Digital Health Assesment in Hydro Power

voith.
com
Digital Health Assessments in Hydropower

How Voith puts data science into practice
Dr. Alexander Jung & Dr. Matheus Habets | Webinar on HydroWorld 2019 | 2019-09-26
Agenda
Introduction to the OnPerformance.Lab
2 Our Digital Health Assessments
3 How we apply data science
4 Real life examples
5 Before you need our help
Webinar on HydroWorld 2019, 26th of September | Digital Health Assessments | Dr. A. Jung & Dr. M. Habets 2
Today’s main challenges in hydro
Hydropower plants face three main challenges that
impact the way they run maintenance
1 Changing energy sector 2 Under financial pressure 3 The journey of digital

transformation
Dynamic renewable energy Hydropower plants face Digitization is transforming

supply is constraining increasing cost pressure hydropower operations
operating conditions and maintenance
Power plants already …and experience pain

take actions to cope… points in the process.
Digital pains
There are several challenges that are slowing
the data-based value creation
What our customer has told us …
“We can’t afford having the “We use the data in a reactive “The longer you stay online in “Once we have all of that data
people who can evaluate this way, if something breaks down remote troubleshooting, the in a database, then maybe
data and make useful insights to troubleshoot problems.” more exposed you are to a Voith could help, but we are
out of it.” American customer hacker attack.” not there yet.”
Swedish customer German customer American customer
Lack of expertise & No fast help on Fear of loosing data Unstructured and
resources for pro-active complicated and severe control & security inaccessible condition
health evaluation problems breaches monitoring data
Our Solution:
Help hydro operators to reduce costs

and (unplanned) downtime with our
OnPerformance.Lab Digital Services
OnPerformance.Lab Digital Services
We support optimizing maintenance and operations
routines
We combine our OEM & hydro domain know-how with state-of-the-art data analytics
Focus
Digital Health Assessment Consumed life monitoring Remote expert support
Optimize maintenance cycles by Understand how your operations Chat & call our experts no matter
pro-actively evaluating machine’s have an impact on components the nature of your problem
condition and giving actionable device
Agenda
1 Introduction to the OnPerformance.Lab
Our Digital Health Assessments
A common run into failure
Knowing issues ASAP is our core value contribution
Digital Health Assessment
Improved machine condition
!
Issue begins
Machine health
Physical inspections
Condition monitoring system
Smoke, heat, loud noise
Break down
Time
What it means for your business
Area Our advice Business impact
Anomaly Predict major outages before they occur Improve plant’s profitability
detection based on abnormal patterns.
Stretch Apply 140 engineering rules (algorithms) to

intervals monitor thoroughly your equipment’s health.
Improve
Improve Understand the wear and tear of components plant’s
planning to enable preventive maintenance actions. availability
Spare parts Determine spare parts needs based on the

optimization condition of your equipment. Increase
plant’s Improve
life plant’s
performance
Our focus areas for the Digital Health Assessment
Concentrate on malfunctions*
Auxiliaries Generator
Shaftline & bearings
Turbine
Main Inlet Valve (MIV)
* a malfunction is defined as a trending equipment failure
Analyze for the most common malfunctions
Generator
• Winding insulation defect
• Brushes worn
• Braking system insufficiency
Auxiliaries • ...
• Cooling water filter clogged

• Leaking oil pan
• Auxiliary pumps degradation • Shaft seal worn
• … • Unbalance/shaft misalignment
• Thrust/guide bearing wear
• …
Main Inlet Valve (MIV) Turbine

• Pump degradation
• Labyrinths worn
• Operating seal leakage
• Wicket gate bushings worn
• Hardening
• Wicket gate leakage
• ...
• ...
Minimize customer failure cost*
Generator
• Winding insulation defect
• Brushes worn
• Braking system insufficiency
Auxiliaries • ...
• Cooling water filter clogged

• Leaking oil pan
• Auxiliary pumps degradation • Shaft seal worn
• … • Unbalance/shaft misalignment
• Thrust/guide bearing wear
• …
Main Inlet Valve (MIV) Turbine

• Pump degradation
• Labyrinths worn
• Operating seal leakage
• Wicket gate bushings worn
• Hardening
• Wicket gate leakage
• ...
• ...
* Estimated for a 100 MW power unit incl. loss of revenues
Agenda
How we apply data science
Diagnosis Methodology
Digital Health Assessments
Condition monitoring vs. health state assessment
From raw signal thresholds to virtual signal analysis
Condition monitoring Diagnosis approach

Adding the
yellow light!
Virtual signal
Raw signal value
threshold value threshold value
Time Time
“Green and red don‘t “How often did I just slightly miss
really add value!” the alarm? Did this change in the
recent past?”
What is a virtual signal?
Simple example: Time for braking
Raw signal: speed n Virtual signal: time for braking tb Trend: approx. 5% braking
time reduction
• better touch of braking
time interval / s
pads?
• wear in bearings?
30% > n > 2%
• change in friction / oil /
temperatures?
• …
Virtual signal: Basis for diagnosis of multiple malfunctions!
Extracting relevant information
From signal analysis to rule-based diagnosis
Virtual signals Anomaly detection Rule-based diagnosis

Machine behaviour Malfunctions
1 2 3 A B C
Signals
Virtual
Signals
Raw
Anomalies Malfunction Cluster

Value
Value
Time Time
From signal to health status
Aggregate the data to yield health status indicators
Health Status Indicator – HSI*:

• Single, normalized value that results from intelligently aggregating multiple inputs.
• Indicates the probability of a certain malfunction.
• Triggers the traffic light colors: green  yellow  red
• Describes the urgency for action.
• Is associated with concrete recommended actions.
Anomaly Diagnostic
Signals Limits HSI
score rules
* also referred to as KDI – Key Diagnostic Indicator
Example for Health Status Indicator
Thrust bearing wear
Description of malfunction Input: VS VS_1

VS_2
VS_3
What is detected by diagnosis rule? Normalized Virtual Signals
with pre-configured limits
Increased wear on thrust bearing pads
Failures/damages Recommended
associated with actions
malfunction
wear on bearing pads reduce axial thrust; Output: HSI HSI thrust bearing wear
HSI_thrust_bearing_wear
renew thrust bearing

Health Status Indicator
wear on sliding ring reduce axial thrust; from aggregation of input
renew thrust bearing signals
bearing oil contamination filtering of oil,

replacement of oil
Reliability, concreteness and significance of signals
Transforming data into useful information
Yellow traffic light triggered by: Signal quality rating
HSI: thrust associated with concrete

bearing wear recommended actions
added value / significance

added value / significance
Health Health
Status Status
Indicator Indicator
VS: char. anomaly in VS can
have multiple reasons,
Virtual lift-up med. only some of them may
Virtual
Signal
Signal pressure need special attention
Automation / Automation / threshold values are

monitoring monitoring
Pressure in critical and usually set to
signal signal lift-up pump protect equipment
concreteness reliability
Agenda
Real life examples
Proven value add in Switzerland
Avoided an unplanned outage worth $35K/day
Raw signal: labyrinth pressure What was the challenge?

Data-based turbine bearing health
Clogged pipes in pressure assessment.
measurement equipment
What did Voith do?
The OnPerformance.Lab analyzed
the pressure drop at labyrinth seal
position and recommended to clean
Virtual signal: pressure drop interval
the measurement piping.
Same operating point but
different duration for pressure What was the value to the
equalization from 2 to 1.5 bar
customer?
The customer avoided heavy wear
mud and dirt on the axial bearing and an
from pipes unplanned outage.
Our expert support at work in Guatemala
Reduced > 1 weeks downtime worth > $270K
What was the challenge?

Customer received vibration warnings and
wanted to re-align the main shaft.
What did Voith do?

The OnPerformance.Lab analyzed the data,
recognized a natural frequency problem, and
recommended to use new sensor brackets.
Before After
What was the value to the customer?
Our advice avoided an inane shaft re-
alignment with a consecutive outage of more
than a week for a 150 MW unit.
OnCare.Acoustic at its full strength
Avoided clogging damage in Germany
What was the challenge?

Surveillance of plant operation between
inspection rounds.
What did Voith do?

OnCare.Acoustic produced warnings due to
the new sound pattern. OnPerformance.Lab
informed the customer.

The customer sent a service person to the
power plant who restarted the power unit.
This avoided wear and damage of turbine
components and recovered the lost power.
Our holistic data approach
Optimized turbine flushing of a run-of-river plant
4th stage
3rd stage What was the challenge?
2nd stage The turbines of a run-of-river plant suffered
1st stage from clogging by floating refuse. Operator has
.…. to visit plant to hear if flushing is required.
Power deficit Power surplus

What did Voith do?
.…. The OnPerformance.Lab provided early
.…. Discharge decrease recommendations based on sound pattern and
.…. operative data analysis.
.….
24hrs
Flushing can be done earlier, with smaller
sound pressure active power flushes. Leading to increased revenues, +5%
discharge head water level
power, and minimized wear & tear of unit.
Anomaly detection by OnCare.Acoustic
High sensitivity for detection of turbine clogging
sound pressure level
Info “turbine clogging”:
speed range Cause: Foreign objects get stuck in distributor or runner

Significance: Noise, vibration, increased wear of components,
reduced efficiency, reduced power, reduced revenue
Manual load rejection
power (“big flush”)
• Upon notification by the OCAc malfunction
OnPerformance.Lab, detection: “turbine
diffuser customer initiated flushing clogging”
procedure
 early warning (already at
• Site personnel reported incipient stage)
impeller opening
subjective improvement,
OCAc data, however, still  very high sensitivity
showed anomalies (better than site experts)
Standard cleaning
Start of clogging; procedure (“small
upper water level
OCAc warning • Upon notification, manual load  allows optimization of
flush”)
rejection was initiated to cleaning procedure
completely flush the turbine
Defective cooling water pumps control in storage plant
initial warning due to an intended pump What was the challenge?

switchover after maintenance activities
Acoustic monitoring of storage plant
components including auxiliaries.
What did Voith do?

Three hours later: warnings due to pump
Classified new abnormal sound
switchovers which recurred every 3 minutes pattern after control system
maintenance activities
What was the value to the

customer?
OnCare.Acoustic created warnings
of the anomaly to inform customer
about control system issues which
would prevent a proper unit start.
Defective pressure control valve after unit shutdown
shutdown period with
sound pressure level

banging noise
 Unit shutdown during thunderstorm
 Roughly 5 hours later various microphones
detected multiple banging noise, which
were classified as warnings by
speed range OnCare.Acoustic
 The customer was informed and confirmed
a defective pressure control valve in the air
system of the brakes, which was replaced
power
afterwards
Agenda
Before you need our help
Digital Health Assessment journey
How we work to fulfill your health assessment focus
1 2 3 4
Customer attraction Product presentation Requirement analysis Technical

via website or our sales team through an on- or off-site visit research & setup
5 6 7 8
✓
Information upload to Technical analysis for Health assessment Regular health assessment
the digital platform health assessment review with & conversation with
OnPerformance.Lab by OnPerformance.Lab customer OnPerformance.Lab experts
Interact expert
OnPerformance.Lab Interact
Easily request and review health assessments, and
enable future decision-making
Request health assessment Review recommendations Track progress
• Easy planning of health assessment • Evaluate recommendations through our • Retain interactive reports for future
interactive digital report reference
• Full control over the data shared
• Meet our expert to discuss • Track the progress of the health of your
• Interact with our expert throughout our
recommendations machines and associated events
transparent evaluation process
Regular annual pricing for one hydropower unit
Different packages for different needs
Limited time offer

Trial
5 malfunctions
Free 1 health
your selection assessment
Economy Premium 1st class

5 malfunctions 10 malfunctions
your selection your selection
All malfunctions
+5 malfunctions 2 health +10 malfunctions 2 health

available
4 health
Voith selection assessments Voith selection assessments assessments
30 hrs. remote expert support 60 hrs. remote expert support
Wrap up
Voith’s Digital Health Assessment is...
• Robust forecast based

on data (uploads),
engineering rules, & analytics
• Safeguard for malfunctions
followed up by actionable
advice
• Bring share reactive
maintenance down
vs. preventive & condition-
based up
• Now available: A limited
time Free Trial offer
Thank you!
Questions?
Contact:
Dr. Alexander Jung
Head of Digital Hydro Solutions
Phone +49 7321 37-7635
alexander.jung@voith.com
Contact:
Dr. Matheus Habets
Global Product Manager
Phone +49 7321 37-9624
matheus.habets@voith.com

Digital Health Assesment in Hydro Power

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voith.

Digital Health Assessments in Hydropower

Introduction to the OnPerformance.Lab

2 Our Digital Health Assessments

3 How we apply data science

4 Real life examples

5 Before you need our help

1 Changing energy sector 2 Under financial pressure 3 The journey of digital

Dynamic renewable energy Hydropower plants face Digitization is transforming

Power plants already …and experience pain

Help hydro operators to reduce costs

1 Introduction to the OnPerformance.Lab

Our Digital Health Assessments

3 How we apply data science

4 Real life examples

5 Before you need our help

Digital Health Assessment

Improved machine condition

Condition monitoring system

Smoke, heat, loud noise

Area Our advice Business impact

Stretch Apply 140 engineering rules (algorithms) to

Spare parts Determine spare parts needs based on the

* a malfunction is defined as a trending equipment failure

• Cooling water filter clogged

Main Inlet Valve (MIV) Turbine

• Cooling water filter clogged

Main Inlet Valve (MIV) Turbine

* Estimated for a 100 MW power unit incl. loss of revenues

1 Introduction to the OnPerformance.Lab

2 Our Digital Health Assessments

How we apply data science

4 Real life examples

5 Before you need our help

Condition monitoring Diagnosis approach

threshold value threshold value

Virtual signal: Basis for diagnosis of multiple malfunctions!

Virtual signals Anomaly detection Rule-based diagnosis

Anomalies Malfunction Cluster

Health Status Indicator – HSI*:

* also referred to as KDI – Key Diagnostic Indicator

Description of malfunction Input: VS VS_1

renew thrust bearing

bearing oil contamination filtering of oil,

Yellow traffic light triggered by: Signal quality rating

HSI: thrust associated with concrete

added value / significance

Automation / Automation / threshold values are

1 Introduction to the OnPerformance.Lab

2 Our Digital Health Assessments

3 How we apply data science

Real life examples

5 Before you need our help

Raw signal: labyrinth pressure What was the challenge?

What was the challenge?

What did Voith do?

What was the challenge?

What did Voith do?

What was the value to the customer?

Power deficit Power surplus

Info “turbine clogging”:

speed range Cause: Foreign objects get stuck in distributor or runner

initial warning due to an intended pump What was the challenge?