POWER September 2015 - 61

OPERATIONS & MAINTENANCE
2. Just in time. After predictive analytics
software identified vibration changes, a borescope
inspection verified that shroud material
was missing from the turbine. After removing
the shells, it was apparent that several other
shrouds were also close to liberating. Courtesy:
Schneider Electric
material and revealed several other segments
that were close to liberating (Figure 2). Had
this issue not been identified with predictive
analytics software, it could have caused immediate
unplanned downtime, loss of generation,
possible catastrophic failure, and danger
to personnel. This single early warning notification
and the following action resulted in
a potential estimated savings of more than
$4 million in lost revenue and repair costs,
in addition to maintaining the safety of the
operating engineers.
Validation: Monitoring Across
Multiple Plants
A midsize generation and distribution utility
in North America uses the Wonderware eDNA
real-time historian to manage generation data
across seven sites, and each site has a local redundant
history for up to eight years of data.
The highly available historian uses lossless
data compression to quickly store and retrieve
operational data. The data management infrastructure
enables efficient sharing of information
between systems, applications, and users.
which assets to monitor based on strategic
importance to the business. The models are
typically implemented in phases, and assets
that have had continuous problems, those
that directly affect availability, or those likely
to have a quick return on investment may be
modeled first.
Predictive analytics software enables utilities
to spend less time searching for issues
or, worse, waiting for an important piece of
equipment to fail. Instead, staff is immediately
notified through an alert that an asset
is not operating as expected. These insights
help engineers and operators better plan and
prioritize maintenance activities, such as determining
when an asset can continue running
as is or needs to be serviced or replaced.
Early Warning Notification
In one example, a large North American
power utility with more than 50,000 MW
of generating capacity and plants in multiple
states had estimated savings of more
than $8 million in avoided costs over one
year through early warning detection of
issues that indicated an asset was headed
toward failure.
In a significant catch, plant engineers
received an email notification from the
predictive analytics software indicating
that an aging steam turbine experienced a
vibration step change that would not have
been detected through standard monitoring
practices. Plant personnel verified that
a proximity probe and casing vibration had
both changed. Further analysis showed a
possible loss of mass in the turbine blade
path. Based on the unit's operating history,
staff immediately suspected shroud material
had been lost. It was determined that
the unit could continue to run at a reduced
output, under increased observation, until a
more convenient and strategic time to bring
it offline.
After the unit was brought offline, a borescope
inspection verified missing shroud
September 2015 | POWER
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61
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POWER September 2015

Table of Contents for the Digital Edition of POWER September 2015

Contents
POWER September 2015 - Cover1
POWER September 2015 - Cover2
POWER September 2015 - Contents
POWER September 2015 - 2
POWER September 2015 - 3
POWER September 2015 - 4
POWER September 2015 - 5
POWER September 2015 - 6
POWER September 2015 - 7
POWER September 2015 - 8
POWER September 2015 - 9
POWER September 2015 - 10
POWER September 2015 - 11
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POWER September 2015 - 14
POWER September 2015 - 15
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POWER September 2015 - 17
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POWER September 2015 - Cover3
POWER September 2015 - Cover4
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