May 2014 / Power Systems Division / Power Generation

Symphony Plus
Symphony Plus Condition Monitoring

© ABB
December 17, 2015 | Slide 1
Rotating Equipment
Familiar Challenges

Flexible Demand
Machine Availability
Response

Machine Efficiency
Reliability Safety

System Complexity Operational Costs

© ABB
December 17, 2015 | Slide 2
Rotating equipment
Maintenance practices: different philosophies for different assets

 Maintenance is the single largest controllable cost in a plant

 Traditional maintenance labor often results in no action and lower return on the assets
 Difficult to streamline and collaborate between daily operations and maintenance activities

Cost of maintenance Asset categorization

10x
5%
Critical - Predicitve (continuous)
5x 25% - Condition based (periodic)
Essential
1x - Preventive
30% Important
Predictive Preventive Corrective
Corrective maintenance can cost ten times as 40% Basic - Reactive
much as a predictive maintenance strategy.

© ABB
December 17, 2015 | Slide 3
Predictive Maintenance on Rotating Machinery
Why is it important?

 Rotating machines are the backbone of nearly all major plant

operations
 Modern reliability studies show that nearly 66% of all machine
failures occur randomly – often with early warning signs
 A sudden breakdown of these machines may result in an
unplanned outage
 Lost production/revenues

 Penalties from the IPP if load demand is not met

 Increased maintenance cost

 May lead to big capital expense in case of catastrophic failure

 Prolonged reduction in capacity in case of catastrophic failure

© ABB
December 17, 2015 | Slide 4
Predictive Maintenance on Rotating Machinery
Why is it important?

Estimated lost recovery generation with additional

savings in 1 year (500 MW machine)
Eliminate unplanned Reduce your
Function Time Savings Cost Savings outages maintenance costs
Reduction in forced 48 Hours $1,200K
outages and start-up
delays*
It affects the
Reduction in 48 hours $55K bottom line!
maintenance hours

Implementation of 2 hours $100K

automatic turbine start-up Reduce and eliminate Reduce insurance
catastrophic machine premiums and
Total Savings $1,355K failures warranty risks
* Assumes opportunity cost of $500 per hour for each MW of capacity

© ABB
December 17, 2015 | Slide 5
Symphony Plus
Condition Monitoring
 No other single process parameter provides as much
information about the health of a rotating machine than
vibration

 Unlike other process variables vibration is more than just an

amplitude – it is a complex waveform rich with information
about the overall health of the machine; it provides:

 Amplitude

 Phase

 Form

 Frequency

 Position

© ABB
December 17, 2015 | Slide 8
Symphony Plus Condition Monitoring
End-to-end engineered solution
Eccentricity

Speed
Event Marker
XY Vib XY Vib XY Vib XY Vib XY Vib XY Vib

High
Low Pressure
Pressure Generator
Turbine Turbine

Thrust Position Case Expansion Differential Expansion

 End-to-end engineered solution using ABB equipment for data collection and data analysis and 3rd party
instrumentation and expertise
 Continuous monitoring and protection
 Determines present condition of equipment
 Provides data for predictive/preventive maintenance

© ABB
December 17, 2015 | Slide 9
Symphony Plus
Condition Monitoring offering

MCM800 SPCMM11 Analyst Software

MCM800 Series 16
16-channel system

Detects and presents warning signs of a pending failure Gives you opportunity to take corrective actions

© ABB
December 17, 2015 | Slide 10
Symphony Plus Condition Monitoring
MCM800
 MCM800 collects high resolution vibration data from vibration sensors for
monitoring and protection

 Performs other monitoring and protection measurements commonly referred

to as Turbine Supervisory Instrumentation

 The MCM800 offers redundant RS-485 ports for either Profibus or Modbus
communication to DCS controllers and systems

 The high resolution vibration data is made available to the Analyst Graphical
User Interface software via on-board Ethernet connection

 All the features reside in a single module, eliminating the need for additional
hardware other than power supplies (this reduces the need for spare parts)

 The MCM800 has four input channels that can be independently configured
for any function or sensor type commonly used in Condition Monitoring

© ABB
December 17, 2015 | Slide 11
Symphony Plus Condition Monitoring
800 Series: MCM800
Ethernet to  Universal module - configurable to measure on different channels:
 OPC Server
 ABB Diagnostic Server
 Configuration and
 Vibration: relative, seismic or absolute
Monitoring Tool
 Eccentricity

 Thrust position

 Case expansion
BNC Connections
(buffered)  Differential expansion (complementary and ramp)

 Accepts any combination of proximity probes, seismic probes and DC LVDT

 Self calibrating to achieve accuracy of +.25% of full scale

Event Marker  1 alert and 1 danger relay on board

Channels 1 to 4
Power
 Speed measurement, event marker, “0 speed” detection

MCM800 - Machinery Condition Monitor  Ethernet connection to OPC Server and ABB diagnostic server

 Vibration analysis
© ABB
December 17, 2015 | Slide 12
Symphony Plus Condition Monitoring
800 Series: MCM800 Series 16

 Accepts up to 16 transducer inputs

 Any combination of proximity probes, seismic probes and

DC LVDT inputs

 Features 4 universal monitoring modules

 Each channel configurable to measure:

 Vibration; relative, seismic or absolute

 Eccentricity

 Thrust position

 Case expansion

 Differential expansion including complementary and ramp

MCM800 Series 16  Buffered outputs of all transducer and event marker

inputs accessible from front panel
16-channel system

© ABB
December 17, 2015 | Slide 13
Symphony Plus Condition Monitoring
800 Series: MCM800 Series 16

Bar graphs

Panel 800 Display

Trends

Machine Train Diagrams

© ABB
December 17, 2015 | Slide 14
Symphony Plus Condition Monitoring
Harmony Rack: SPCMM11
 SPCMM11 collects high resolution vibration data from vibration
sensors primarily for monitoring and protection

 Performs other monitoring and protection measurements

commonly referred to as Turbine Supervisory Instrumentation

 The high resolution vibration data is available for the Analyst

Graphical User Interface software via on board Ethernet
connection

 Natively communicates to S+ Harmony Rack (and earlier

generation) controllers via expander bus

 Offers Modbus communication to other DCS controllers and

systems

 All the features reside in a single module, eliminating the need

for additional hardware other than power supplies (this reduces
the need for spare parts)

© ABB
December 17, 2015 | Slide 15
Symphony Plus Condition Monitoring
Analyst
 Provides a Graphical User Interface that allows a vibration specialist to
view historical vibration data in ways that cannot be accommodated on
DCS operator consoles

 Presents detailed diagnostic information from MCM800 or SPCMM11

 Provide quick recognition of performance patterns and trends

 Accesses historical data stored in servers via an Ethernet connection

 Used in plant Local Area Network or Wide Area Network for remote
access

 Client / server operation

 The server collects and stores the vibration waveforms in a database

 Upon request, client retrieves waveforms and displays in variety of

plot types for analysis

© ABB
December 17, 2015 | Slide 16
Symphony Plus Condition Monitoring
Analyst
 Displays the waveform data and process variables in variety of
plot types
Process variables High-precision waveform data

X – Y plot Time waveform

Bode plot Direct orbit

Polar plot Direct time waveform

Polar + trend plot (Full) spectrum

Filtered orbit plot (Full) cascade

Shaft centerline plot

 Monitor current condition of the equipment

 Compare present and past conditions to assist in predicting

potential risks and failures, and preparing for schedule outages
Enabling predictive maintenance: plot types allow vibration
 Allow configuration of the vibration modules prior to equipment
specialist to easily determine root cause of degrading rotating
equipment performance operation

© ABB
December 17, 2015 | Slide 17
Symphony Plus Condition Monitoring Office Remote Workplaces

System architecture
S+ Engineering Workplace
Composer Harmony & Field S+ Operations Workplace S+ Analyst Client

System Servers

PN800 Plant Net 100 MB Ethernet

HPC800
HPC800 PDP800
Analyst
Server

SD I/O S+ Turbine

Rack I/O S800 I/O

MCM800

HAI805/HAO805 HART

© ABB
December 17, 2015 | Slide 18
Symphony Plus Condition Monitoring
Streamlined proactive remediation work process

SMS alarm notification

+
Call acknowledgement

Rotating equipment – S+ Operations

alarm state alarm notification
 Predictive condition alarming
 SMS alarm notification with remote users
View current CMMS schedules from
 Detailed root directly
cause analysis
S+ Operations
Maintenance –

Rotating equipment –
 Easy communication with and navigation to asset specific CMMSvibration
activities
specialist

normal state  Quick resolution of maintenance issues before catastrophic failure occurs
If not scheduled, create and submit CMMS
malfunction report from S+ Operations

Seamless interaction
Root cause analysis via
Proactive response between
Analyst software package
S+ Operations and CMMS
© ABB
December 17, 2015 | Slide 19
Symphony Plus Condition Monitoring
Capabilities

 On-site supervision
 Manpower resources provided by the plant

 Start-up technical support

 Complete turnkey installation

 Complete design, installation and commissioning responsibility

 Relationships with major AE organizations

 Industry recognized by contractors and service providers

 Other Services
 Site specific training for operators and/or maintenance personnel

 Vibration analysis and turbine balancing

 Site audits and assessments

© ABB
December 17, 2015 | Slide 20
Symphony Plus Condition Monitoring
Key Takeaways
ABB’s Symphony Plus Condition Monitoring is an end-to-end engineered solution that protects against
costly unplanned events

 Majority of failures of rotating machines are sudden – but have early warning signs

 Recognizing these warning signs enables preventive action to avoid potential catastrophic disasters

 MCM800 and SPCMM11 collect high resolution vibration data from vibration sensors for monitoring
and protection

 Analyst software provides an ergonomic GUI for critical vibration root cause analysis

 Symphony Plus condition monitoring solution results in a streamlined proactive remediation work
process

 Symphony Plus condition monitoring hardware and software can stand alone with 3rd party DCS
capable Profibus, Modbus, and OPC communication

© ABB
December 17, 2015 | Slide 21