Field Service Innovation
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Field Service Innovation
Committed to keeping you competitive
Securing availability, flexibility and profitability of power plants is an ongoing process and specific to each facility. It can require new service products to appropriate address ever-changing plant and market requirements. Siemens Field Service offers a variety of innovative service packages and solutions to accommodate individual and specific support needs.
Remote system monitoring
Our remote online Siemens Power DiagnosticsTM Services allow us to monitor aspects of your gas and steam turbine performance from several centers worldwide. Using installed monitoring systems, we can conduct data analyses, investigate system flags and rapidly communicate findings to plant personnel.
Lengthy repair times can be reduced and new/repaired component shipping delays eliminated with our onsite machining (OSM) services. With the help of innovative portable equipment rom Siemens, our Field Service experts can perform many required machining repairs directly at your site and a lot faster than shipping for factory repairs.
For quick, accurate inspections of all stationary and rotating turbine and generator components, our Field Service specialists use advanced non-destructive examination (NDE) tools. Many potential issues, such as crack growth mechanisms, can be identified and dealt with before they lead to failures.
Fact finding and reporting
Our highly skilled Field Service staff can also provide on-Site assistance in detecting and investigating operational issues following a system outage, maintenance work or overhaul.. Data can be shared in meetings and discussions with the client, along with recommendations.
Testing without Tracks
Field inspection specialists are trained with advanced NDE tools that allow them to perform industry-leading turbine and generator inspections with special attention to critical areas only the OEM can provide. Using this information, we can disposition results more accurately allowing you better decision-making ability regarding your service options. In addition to our basic NDE services, we also offer advanced services such as phased-array ultrasonic testing and thermal imaging crack detection.
Siemens NDE Field Service Technicians are trained with state-of-the-art NDE tools and are certified to national and international standards. This allows us to perform industry-leading turbine and generator inspections with special attention to critical areas that only we, as the OEM, can provide. Using this information, we can easily disposition inspection results more accurately than non-OEM; allowing you better decision-making ability regarding your service options. In addition to our basic NDE services, we also offer a wide array of advanced services such as UT/PA inspection, thermal imaging crack detection, robotic inspections of generators and retaining rings, and material assessments of turbine components.
Service Innovations with On-Site Machining
As an OEM, we are highly familiar with the specific challenges our customers are facing – such as the need for high availability, long service intervals, shortest possible repair times as well as costs. This is precisely where our cutting edge can play a key role. It bundles our expertise in cutting technologies, automation, and drive technology in innovative service solutions. On-Site Machining offers you a comprehensive portfolio of mobile machine tools for highly complex, time-critical machining operations on gas and steam turbines as well as generators in your power plant. On-Site Machining saves valuable time for transports – and you are ideally equipped to deal with any possible findings, and maintain or reduce planned downtimes of your plant.
Our technological edge begins where we leave standard solutions behind. We have been working with On-Site Machining for decades and have made successions of proprietary developments in this field. This approach is crucial as we continue to meet ever-increasing precision and quality requirements.
Based on our comprehensive expertise in development, design, commissioning and execution of CNC On-Site Machining you will benefit from the solution that we can offer tailored to your need.
This is what you can expect from us
For us, reliability begins with precision. And with the sense of responsibility that comes with offering you the best possible service wherever you may need us. We believe reliability also means working with proven, clearly structured processes and checking our improvements at regular milestones – all with the objective of getting your plant up and running again faster than ever.
Tuning, Commissioning, Balancing and Alignment Services
Field Technology Services (FTS) provides a variety of performance enhancement and evaluation services for nuclear, fossil, combustion and industrial turbine-generators.
Our highly trained and experienced FTS field engineers leverage OEM fleet knowledge, processes and field procedures to provide quality services in the areas of Diagnostics, Metrology & Alignment, and Controls & Auxiliaries.
Dependent upon the scope of work, some services are performed with the unit operating and others during maintenance outages. Benefits that may be realized from these services include:
Rotating Equipment Balancing
Vibration levels in excess of OEM recommended operating limits can cause undue stress to rotating and stationary components. These stresses can potentially result in reduced operating life and accelerated integrity deteriorations. Rotating equipment vibration analysis utilizes proprietary software, SE-MEASURE™, to acquire transient and steady-state vibration data to determine rotor unbalance conditions. Extensive fleet influence coefficients aid field balancing efficiency which can reduce the number of balance moves. Data collection is performed during unit operation, whereas balance moves are performed during a unit shutdown.
SE-MEASURE™ is available for external software licensing. The program drives a 32 channel data acquisition system that utilizes off the shelf hardware.
Slow Speed Balancing
Slow speed balancing can minimize and potentially eliminate the need for field balancing when the unit is returned to service. This process addresses changes in weight distribution of the rotor which can result from blade repair/replacement work. Slow speed balancing is performed during an outage when the rotor is removed from the cylinder or on spare rotors between outages. Balance weight consolidation is performed during the process to maximize the number of balance holes available for field balance needs. Slow speed balance experience list includes: ST and CT turbine rotors, industrial rotors, FD/ID fans, BFPT's and motor armatures.
NOTE: If field balancing has been unsuccessful in reducing elevated operating vibration levels, slow speed balancing may be considered to address changed rotor weight distribution.
Gas Turbine Post Outage Commissioning
Commissioning activities are performed following the completion of maintenance outages or performance enhancements in an effort to maximize the success of the unit startup. Applicable operational and startup service bulletins and internal procedures are also reviewed, for proper unit startup and optimal operational characteristics, per specific site requirements. Toward the end of the outage, a final inspection checklist is performed to confirm that the unit is ready to start.
Checklist inspections include:
Gas Turbine Tuning
Combustion tuning is performed on Gas Turbines with ULN/DLN premix or standard combustion systems operating with natural gas or oil. Unit control settings are optimized in order to help minimize NOx and CO emissions and combustion dynamics. During the tuning process, the gas turbine is loaded to various load points (typically break points on the control curves) within the unit’s normal operating range. In special situations, tuning is also performed at lower loads to improve turndown or startup emissions. Combustion tuning is typically performed when a unit is exiting an outage, but may also be done when an emissions or combustion dynamics issue exists. Seasonal tuning may also be performed, typically at the onset of cold weather and then again when warm weather returns.
3D Optical Coordinate Measuring System
This form of stationary component alignment is used to help optimally align the internal components. This service simplifies and optimizes the internal alignment through the use of photogrammetry principles. Unlike a tight wire or laser, there are no wires to trip on or beams to reset, which can result in improved outage time savings.
Fluid Systems Services
Value-added, engineered solutions
Siemens provides comprehensive and cost effective oil system and piping services. Our work in the power generation industry for over 35 years has enabled us to provide major improvements in the lube oil, seal oil and piping technologies. Siemens’ dedicated team of engineers and technicians utilize this experience to effectively analyze and provide tailored solutions for your fluid systems.
The value of our service is clear
Comprehensive and cost-effective oil system and piping services
Piping inspection and repairs
As in all systems, piping can degrade as it reaches the end of its design life or due to other factors. Long-term exposure to heat and/or water can accelerate degradation, creating a need for more frequent inspections. Siemens provides a comprehensive inspection service for piping systems to look for existing and potential system failures. Fiber optics are used to visually inspect and locate problems in areas such as guarded oil, seal oil and generator gas piping systems. Predesigned piping kits reduce the time required for modification and repairs.
Engineered hydro blast
Significant amounts of water in the oil system can lead to oxidation of the lube oil piping causing a heavy layer of scale build-up. The hydro blast process uses high-pressure water, in excess of 9000 PSI, to blast the scale from the piping surface. An oil rust-inhibitor is applied to protect the piping from oxidation, followed by a high velocity oil flush of both supply and drain lines to remove debris.
Engineered high velocity oil flush
The engineered high velocity oil flush is a unit-specific, sequence-controlled procedure that removes oil system contaminants. Critical elements that accelerate the cleaning process are three-micron absolute high efficiency filters, specially designed adapters for quick connects/ disconnects and above normal high velocity oil flows. All bearing oil and seal oil supply lines are individually sampled to monitor progress and verify the lube oil system’s cleanliness. During the high velocity oil flush, real time ISO oil sampling data is used to trend the cleaning progress. Final acceptance criteria is based on Siemens’ full-flow sampling method, which monitors particle quantities collected through a 150- mesh strainer for 30 minutes.
Chemical Cooler Cleaning
Over time, sludge and debris can build up, reducing the heat transfer ability of the coolers. Equipment damage may occur as dirt gets pushed out of the coolers into the rest of the lube oil system. Cooler cleaning is essential to maintaining lube oil system cleanliness.
Siemens’ investment in R&D has produced many upgrade options to help improve system efficiency and reliability. New designs in filtration, inlet piping, control oil and seal oil systems are available for your unit and can be installed during most scheduled outages. Upgrade options include:
The benefits of using Siemens for youroil system services can include:
Ultrasonic cleaning and testing-for better performance and greater efficiency
Additional offering for SGT5-4000F and SGT6-4000F premix and pilot gas burners
Experience with our fleet of turbines with annular combustion chambers has shown that deposits can form on burners over time during operation depending on the fuel used and the ambient conditions. It can affect operating behavior in many ways, including:
We offer ultrasonic cleaning of the premix and pilot gas burners in combination with dual-flow measurement. You can see what benefits the cleaning provides, and we can verify the success of this key service.
Flow measurement for proven results
In our work process, considerable attention is paid to flow measurement before and after cleaning, because this is a key indicator of the effectiveness of the cleaning. It also provides verification that the cleaning process did not affect operation of your gas turbine. Our internal specifications define in detail the procedure for performing flow measurement.
Using flow measurement, we calculate the effective through flows and the deviation from the mean value of the entire burner set. This allows the cleaning process to be controlled to help prevent damage to the burner. Documentation of the measured values before and after the cleaning provides Siemens Service Engineering with important information for assessing the complex burner system as well as any service measures that may be recommended. Or would you rather rely solely on a visual inspection of the burners?
Siemens’ experience with burner cleaning without thermal pretreatment is that it can in many cases yield less than desirable results. Siemens’ process for thermal pretreatment for burner cleaning is designed to remove organic residues, especially from inside the components to be cleaned. These include residues of, for example, grease, oil, cooling lubricants, and conservation agents as well as combustion residues – and elemental sulfur, which are often difficult or impossible to remove. The components are heated in a furnace and then, after a prescribed dwell time, they are cooled in a controlled process that can take several hours.
Especially in the case of operationally stressed components, loose particles may be present inside the components after thermal treatment has been performed. We remove these particles by blowing them out with compressed air in order to achieve faster results with the citric acid cleaning process described below.
Immersion cleaning in citric-acid bath
The components are placed in the heated citric-acid bath. The cleaning effect of this bath is accelerated and intensified by means of ultrasonic waves of a particular frequency. We can vary the cleaning time according to the thickness and type of contamination. The citric-acid cleaning process can take up to several hours. On the basis of past experience, Siemens typically performs two cleaning cycles on operationally stressed components for maximum effectiveness. Results are also confirmed by post-cleaning flow measurement.
Following the citric-acid bath, the parts are rinsed wet-on-wet inside and out with water.
In order to help prevent rust, non-rustproof components are briefly passivated by immersion in a degreasing bath for a short time after rinsing.
Partially dissolved particle layers can still remain inside the components after the acid treatment. These can then later detach in operation and impair the function of the components. For this reason, we perform another blow out with a compressed air device.
Blowing out with compressed air helps remove remaining particles and dries the components, especially inside, to remove residual humidity which can affect the conservation process.
We visually inspect the burner components for contamination externally and also internally using an endoscope and follow a rigorous process to disposition findings. If we ascertain that there are any large, loose particles still inside, we can draw on further treatment processes which have been approved by Siemens Service Engineering.
Finally, we coat components made of non-rustproof material by immersion in or spraying with a universal corrosion resistance agent.
Translating digital inspection data into smart inspection data
Siemens advanced borescope solutions transfer data into potential trends that can anticipate your needs
Siemens uses smart inspection tools to gather vast amounts of data during turbine inspections. Our engineering expertise combined with the knowledge gained from our vast global Siemens fleet helps us translate this information into smart data.
We use these insights to provide customized value-added solutions based on how your specific equipment operates which leads to lower maintenance requirements, improved reliability and better performance.