Experience using the PI System for

Vibration Monitoring at PGE

Austin Curtis, PGE | Steve Sabin, B&K Vibro

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About Portland General Electric
• Serves ~885 thousand customers in Portland, Salem, and
surrounding Oregon communities (51 cities total)
• 2900 employees
• Five Natural Gas-Fired Plants [CATEGORY
[CATEGORY
NAME]
Plant Capacity NAME]
[PERCENTA
Beaver 509 MW [PERCENTA
GE]
GE]
Carty 437 MW
Coyote Springs 249 MW
[CATEGORY
Port Westward 1 411 MW NAME] [CATEGO
[PERCENTA NAME
Port Westward 2 225 MW [CATEGORY
NAME] GE]
[PERCEN
[PERCENTA #PIWorld ©2019 OSIsoft, LLC GE]
2
GE]
About PGE’s Beaver Plant
• Operating since 1974
• 6-on-1 combined cycle
• Units 1-6: 6 x GE 7B
combustion turbines
• Unit 7: 1 x 155MW
GE steam turbine
• Unit 8: 1 x 25 Alstom
simple-cycle Beaver Plant
Clatskanie, Oregon
combustion turbine

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How our journey began…
July 17, 2015

Hi, I ran across your PI usergroup

presentation and I'm interested in
more information on your CBM.
Portland General Electric operates
three combined cycle, ~400 wind
towers, a sub-critical coal plant, and
two large hydro projects. We're
interested in centralizing our
monitoring efforts for critical
equipment and adding balance of
plant equipment to this effort.

Thanks,
Ken Kubo

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Vibration Monitoring Systems (As-Found)
Unit Machine Size Sensors MPS CMS

1 GE Frame 7B* 60MW Velocity GE Speedtronic None

2 GE Frame 7B* 60MW Proximity GE Speedtronic None
3 GE Frame 7B* 60MW Velocity GE Speedtronic None
4 GE Frame 7B* 60MW Velocity GE Speedtronic None
5 GE Frame 7B* 60MW Velocity GE Speedtronic None
6 GE Frame 7B* 60MW Proximity BN3500 None
7 GE steam turbine 155MW Proximity BN3500 None
8 Alstom GT10B2* 25MW Proximity BN3500 None
Typical as-found monitoring
* Combustion turbines system (Bently Nevada 3500
Series on Beaver Unit 8)

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Velocity Vibration Measurements

Velocity
(in/sec 0-pk)

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Proximity Vibration Measurements

Y-probe X-probe

Displacement
(mils pk-pk)

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Problems

1. No online ConMon = no data when needed

• Reactive – not there when problems occur
• Gather data “after the fact” (problem may no longer be
present); scene of the crime may be devoid of evidence.
• Often MISS critical data – no means to forecast and model

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Problems

2. No remote access
• Specialist flies to site to collect data manually
• Requires moving people, not data; involves plane tickets and
5-hour travel times
• SLOW

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Problems
3. Siloed data
• Incumbent provider’s CM
software entails a separate
“silo” just for vibration data
• Integration effort to combine
and determine cause/effect VIBRATION PROCESS
• Additional IT burden DATA DATA
(2 systems)
• Not in PI = Not accessible to
other analytic tools such as
APR

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Problems

4. “Closed” data
• Special viewer software and licensing required
• Hard to share data when/where needed
• FTP sites required to share large files
• Impedes collaboration to solve problems

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Problems

5. Can’t easily build/share “asset health”

dashboards with plant management
• Extra integration effort to do in PI
• Extra software licensing and training to
do in native CM environment

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Solution: PUT THE DATA INTO PI!
SETPOINT® Edge Device and
Machines PI System
Machinery Protection System

ALL*
Vibration
Vibration
Sensors
Data

*Includes high-speed
waveform data

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Vibration Monitoring Systems (As-Left)
Unit Machine Size Sensors MPS CMS

1 GE Frame 7B* 60MW Proximity SETPOINT SETPOINT

2 GE Frame 7B* 60MW Proximity SETPOINT SETPOINT
3 GE Frame 7B* 60MW Proximity SETPOINT SETPOINT
4 GE Frame 7B* 60MW Proximity SETPOINT SETPOINT
5 GE Frame 7B* 60MW Proximity SETPOINT SETPOINT
6 GE Frame 7B* 60MW Proximity SETPOINT SETPOINT
7 GE steam turbine 155MW Proximity BN3500 SETPOINT
8 Alstom GT10B2* 25MW Proximity BN3500 None
Integrates machinery
* Combustion turbines protection and condition
monitoring functions

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Enables

1. Online ConMon = never miss important data

• Specialist analyzes data, rather than collects data
• Proactive – doesn’t matter if not there when problems occur
• i-factor technology detects change automatically and does
not rely on human-intensive alarm setting/management

ALL DATA PRESENT

AND ACCOUNTED FOR!
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Enables

2. Remote access
• Data is accessible remotely and securely to offsite specialist
• Can access in minutes instead of hours
• Move data, not people

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Enables
3. Integrated data
• Uses PI as repository for all
data
• Process and vibration is in one PROCESS
place; correlation and DATA
cause/effect more easily VIBRATION
ascertained +
DATA
• Reduced IT burden VIBRATION
(1 system) DATA
• In PI = Accessible to other
analytic tools such as APR

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Enables

4. Viewer software is PI and special

free download
• Open (.cms) file format similar in concept to
PDF
• Easy to share data when/where needed
• No extra licenses or fees
• Enhances collaboration to solve problems

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Enables

5. Easily build/share “asset health”

dashboards with plant management
• No special integration effort to do in PI
• Can drill down to special visualization tool when required
to do deep diagnostic analysis

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 DEMO
Sample Screens for Anomaly Detection

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 Compare cold starts
using event frames

PI Vision screen w/
bearing amp / phase data

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 PI Vision screen overlaying
cold start events

Drill down even further into CMS Display

app to view WAVEFORMS and specialized plots
in region of interest (e.g. startup)

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 Now in CMS Display app
w/ “deep dive” tools

Full Spectrum Cascade

Orbit / Timebase (frequency domain waveforms)
(time domain waveforms)

Time slider
with multi-variable trends
(80ms resolution)
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 Now in CMS Display app
w/ “deep dive” tools

Bode Plot
(amp/phase vs. speed)

Polar Plot
Detailed profile showing startup, (amp/phase vs. speed)
steady-state, and shutdown

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 Portland General Electric
Putting comprehensive vibration data into the PI System

CHALLENGE SOLUTION RESULTS

No online condition monitoring SETPOINT® Edge Device Overall company risk

data when machinery decisions streamed all vibration data into significantly reduced.
needed to be made. existing PI System
• Eliminated separate infrastructure;
• Incumbent system required used PI System already installed • Can now identify critical asset
expensive additional infrastructure • All data in same “system of record” for health accurately
ease of correlation • We know when we’re healthy (and
• Offline approach was too reactive
and involved 10-hour roundtrip • Accessible to everyone in the plant when we’re sick)
travel to/from site • WAVEFORMS IN PI! • Data analysis done in 1 hour
(the key to accurate analysis) instead of 15+ hours

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 Questions? Please remember

Please wait for

the microphone
DOWNLOAD
THE MOBILE
State your
APP
name & company

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Your presenters
• Austin Curtis
• Maintenance Manager
• Portland General Electric
• [email protected]
• Steve Sabin
• VP – Marketing & Product Management
• Brüel & Kjær Vibro
• [email protected]
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