Power 

Health data improves planning, prevents damage & saves costs
Information about machinery health and prediction of future development of detected faults help the staff plan pit stops and revisions, and to decide and prioritize which machinery need maintenance. The plant operators check the early warning messages issued by the monitoring system on a daily basis. To verify the seriousness of detected faults, they are supported by DONG Energy engineers, who combine the remotely monitored health data with operational data (load, temperature etc.) using the monitoring system’s diagnostic tools.

“In most cases we conclude from the data that a machine can safely run at normal or adjusted operational conditions until the next planned overhaul. The fact that we don’t have to immediately stop and disassemble a machine for inspection saves repair costs and unplanned downtime. Emergency stops also have a negative impact on our NOx emissions. And with spare part delivery times of up to 6 months, early warnings are crucial,” Mr. Lange emphasizes.

Examples of downtime and costs, DONG Energy has avoided because early fault detection enabled repair during the next planned overhaul:

• Rolling element and outer race defects on recirculation fan motor. Avoided potential damage costs of approx. EUR 70,000
• Critical shaft damage on main water cooling pump. If unnoticed, it could have run to failure and caused damage and costs around EUR 67,000
  Diagnosed resonance problem in cooling water pump enabled the staff to adjust the operational mode in order to avoid critical speed range
• Vibration problem on turbo expander gas pipes was identified and a solved before it posed a serious risk to people and machinery. Worst case for such a high impact, low probability problem could be fatalities and downtime for more than a month with a production loss of up to EUR 2 million.