Presentation on theme: "System 1® Software GE´s Optimization and Diagnostics Platform US Patent # 6421571 System 1™ SW is a significantly different product than previous BN SW."— Presentation transcript:
1 System 1® Software GE´s Optimization and Diagnostics Platform US Patent # 6421571 System 1™ SW is a significantly different product than previous BN SW products. As we will cover in the rest of the discussion, System 1™ offers users a number of targeted application packages for managing plant assets…leveraging a common SW Platform.There are two additional points to make in this introduction:1. System 1™ has recently been granted a US patent (# ) and there are a few more pending. The patent essentially covers a number of key capabilities related to managing groups of assets, diagnostic tool capabilities, and all existing on one SW platform.2. Bently Nevada is a MS Solution provider. System 1™ utilizes MS products under the hood. Our relationship with MS gives us access to MS tools, people, and future development information enabling us to better develop, deliver and support System 1™.
2 Please Feel Free to Ask Questions AgendaBently Nevada by the numbersThe Business Challenge?What is System 1® Software?How is Value Delivered?Please Feel Free to Ask Questions
3 Bently Nevada by the numbers 1700 Employees100 Sales & Services world wide offices2 million transducers2000 Software Systems30000 Projects/ Services CompletedBently Nevada Sweden AB has a sales office located in Solna. Our service organization covering Scandinavia and Finland has service representatives located in Sweden, Finland and Norway.Bently Nevada Sweden ABBox 1567SolnaTelephone: +46 (0)Telefax: +46 (0)
4 Please Feel Free to Ask Questions AgendaBently Nevada by the numbersThe Business Challenge?What is System 1® Software?How is Value Delivered?Please Feel Free to Ask Questions
5 Today’s Business Challenge Profitability through Optimization How to Increase the Effectiveness & Efficiency of Our PeopleEquipment AvailabilityEquipment ReliabilityOptimized Maintenance SpendCapture, Embed, & Use KnowledgeContinuous Improvement ProcessesHighly competitive businesses are continuously challenged to be more effective and efficient with all available resources.Common Metrics for Business Leaders include:Increased Plant Availability…Equipment are a key element of this. Being able to seize a short term market opportunity to sell their product at a higher price can make the difference for profitability.Equipment reliability is essential to achieve profitability targets. There are many different metrics but all strive to measure the success of plant maintenance processes and programs.Maintenance expenses are necessary but the objective is to get the most for every “$” spent. This includes condition based maintenance rather than time based maintenance and selective maintenance scope based on component condition information. Many business leaders are even willing to spend more on maintenance if they can get an even greater return on availability. It is best not to work on equipment if no problem existing.Capturing and using knowledge is essential to work smarter rather than harder. Most businesses are faced with a reduced work force and the loss of experts in the plant. This trend is expected to continue and leads to a challenge for how to prevent recurring problems and to quickly make proper decisions.Businesses must put programs and processes in place to enable them to identify the most significant opportunities to improve the business, embed lesson learned, and build on successes.Overall…businesses are challenged to fully leverage their data, systems, and people.How to do MORE with LESS?
6 Today’s Business Challenge Fully Utilizing Your Data What we Need is… INFORMATION!Stand-Alone Data SystemsDoc’s, Guides, & ManualsVibration AnalysisDATAThermo-graphy ImagingMotor CurrentDCSData HistorianManual LogsOil / Lube AnalysisElectrical SystemsMost plants have a wealth of data. In fact, in many cases there is simply too much data and not enough people to review it.Experts can looks at data and produce information. However, there are fewer and fewer experts available.The challenge is in figuring out how to effectively and efficiently distill the data into valuable information…and then deliver it to the right people at the right time. Information enables all people to make decisions and take appropriate actions.Ideally, to do so quickly and consistently 24 hours a day, 365 days a year.Boiler OptimizationThermo-Dynamic Perform.Water System MgmtToo much Data…Not enough Information!!!
7 Today’s Business Challenge Profitability through Optimization ERP, CMMSPlatform = MaximoProcessAdvanced Process ControlPlant AssetsPlant Asset ManagementPlatform = System1™This slide looks at the business broken down into three components. Each component uses a modern day concept to optimize it. For example, Business Management is typically done using the concept of Enterprise Resource Planning. The leading edge technology today would be SAP or Oracle software platforms.Similarly, managing equipment effectively and efficiently means a modern management methodology. Plant Asset Management (with Information) is the concept, System 1 is the software platform that enables it.Process optimization has been given a lot of attention in the past decade with large investments made in “advanced process control” systems. They enable process bottlenecks to be identified and optimized.Caution: Most process control systems apply instrument management techniques to mechanical equipment health. Caution: it takes a lot more data to manage a mechanical asset than it does to control it.One example is the difference between “static” (amplitude only) data and “dynamic” (for example, high speed Digital Signal Processing of vibration signals) data. The dynamic data needs to be sampled at rates well beyond a process control system. It needs to be able to capture transient events, trips, startups, alarms by capturing all the dynamic data in parallel, and all synchronized to be able to be used for Root Cause Failure Analysis. System 1 enables this and enables the collection and storage of static data at rates of up to 0.1 second for all channels connected to the system. System 1 is capable of doing this for machinery while also collecting “static data” from other mechanical, electrical, instrument assets.Platform = DCSIntegrated Platforms – key aspects for optimization
8 Why Plant Asset Optimization? Production & SafetyImproved:Safety, environmental complianceReliability, availability, throughput, qualityMaintenance planning and scheduling“Wrench time”Spare parts inventoryReduced:DowntimeEnergy consumptionMaintenance costsMaintenance CostsPlant Asset OptimizationIncreased production and safety at lower costs is a situation most companies face in a world of increased competition. Plant asset optimization is essential to meet these challenges.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
9 How is Plant Asset Optimization Achieved? Corrective MaintenanceWork ManagementPersonnel TrainingData / InformationTechnical DocumentsInventory ControlPolicies & ProceduresReliability AnalysisPM / Pdm MaintenanceProblem SolvingPlant Design ChangesDisposal / SurplusPerformance MeasuresCapital PlanningReportingTechnologyMethodologyPeopleSuccessful Plant Asset Optimization requires strategic integration of technology, maintenance best practices, processes, and reliability methodologies in a coordinated, sustainable program and change in cultureImpactsReliabilityStaff/PublicSafetyProductivityQualityRegulatoryComplianceO&M Budget
10 Please Feel Free to Ask Questions AgendaBently Nevada by the numbersThe Business Challenge?What is System 1® Software?How is Value Delivered?Please Feel Free to Ask Questions
11 What is System 1? Switchgear Emissions HRSG Steam Turbines Operating Coil MonitoringPneumatics & HydraulicsGas Temp & PressureEmissionsCEMsOptimizationHRSGEfficiencyWater QualityDuct Burner monitoringSteam TurbinesEfficiencyTemperatureCase & DE ExpansionVibrationInlet FoggersOptimizationFlow MeasurementWater qualityInlet pressureAmbient HumidityPump monitoringGeneratorsVibrationTemperatureHydrogen CoolingMoistureGas TurbinesEfficiencyOptimizationTemperatureVibrationFlame SensorsCooling TowersEfficiencyWater QualityFlow measurementPump monitoringChemical Injection SystemTransformersCooling SystemsLoad Tap ChangersDissolved Fault GasesOil AnalysisPump MonitoringLube OilSystemPump monitoringOil qualityOil flowPiping – Filters, etc.ExcitationDigital Generator Protection (DGP)The picture and examples of assets in this slide come from the power industry, which is one traditional core business for Bently Nevada. However, it could just as well be any facility where you monitor, trend and manage assets, such as petro chemical, steel, pulp & paper, hospitals, manufacturing, assembly, process, food and more.As mentioned earlier in the miniature slide in the left, bottom corner regardless of industry a common challenge is the huge amount of data collected from different assets and often presented in different stand-alone data systems. System1 is a platform where data from all different kinds of systems can be gathered, analysed and presented in one common user interface.Fuel Handling SystemOptimizationPump monitoringValve positionFuel qualityFuel flowPiping – Separators, Filters, etc.InstrumentAir SystemVibrationTemperatureMoistureRaw WaterConditioningWater QualityFlow MeasurementPump Monitoring
12 ACTIONABLE INFORMATION FINANCIAL DATA ERP, SAP, etc. What is System 1?SYSTEMSACTIONABLE INFORMATIONOPERATORSMAINTENANCEENGINEERSMANAGERSSystem 1®DECISION SUPPORTDIAGNOSTICSFINANCIAL DATA ERP, SAP, etc.RELIABILITYDATAPROCESS DATADCS, HistorianMAINTENANCECMMS InterfacesMAXIMOSystem 1™ InterfacesSystem 1®DATA ACQUISITIONSteps to explain this slide:The vertically integrated components of System 1 are shown first. The system is vertically integrated, backward compatible, one vendor for all assets.System 1 is the focal point for all other data associated with understanding the mechanical (and thermodynamic) condition of the asset. DCS: Asset Critical process data CMMS: Asset status (running, down, overhaul), work history, faults, costs, etc Reliability: Availability, MTBR, MTTR, Pareto driven priorities, probability and prediction of failure. ERP: Financial data, plant production yield, throughput, $/Maintenance Unit, Revenues, Operation costs.Note the CMMS and Reliability systems only deal with Data. They are not connected to the asset directly.Decision Support AUTOMATES the process of converting data into information.It is vital to correlate data from all sources. Once correlated Decision Support can be configured to Convert data into Information.The final part of the slide shows the loop being closed using Notifier to send , advisories, specific information to specific users.Feedback loop is vital part of Plant Asset Management. The overall strategy is to use feedback to continuously improve. That is the essence of Reliability Centered Maintenance and Total Productive Maintenance.MEASUREMENTS & MONITORINGActionable Information to People and Systems
13 What is System 1TM? Optimization and Diagnostics for Applications Trendmaster &WirelessCool BearingHot BearingWhat is System 1TM? Optimization and Diagnostics for ApplicationsThe Application Packages Deliver Value for “Targeted” Applications.The Platform Provides a Common Technology Base to Expand Systems…and…Pre-Engineered Application Integration!ApplicationPackagesTurboMachAssetsThermo-Dynam. PerformPortable Data&On Line PeriodicElect. Assets&MotorsFired/ Fixed AssetsLube OilThermo-graphy AnalysisPlatformSystem 1™System 1™ Software PlatformWe call System 1™ a platform, because it was developed to integrate all Condition Monitoring applications, other Asset Management applications, and provide an interfaces to other plant information systems. This slide shows several examples of applications within System1. Other examples are Reciprocating assets, water treatment/chemistry, wind turbines, hydro turbines and more.DATAIntegrated Suite of Applications on one Platform
14 What is System 1? Optimization and Diagnostics for Users Selectively Delivering Information to UsersOEMRot EquipmEngineer3rd PartyConsultantPlantOperatorInstrumentTechReliabilityEngrMgmtInformation UsersInternetDisplayCritical Rotating AssetsRecip. AssetsBOP AssetsThermo Perform-anceCoal Fired BoilersOil & Lube AnalysisWind Turbine…Water ChemSystem 1 consists of many targeted applications and the base platform. Information from the system can be delivered in many formats.OtherSystem 1™ PlatformSystem1 Helping to Make Better Decisions
15 What is System1 A plant set up ReliabilityMaximoOPC or DDEHistorianNon Critical MachineryDCS Man MachineInterface (MMI)Control NetworkPROTECTIONModbus Gateway orIntegrator DeviceExample of a system layout in a plant consisting of rotating machines of different criticality. The criticality determines the type of system connected to System1. As discussed earlier System1 can by used in any type of plant and not just plants with rotating equipment. No matter how the data from different assets is collected it can be imported to System1 via OPC, DDE, ModBus or other protocols.Data (e.g vibration, temperature, pressure, ...) from critical machinery is acquired by System1 through a protection system. The protection system is equipped with relay outputs for alarm notifications and trip signals.From non critical machinery data can be acquired through an on-line scanning system or an off-line portable system.Process data from the DCS system is acquired via OPC, DDE, ModBus or other protocols.Other systems, such as CMMS, reliability systems and historians can also communicate with System1 via OPC, DDE, ModBus or other protocols.Alarm ContactsCritical MachineryCritical MachineryMachine Control System
16 Lets demonstrate System1 Questions so far?Lets demonstrate System1A few screen shots are shown in thefollowing slides.Please see notes for explanations.
17 The System1 Display can be customized to suit every individual user The System1 Display can be customized to suit every individual user. In this example The box at the top represents the enterprise view, where all levels in the enterprise are shown as graphics. In this picture two machine trains are shown. Buy double clicking on one train the next level with details on specific components of that machine train appear.The lower left box represents the enterprise hierarchy where all levels of the enterprise are shown in a ”tree structure”. It is possible to navigate through the enterprise in the hierarchy as well as in the enterprise view.The lower right box represents tailor made plot session. Each user can set up plots frequently used for quick access. All plots can also be reached manually by using the plots drop-down menu or the icons on the top of the page.Other examples of views are instrument views and hierarchies, collection groups and bargraph sessions.
18 By double clicking one of the plot sessions in the previous slide a pre configured plot appears. In this example a performance plot (Efficiency vs. Flow) for the Propane Compressor is shown.
19 This is an example of a rotor/stator plot from a hydro power station. The Rotor/Stator Plot displays “roundness” and “center offset” values for both the rotor and the stator, based on mathematical analysis of the air gap readings. This plot requires that at least 4 air gap sensors are installed in the generator – and that they are properly configured in the System 1 Enterprise – in order to ensure that the waveform samples are correctly time synchronized. Any even number of sensors can be used, up to a maximum of 16.Sensor locations are indicated on the outer (stator) curve as blue triangles. This curve is a “derived” data set, since there are no sensors actually looking outward from the rotor toward the stator. The math is fairly involved, but it can be summarized: First, the air gap at each probe location is combined to calculate a mean air gap over all poles passing in front of the probe. The stator shape curve is then interpolated based on comparing the individual measurement at each probe with the mean air gap value.Each sample on the stator curve represents a tooth on the stator . The number of teeth on the stator is configured through the System 1 Configuration application. When moving through samples on the stator curve, the plot header will show the currently-selected tooth. Similarly, the inner curve (rotor) is plotted with each sample representing a pole. The distance between the two curves is the air gap. When moving through samples on the rotor, the header shows the current pole number.
20 This is an example of a Pressure vs This is an example of a Pressure vs. Volume plot for a reciprocating compressor.Data plotted versus percent displaced volume. This format of cylinder pressure data shows the cylinder pressure on the vertical axis and the displaced volume on the horizontal axis.This format is very useful for detecting valve condition, pressure ring condition and pressure packing condition.
21 System1 contains a module called Decision Support System1 contains a module called Decision Support. Decision Support will be discussed later in the presentation but in short it is used to correlate all data collected in System1 and transform it to actionable information.This information can be communicated via s, cell phones, pop-up screens ,...The information answers the following questions;What is the problem?Where and when did it happen?How bad is it? The severity is configured in a 1-4 scale, where 4 represents the highest severity.What data is this notification based on? All data is accessible for further analysis.What is the recommended action? Actionable Information configured for each specific situation.
22 If an event occurs through Decision Support it is always possible to get supporting evidence. What data is this event based on? Is the data OK?
23 Please Feel Free to Ask Questions AgendaBently Nevada by the numbersThe Business Challenge?What is System 1® Software?How is Value Delivered?Please Feel Free to Ask Questions
24 ACTIONABLE INFORMATION FINANCIAL DATA ERP, SAP, etc. How is Value Delivered By providing Actionable Information (not only data)OPERATORSMAINTENANCEENGINEERSMANAGERSSYSTEMSACTIONABLE INFORMATIONSystem 1®DECISION SUPPORTDIAGNOSTICSFINANCIAL DATA ERP, SAP, etc.RELIABILITYDATAPROCESS DATADCS, HistorianMAINTENANCECMMS InterfacesSystem 1™ InterfacesSystem 1®DATA ACQUISITIONRefer to slide 12.Up to “diagnostics” the system can be used to analyse what has happened in the past and perform a root cause failure analysis. High resolution data from just before, during and after an event is captured and stored for future analysis.Knowledge from the root cause failure analysis as well as other knowledge can be embedded in the Decision Support module to automatically warn early about events that are about to happen and communicate information to different users how to avoid it.MEASUREMENTS & MONITORINGActionable Information to People and Systems
25 How is Value Delivered Build Rules Using Failure Mode Effect Analysis Compressor FailedY = x1 + x2 + x3 + x4+x5Rotor FailureCoupling FailureAsset FailureBearing FailureDriver Failurey5 = x51 + x52 + x53Filter FailureQuality FailureFailure ModesFilter blockedy53 = x531 + x532 + x533Installation problemFODy533 = x5331+x5332+x5333+x5334Problem TypeNo cleaining of suction lineDirty GasSymptoms1X VibrationFilter delta P IncreaseSub SynchronousVibrationDischarge Temp IncreaseFailure Mode and Effect Analysis (FMEA) is one of many tools to embed knowledge into the system. This tool is used to pro-actively analyse possible failure modes of an asset and the effect of these failure. How this tool can be used to embed knowledge into System1 will be explained in the coming slides.What can fail on a compressor? In this examples we concentrate on filter failure.What failure modes can a failing filter have? In this examples we proceed with filter blocked.What problem types can a blocked filter have? In this examples we look at dirty gas.What are the symptoms of dirty gas?Discharge temperature increase1X vibrationsSub synchronous vibrationIncreased delta pressure over the filter.If these symptoms can be detected they can form the inputs to a rule in Decision Support that will detect at an early stage that the compressor is about to fail.Data set needed – Filter Delta P, Dis ch Temp,1X Vibration, Sub Synchronos Vibration
26 A Machinery Malfunction Rule - Inlet Filter Fouling - How is Value Delivered Embedding Knowledge in the SystemA Machinery Malfunction Rule- Inlet Filter Fouling -InputsFunctionsResultsThe inputs from the previous slide can be used to write a rule on how to detect a fouling filter. The inputs are combined with different functions to form results. The results have different severities as the fouling progresses.If the delta pressure is greater than 0,2 the result has a severity level of 1.If the delta pressure is greater than 0,3 and the discharge temperature is 10 degrees greater than designed temperature the result has a severity level of 3.If the delta pressure is greater than 0,4 and the direct vibration is greater than 3,0 the result has a severity level of 4.
27 How is Value Delivered Embedding Knowledge in the System An Action PlanAlarm LevelMalfunction TypeAssetDate malfunction occuredTo the results on the previous slide Actionable Information can be tied. This information can be communicated via s, cell phones, pop-up screens and more.The information answers the following questions;What is the problem?Where and when did it happen?How bad is it? The severity is configured in a 1-4 scale, where 4 represents the highest severity.What data is this notification based on? All data is accessible for further analysis.What is the recommended action? Actionable Information configured for each specific situation.Notification / Actions to be taken
28 How is Value Delivered Leveraging Knowledge to the right systems or persons There are 5 ways in System1 for notification- Smart Notifier- Beeper/ Text message- Event Relay Notifcation- message- MAXIMO NotificationThere are 5 ways in System1 for notification- Smart Notifier- Beeper/ Text message- Event Relay Notifcation- message- MAXIMO Notification
29 How is Value Delivered Embedding and Leveraging Knowledge Manageable ProcessesComm Plans(Knowledge)Early EventDetectionAction Plans(Knowledge)++Actionable InformationAs discussed earlier successful plant asset optimization must involve;TechnologyMethodologyPeopleEarly detection of a problem must be matched with an action plan and a communication plan to form actionable information.Define Business Need & ObjectiveEmbed Knowledge as Rules, Action Plans, and……Communication Plans (Notification Advisories)Leverage Your Data, Processes, & PeopleRCMDigitizing and Using Your Knowledge
30 Information about the event configured in System1™ How is Value Delivered Sharing Knowledge with MAXIMO and Feedback of KnowledgeSystem1 will automatically send a work-request to MAXIMOInformation about the event configured in System1™Information configured in System1 can be view in Maximo by double clicking the work order.
31 MAXIMO Notification Configuration Step 1 about which Assets?at what severity levels?for which categories of problems?There are three steps to configure the Maximo link in System1. In the first step it is configured for which assets, for what kind of problems and at what severity levels information from System1 should be sent to Maximo.
32 MAXIMO Notification Configuration Step 2 Following fields determined by Maxmimo User;-Reported by-Failure Class-Problem Code-Work TypeIn the second step the following fields are determined by the Maxmimo User;-Reported by-Failure Class-Problem Code-Work Type
33 MAXIMO Notification Configuration Step 3 Linking Equipment in S1 with Equipment in CMMSIn the third and last step the equipment in System1 is linked to the equipment in Maximo.
34 Let see how System1 integrates to Maximo Questions so far?Let see how System1 integrates to Maximo