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System 1® SoftwareGE´s Optimization and Diagnostics PlatformUS Patent # 6421571
Agenda
Bently Nevada by the numbers
The Business Challenge?
What is System 1® Software?
How is Value Delivered?
Please Feel Free to Ask Questions
Bently Nevada by the numbers
• 1700 Employees• 100 Sales & Services world wide offices• 2 million transducers• 2000 Software Systems• 30000 Projects/ Services Completed
Agenda
Bently Nevada by the numbers
The Business Challenge?
What is System 1® Software?
How is Value Delivered?
Please Feel Free to Ask Questions
Today’s Business ChallengeProfitability through Optimization
1) Equipment Availability
2) Equipment Reliability
3) Optimized Maintenance Spend
4) Capture, Embed, & Use Knowledge
5) Continuous Improvement Processes
How to do MORE with LESS?
How to Increase the
Effectiveness & Efficiency of Our
People
Today’s Business ChallengeFully Utilizing Your Data
Too much Data…Not enough Information!!!
What we Need is… INFORMATION!
Vibration
Analysis
Oil / Lube Analysis
Motor Curren
t
Thermo-graphy Imagin
g
Data Historian
Manual Logs
Doc’s, Guides, & Manuals
Thermo-Dynamic Perform.
Boiler Optimizatio
nWater
System Mgmt
Electrical
Systems
DATA
Stand-Alone Data Systems
DCS
BusinessBusinessERP, CMMSERP, CMMS
ProcessAdvanced Process ControlAdvanced Process Control
Platform = Maximo
Platform = DCS
Plant Assets Plant Asset ManagementPlant Asset Management
Platform = System1™
Integrated Platforms – key aspects for optimization
Today’s Business ChallengeProfitability through Optimization
Why Plant Asset Optimization?
Optimization of plant asset performance and reliability is essential to meeting the challenge of increased production at lower costs - a situation faced by many companies in a world of increased competition
Improved:Improved:• Safety, environmental compliance• Reliability, availability, throughput, quality• Maintenance planning and scheduling• “Wrench time”• Spare parts inventory
Reduced:Reduced:• Downtime• Energy consumption• Maintenance costs
Plant Asset Optimization
How is Plant Asset Optimization Achieved?
Corrective Maintenance
Work Management
Personnel Training
Data / Information
Technical Documents
Inventory Control
Policies & Procedures
Reliability Analysis
PM / Pdm Maintenance Problem Solving
Plant Design Changes Disposal / Surplus
Performance Measures
Capital Planning Reporting
ReliabilityStaff/Public
SafetyProductivity
Regulatory Compliance
O&M Budget
Impacts
Quality
TechnologyTechnology
MethodologyMethodology
PeoplePeople
Agenda
Bently Nevada by the numbers
The Business Challenge?
What is System 1® Software?
How is Value Delivered?
Please Feel Free to Ask Questions
Today’s Business ChallengeFully Utilizing Your Data
Too much Data…Not enough Information!!!
What we Need is… INFORMATION!
Vibration Analysis
Oil / Lube Analysis
Motor Current
Thermo-graphy Imaging
Data Historian
Manual Logs
Doc’s, Guides, & Manuals
Thermo-Dynamic Perform.
Boiler OptimizationWater
System Mgmt
Electrical Systems
DATA
Stand-Alone Data Systems
DCS
Emissions• CEMs• Optimization
Fuel Handling System• Optimization• Pump monitoring• Valve position• Fuel quality• Fuel flow• Piping – Separators, Filters, etc.
HRSG• Efficiency • Water Quality• Duct Burner monitoring
Cooling Towers• Efficiency• Water Quality• Flow measurement• Pump monitoring• Chemical Injection System
Excitation• Digital Generator
Protection (DGP)
Inlet Foggers• Optimization• Flow Measurement• Water quality• Inlet pressure• Ambient Humidity• Pump monitoring
Gas Turbines• Efficiency• Optimization• Temperature• Vibration• Flame Sensors
Transformers• Cooling Systems• Load Tap Changers• Dissolved Fault Gases• Oil Analysis• Pump Monitoring
Lube Oil System• Pump monitoring• Oil quality• Oil flow• Piping – Filters, etc.
Steam Turbines• Efficiency• Temperature• Case & DE Expansion• Vibration
Generators• Vibration• Temperature• Hydrogen Cooling• Moisture
Instrument Air System• Vibration • Temperature• Moisture
Raw Water Conditioning• Water Quality• Flow Measurement• Pump Monitoring
Switchgear• Operating Coil Monitoring• Pneumatics & Hydraulics• Gas Temp & Pressure
What is System 1?
What is System 1?
Actionable Information to People and Systems
OPERATORS
MAINTENANCE ENGINEERS
MANAGERS
FINANCIAL DATA ERP, SAP, etc.
RELIABILITYDATA
PROCESS DATADCS, Historian
MAINTENANCECMMS Interfaces
MAXIMO
System 1™ Interfaces
SYSTEMS
ACTIONABLE INFORMATION
MEASUREMENTS & MONITORING
System 1®
DECISION SUPPORT
System 1®
DATA ACQUISITION
DIAGNOSTICS
ApplicationPackages
System 1™ Software PlatformSystem 1™
What is System 1TM?Optimization and Diagnostics for Applications
TurboMach
Assets
Thermo-Dynam. Perform
Portable Data
& On Line Periodic
2. The Platform Provides a Common Technology Base to Expand Systems…and…Pre-Engineered Application Integration!
DATA
Thermo-graphy
Analysis
Fired/ Fixed
Assets
Elect. Assets
& Motors
Lube Oil
Platform
1. The Application Packages Deliver Value for “Targeted” Applications.
Cool BearingHot Bearing
Trendmaster &Wireless
Integrated Suite of Applications on one Platform
System 1™ Platform
What is System 1?Optimization and Diagnostics for Users
Coal Fired
Boilers
Thermo Perform-
ance
Critical Rotating Assets
Recip. Assets
BOP Assets
Wind Turbine
Oil & Lube
Analysis
Water Chem
…
Other
Display
Selectively Delivering Information to UsersSelectively Delivering Information to Users
Internet
OEM
Rot EquipmEngineer
3rd PartyConsultant
Plant Operator Instrument
Tech ReliabilityEngr
PlantMgmt
Information Users
System1 Helping to Make Better Decisions
What is System1A plant set up
Machine Control System
Control Network
Modbus Gateway orIntegrator Device
DCS Man MachineInterface (MMI)
PROTECTION
Alarm Contacts
Reliability Maximo
OPC or DDE
Historian
Hub
Critical Machinery
Industrial Gas Turbine Generator Industrial Gas Turbine Generator
Critical Machinery
Non Critical Machinery
Lets demonstrate System1
Questions so far?
A few screen shots are shown in the following slides.
Please see notes for explanations.
Agenda
Bently Nevada by the numbers
The Business Challenge?
What is System 1® Software?
How is Value Delivered?
Please Feel Free to Ask Questions
How is Value Delivered By providing Actionable Information (not only data)
Actionable Information to People and Systems
FINANCIAL DATA ERP, SAP, etc.
RELIABILITYDATA
PROCESS DATADCS, Historian
MAINTENANCECMMS Interfaces
System 1™ Interfaces
MEASUREMENTS & MONITORING
OPERATORS
MAINTENANCE ENGINEERS
MANAGERS
SYSTEMS
ACTIONABLE INFORMATION
System 1®
DECISION SUPPORT
System 1®
DATA ACQUISITION
DIAGNOSTICS
Compressor Failed
Ass
et F
ailu
re Rotor FailureCoupling Failure
Driver FailureBearing Failure
Y = x1 + x2 + x3 + x4+x5
Filter Failure
Fai
lure
Mod
es
Quality Failure
Installation problemFilter blocked y53 = x531 + x532 + x533
Pro
ble
m T
ype
FOD
No cleaining of suction liney533 = x5331+x5332+x5333+x5334
Data set needed – Filter Delta P, Dis ch Temp,1X Vibration, Sub Synchronos Vibration
Dirty Gas
Sym
pto
ms
1X VibrationFilter delta P Increase
Sub Synchronous VibrationDischarge Temp Increase
y5 = x51 + x52 + x53
How is Value Delivered Build Rules Using Failure Mode Effect Analysis
A Machinery Malfunction Rule- Inlet Filter Fouling -Inputs
Results
Functions
How is Value Delivered Embedding Knowledge in the System
How is Value Delivered Embedding Knowledge in the System
An Action Plan
Alarm Level
Notification / Actions to be taken
Asset
Malfunction Type
Date malfunction occured
There are 5 ways in System1 for notification- Smart Notifier- Beeper/ Text message- Event Relay Notifcation- Email message- MAXIMO Notification
How is Value DeliveredLeveraging Knowledge to the right systems or persons
How is Value DeliveredEmbedding and Leveraging Knowledge
Digitizing and Using Your Knowledge
Manageable Processes
Define Business Need & ObjectiveEmbed Knowledge as Rules, Action Plans, and……Communication Plans (Notification Advisories)Leverage Your Data, Processes, & People
++
Early Event Detection
Early Event Detection
Action Plans
(Knowledge)
Action Plans
(Knowledge)
Comm Plans
(Knowledge)
Comm Plans
(Knowledge)
RCM
Actionable Information
How is Value DeliveredSharing Knowledge with MAXIMO and Feedback of Knowledge
System1 will automatically send a work-request to MAXIMO
Information about the event configured in System1™
MAXIMO Notification Configuration Step 1
about which Assets?
at what severity levels?
for which categories of problems?
MAXIMO Notification Configuration Step 2
Following fields determined by Maxmimo User;-Reported by-Failure Class-Problem Code-Work Type
MAXIMO Notification Configuration Step 3
Linking Equipment in S1 with Equipment in CMMS
Let see how System1 integrates to Maximo
Questions so far?