion. Three different linear ranges are available: 25mm (1.0 ), 50mm (2.0 ) and 100mm (4.0 ). The case expansion transducer assembly consists of an LVDT that is housed in a weatherproof protective enclosure. Monitors PT2060/10/20/31/35/40/43/53/91/96/98/90/99 6 / 25

7 Proximity Module (4 channels) Radial vibration Axial/ Thrust position Eccentricity PT2060/10 Differential expansion Low-frequency vibration Speed output Zero speed and speed Reverse rotational protection output Seismic Module (4 channels) Acceleration, Velocity and Displacement PT2060/20 Low Frequency acceleration, Velocity or Displacement Case Expansion Case expansion output paired Case expansion output single PT2060/31 Temperature Module(8 channels ) RTD, TC PT2060/35 Process Input Module 16 channels per module PT2060/40 Relay Module(16 channels) Relay output (SPDT) 7 / 25

8 PT2060/43 Redundant Relay Module(8 channels) Relay output(dpdt) Over Speed Module(1 or 3 channels) Over-speed protection The following function only for channel 3 and channel 4. Radial vibration: monitoring shaft vibration, single or dual XY PT2060/53 Axial/ Thrust position: monitoring shaft thrust position, with 5mm, 8mm, and 11 mm proximity probes Eccentricity Differential expansion Low-frequency vibration Speed output zero speed Reverse rotational protection output System Interface Module Connect to a configuration station PT2060/91 Communicate to PT2060 system racks Communicate to other control systems (PLC/DCS or Historian) Provides two phase references channels Provide storage of system and alarm events Display Module ID each channel, and arrange the routing Setup data collection strategy PT2060/98 Display machine photo and real-time data and status on top of the photo Real-time bar graph/ status list/ alarm status of each channel Alarm events Trend plot on each channel Touch-panel for easy operation Network to control systems (PLC/DCS or Historian) via Modbus 8 / 25

9 PT2060/90 Power Supply Module Redundant Power supply PT2060/99 Standard 19 or 12 rack DTM10/DTM20/ DTM96 DTM Proximity Distributed Transmitter Monitor. With internal driver, for Radial Vibration DTM Proximity Distributed Transmitter Monitor. With internal driver, for Axial Position DTM Proximity Distributed Transmitter Monitor. With internal driver, for Rotation Speed /Phase Reference DTM Proximity Distributed Transmitter Monitor. With external driver, for Radial Vibration DTM Proximity Distributed Transmitter Monitor. With external driver, for Axial Position 9 / 25

10 DTM Proximity Distributed Transmitter Monitor. With external driver, for Rotation Speed /Phase Reference DTM Seismic Vibration Distributed Transmitter Monitor. Run with current mode accelerometer with 100mV/g, velocity sensor with 4mV/mm/s or seismic velocity sensor DTM96 Communication module. Optical isolated, RS485, RS422, RS232 PCM360 Online Condition Monitoring System Introduction of PCM360 ProvibTech s PCM360 is a machine condition management system that collects, stores, analyzes and is capable of transmitting machine status monitoring information over local or wide area network. The PCM360 provides static, dynamic and transient data collection and analysis; such as graphical indication of vibration level, trend, waveform, spectrum, bode plots, cascade plots and much more. All ProvibTech s monitors and transmitters can quickly and easily be integrated to upload machine status and its dynamic data to the PCM360. The PCM360 obtains both critical machinery running status and balance of plant running status. Additionally, the PCM360 collects process data as 4 20mA input or digital monitor input via Modbus, etc. The PCM360 provides an integrated system solution for asset management resulting in a total solution for machine maintenance and protection. Leading Features of PCM360 Integrates plant condition monitoring and process data into one database User friendly interface for instant data analysis with minimal training required of field staff Maximum flexibility and expandability of the software system with object oriented modular design Transient, dynamic and process data collection 10 / 25

11 Built on Microsoft SQL Server database to assure better data management and reliable networking Client/ Server architecture enables user to access data anywhere on intranet/ internet Readily integrates with third party vibration monitors and process monitors with minimum hardware requirements Multiple digital I/O Protocols, such as Modbus RTU/ TCP Multiple hardware output modules ready for further data transfer and annunciation in relays and current transmission 24 hour notification through on site alarms, operator interface and even SMS messaging on GPRS mobile Remote notification with SMS messages to any cellular phone with machine running status Advanced post processing of transient data minimizes data loss, maximizing analysis capability PCM360 Data Flow Introduction In addition to running well with transmitters/monitors of ProvibTech itself, with great integrate ability and versatile interface, PCM360 is also able to interface with diverse transmitters /monitors /sensors or Modbus TCP Server or OPC server from third party which takes great convenience for retrofit projects and makes the plant management more efficient and effectively without spending much money. Apart from these, PCM360 also can play a role as Modbus TCP Server or OPC Server which makes interfacing with third party condition monitoring system available. In conclusion, PCM360 is very flexible and functional. With its reliability, it not only can acquire the data from third party but also share its data with third party. 11 / 25

12 Plots Supported By Different Measurement Points Device Type Channel Type Data Type Measurement Point Single Dual Channel Channel Plots and Lists DAQ Card: bar graph, waveform, spectrum, bode, polar, cascade, 6013, (dynamic, transient) waterfall, 6220,6 250 Acceleratio n, Velocity Dynamic data, Transient data (dynamic, transient, historical) trend, status list, alarm list, transient list bar graph, waveform, spectrum, full spectrum, shaft XY vibration, bode, polar, cascade, full cascade, (dynamic, transient) waterfall, (dynamic, transient, historical) trend, status list, alarm list, transient list bar graph, waveform, spectrum, bode, polar, cascade, Vibration[f rom Prox] Dynamic data, Transient data waveform with DC coupling, (dynamic, transient) waterfall, (dynamic, transient, historical) trend, status list, alarm list, transient list bar graph, waveform, spectrum, full spectrum, shaft XY vibration, shaft centerline, waveform with DC coupling, 12 / 25

13 shaft XY vibration with DC coupling, bode, polar, cascade, full cascade, (dynamic, transient) waterfall, (dynamic, transient, historical) trend, status list, alarm list, transient list Position[fr om Prox], Process Static data bar graph, static trend, status list, alarm list Modbu s DAQ for Proces s Acceleratio n, Velocity, Vibration[f rom Prox], Position[fr om Prox], Static data bar graph, static trend, status list, alarm list Process bar graph, waveform, spectrum, dynamic waterfall, alarm list, Modbu s DAQ for DW Dynamic data, Static data (static, dynamic) trend, status list bar graph, waveform, spectrum, full spectrum, shaft XY vibration, dynamic waterfall, alarm list, (static, dynamic) trend, status list OPC Client Acceleratio n, Velocity, Vibration[f rom Prox], Position[fr om Prox], Static data bar graph, static trend, status list, alarm list Process 13 / 25

14 Plots plot (real time and historical) Waveform plot with DC coupling (real time and historical) Waveform plot (real time and historical) Spectrum spectrum plot (real time and historical) Full 14 / 25

15 vibration (real time and historical) Shaft XY vibration with DC coupling (real time and historical) Shaft XY Trend plot (static, dynamic, transient, historical, and real time, gap) plot (dynamic and transient) Waterfall 15 / 25

16 Bar Graph centerline plot (real time and historical) shaft Bode plot plot Cascade cascade plot Full Polar plot 16 / 25

17 Shaft centerline mode shape Shaft XY vibration mode shape Lists Transient list Alarm list Status list 17 / 25

18 Measurement Illustration Shaft X, Y Vibration (Radial Vibration) Shaft X, Y Vibration is for shaft dynamic motion which is generally measured in a direction perpendicular to the shaft axis, it is also called radial vibration or lateral vibration. It is indicated by PK PK with unitμm or Mil. 5mm or 8mm proximity probes are often used to observe Shaft X, Y Vibration. ProvibTech s proximity probe TM0105(5mm) and TM0180(8mm) will supply complete solution. Please refer to the Figure 1.1 and Figure 1.2.They are showing the typical way for probe installation for Radial Vibration. Apart from the installation way of Figure 1.1 and Figure 1.2, there s another installation way, please refer to Figure 1.3. Probe X is horizontally installed and Probe Y is vertically installed. Sometimes, proximity probes will be mounted inside the machine by probe clamp, and sometimes probes will be mounted with help of probe holder. ProvibTech s TM0393X supply a very cost effective solution for mounting the proximity probes for these machines whatever for normal pressure or high pressure purpose. Customer can replace the probe without opening the machine case which takes great convenience and save lots of time and maintenance cost. Adjustable penetration depth +/ 13mm(0.512 ) makes the installation very flexible. Please refer to Figure 1.4 and Figure 1.5 for installation reference. 18 / 25

19 Thrust Position (Axial Position) Thrust Position is to measure the movement of shaft in the axial direction with respect to some fixed reference. Typically, the reference is the thrust bearing support structure or other casing member to which the displacement probe is mounted. The probe is generally to observe the thrust collar directly or axial shaft surface. Thrust Position is also called Axial Position, and it is indicated by average with unitμm or Mil. 5mm or 8mm proximity probes are often used to observe Thrust Position. ProvibTech s proximity probe TM0110(11mm) and TM0180(8mm) will supply complete solution. Due Thrust Position is very important for some essential machines, it is strongly recommended to use dual proximity probes to monitor Thrust Position as the redundancy will increase the reliability of the monitoring. Please refer to Figure 2.1 and Figure 2.2. Seismic Vibration (Casing Vibration) Seismic Vibration measures the absolute vibration of machine case or structure. This measurement doesn t require other object s position or movement as a reference. Accelerometers and velocity sensors are often used for Seimic Vibration. It is also called Casing Vibration. It will be indicated by PK or PK PK or RMS. The installation direction could be horizontal or vertical. Please refer to Figure / 25

20 Rotation Speed Rotor speed is important measurements during normal machine operating conditions as well as during startup and coast down. Sudden unexpected changes in rotor speed may be an indication of machinery or process malfunction. Over Speed Over Speed protection system is mandatory for critical machines especially like steam turbines. Due the rotation speed for the steam turbine is the most important factor, so generally we use two proximity probes or three proximity probes to compose a system. It could be 2 out of 2 or 2 out of / 25

21 Reverse Rotation For boiler feed pump or some machines, Reverse Rotation monitoring is necessary as the reverse flow will cause the total machine shutdown finally stop water supplying. Typically Reverse Rotation requires two proximity probes to mount on the gear or shaft with a notch. Please refer to below Figure 6.1 for details. Zero Speed When the steam turbine or machine is under turning state, the rotation speed should not be very slow. If it rotates slower than it should be, then it will trip. Zero Speed is similar like speed monitoring, but Speed monitoring is to trip when it rotate too fast than it should be, and Zero Speed monitoring is to trip when it rotate too slow than it should be. 21 / 25

22 Phase Reference Phase Reference is a transducer that produces a voltage pulse for each turn of the shaft. This signal is used primarily to measure shaft rotative speed and serves as a reference for measuring vibration phase lag angle. Typically proximity probe, magnetic pickup, optical pickup are used for measuring Phase Reference. Please refer to below Figure 7.1 for details. Differential Expansion Differential Expansion is to measure the axial position of the rotor with respect to the machine casing at some distance from the thrust bearing. Differential Expansion is usually measured when machine startup and shutdown as the machine has a big thermal expansion during that period. The measurement is typically made with a proximity probe transducer mounted to the machine casing and observing an axial of the rotor. The proximity probe could be mounted by two ways. One is by normal shaft direction, please refer to below Figure / 25

23 Another way is mounted by ramp shaft direction. Please refer to below Figure 9.2. Case Expansion Case Expansion is to measure axial position of the machine case relative to a fixed reference, usually the foundation. Changes in casing axial position are the result of thermal expansion and contraction of the casing during startup and shutdown. It is generally measured by LVDT(Linear Variable Differential Transformer). Please refer to below Figure 10.1 for Case Expansion. 23 / 25

24 Eccentricity Eccentricity is very important for monitoring turbine rotor bow. PT2060/10 PROX proximity module can provide sophisticated on line eccentricity monitoring. The monitor is suitable for virtually all types of rotating machinery in terms of eccentricity. The PT2060/10 PROX proximity module will be continuously measure and monitoring in up to two channels per module. Eccentricity measurements indicate the deviation of the rotor physical center and the theoretical center. The difference has to be small enough to allow machine startup without causing damage. The PT2060/10 PROX proximity module provides peak to peak eccentricity measurement, which measure the difference between the positive and the negative extremes of the rotor bow. It also has one more channel that output the position of the rotor. Operators use eccentricity measurements to determine when a combination of slow roll and heating have reduced the rotor eccentricity to the point where the turbine can safely be brought up to speed without damage from excessive vibration or rotor to stator contact. Eccentricity is the measurement of Rotor Bow at rotor slow roll which may be caused by any or a combination of Fixed mechanical bow Temporary thermal bow Gravity bow 24 / 25

25 Valve Position Valve Position is to measure the position of the process inlet valves on a machine, usually expressed as a percentage of the valve opening; zero percent is fully closed, 100 percent is fully open. Please see below Figure 12.1 for Valve Position. Temperature Temperature monitoring is also an important parameter to monitor the machine health status. When something wrong inside the machine, it will cause more friction which will cause temperature getting higher. Typically we ll use RTD/TC sensor to acquire the process signal and transfer to transmitters/monitors, finally transfer to condition monitoring system. Flow Rate, Pressure and other process variables All these parameters are like temperature as they are process variables, and these are to control something or feedback the health status of the machine. Typically we ll use different kinds of sensors to get the process signals and finally transfer to condition monitoring system. 25 / 25