GE - Bently Nevada Product Line

A Leader in Machinery Protection and Condition Monitoring

The Bently Nevada name

has been synonymous with
machinery protection and
condition monitoring for over
50 years. Our expertise
delivers you advanced,
high-quality machinery
monitoring solutions for
optimum plant safety, uptime
and efficiency.

Industry spend on condition monitoring is ~$1.8B annually

GE provides technology leadership for the industry 1/
GE /
November 9, 2018
 2/
GE /
November 9, 2018 13
Advancement
s in Motor
Condition
Monitoring
Part 1 – Motors and their
failure modes
Faults covered by AnomAlert
Environmental Mechanical
Process
Supply

Motor

Driven equipment
Transmission
Electrical
Operational
5/
GE /
November 9, 2018
Electrical faults
Fault type Causes Effects Impact
Supply distortion Bad supply or Stator or rotor Energy cost
conditioning overheating,
vibration, efficiency
Voltage or current Failing windings or Mechanical damage, Energy costs,
unbalance capacitors, loose efficiency, unneeded rewinds
connections rewinds
Insulation Thermal effects, Shorts, major Secondary damage,
breakdown contamination, damage rebuilds
moisture, wear
Rotor and stator Excessive Loss of power, Process capability,
damage movement, bad severe damage, rebuilds
rewind rebuilds

EPRI – 47% of all motor faults, of which 10% rotors

6/
GE /
November 9, 2018
Mechanical faults
Fault type Causes Effects Impact
Foundation or rotor Bad design, Distortion leads to Breakdowns or
looseness installation, bearing and seal excessive outage
deterioration failures
Unbalance and Bad installation or Mechanical damage, Breakdowns, up to
misalignment maintenance, fouling efficiency loss 10% energy cost

Bearings and Bad installation, bad Progressive Breakdowns, repair

transmission lubrication, wear damage, secondary costs, loss of
problems damage production
Rotor damage Physical damage, Loss of process Process capability,
corrosion efficiency, power rebuilds, debris
consumption damage costs

EPRI – 53% of all motor faults

7/
GE /
November 9, 2018
Operational faults
Fault type Causes Effects Impact
Cavitation in pumps Bad design, High vibration, Breakdowns and
incorrect operation impeller damage reduced production

Flow turbulence in Bad design, Blade and ductwork Breakdowns and

fans, blowers incorrect damage lost production
maintenance
Filter and heat Debris build up Loss of process Energy cost,
exchanger fouling efficiency maintenance cost

Lubrication Greasing schedules, Loss of efficiency, Energy cost,

problems bad lubrication progressive damage breakdowns
system, oil ageing to bearings, trans

8/
GE /
November 9, 2018
Environmental faults
Fault type Causes Effects Impact
High energy Electrical, Unnecessary cost High production
consumption mechanical, costs, green taxes
operational
Low efficiency Bad design, High energy High energy costs
incorrect consumption,
maintenance reduced output
Unbalance and Bad installation or Loss of efficiency Cost of energy for
misalignment maintenance up to 5% efficiency
loss
Loose connections Bad installation or Supply heating 2-3% efficiency loss
maintenance

9/
GE /
November 9, 2018
 Failure modes and distribution
Typically up to 4Kv Typically 4kV and above

Others
Others 6%
Bearing
18%
Failures Stator Failures
13% 66%
Rotor Fluid Film
Ground Insulation,
Failures 6% Roller Turn insulation,
Rotor
Bearing Wedge, Frame
Failures
Stator Failures Core
13% AnomAlert
Failures AnomAlert 51% Rotor Bars,
25% Cage, Core

10 /
GE /
November 9, 2018
The P-F Interval – Motor & load Mechanical Failures

P = Potential Failure Vibration 1-9 months

An identifiable condition
that indicates a functional failure Lube Analysis 1-6
is occurring, or is about to. months
IR
Thermography
6-8 weeks Motor portable CM
P P1 P3 technology 4-8 weeks
P2
Audible noise
P4 1-4 weeks
AnomAlert – Motor P5 Heat by
Anomaly Detection Electrical / Mechanical touch 1-5
Anomaly Modeling. P6 days
2 – 3 months Protection
P7 Relays

F = Functional Failure
The point at which the asset fails
to deliver to it’s intended purpose
F

Time (not linear scale) 11 /

GE /
November 9, 2018
 The P-F Interval – Electrical Failures
P = Potential On-line >4kV motors PD 2 to 12 months but difficult to know
Failure when to correct . Expert analysis required to determine when
An identifiable condition degradation has progressed to the point where the motor needs
that indicates a functional repair.
failure is occurring, or is
Off-Line PD, PI, testing motors >4kV however off-
about to. line testing is typically 1 to 4 years between tests.
Stator winding degradation to failure can happen
within weeks to months and may be missed.
P P1 Stator Winding Temperature
P2 if available, 5-8weeks
P3
IR
AnomAlert – P4 Thermography
Motor Anomaly 1-2 weeks
P5 Heat by
Detection. touch 1-5
3 to 6 months. days
Protective
P6 Relays
F = Functional Failure
The point at which the asset fails to
deliver it’s intended purpose.
Multilin and other protective relays
will trip motor before severe F
damage.
Time (not linear scale) 12 /
GE /
November 9, 2018
Part 2 – Why AnomAlert
Where’s the Value?
AnomAlert where’s the value?
Value proposition Strengths Positioning
• Higher Availability & •S1 connect with •Enables Remote
Predictability additional tools. M&D
•Optimize CM program •Remote OEM
•…Less technologies Service and Support • Cryogenic motor-
to support CM •On-Line Motor AND pump,
•…Less Manpower to Load Anomalies • Slurry
support CM • Motor AND Rotor motor/pumps
•Remote Monitoring & Dynamics • Submerged
Diagnostic Services •Simple, effective, • Nuclear
•Motor rewind, repair easy to install • Offshore
decision making •Diagnostic toolbox • Remote
•Auto Reports • Hazardous
•Track Energy & • Poor access, fin
•Requests CM when
Efficiency & fans
needed.
Optimize….. • Semi to high
•3 year warranty
•Downsize, replace criticality motors
•Tech Support Agree’t
motor? • Cyclic duty 14 /
GE /

• PharmaceuticalNovember 9, 2018
 Machine Train
Availability
Collaborative Environment
Thermo Dynamics
Collaborative Environment

Process Out
Pressure, Flow, Temp, etc.

Energy Out Energy In

Rotor Dynamics Motor Dynamics
V rms
Vibration,
I rms
Heat, etc
Process In
Pressure, Flow, Temp, etc.

Process Dynamics
Collaborative Environment Collaborative Environment

Accountability, Quality,
Predictability 15 /
GE /
November 9, 2018
Condition Monitoring Methodologies
AnomAlert provides one technology
•Vibration that detects anomalies and the
•Temperature cause.
•Motor circuit analysis AnomAlert fault and severity used to
> current determine when other condition
monitoring technologies are required
> voltage to study and correct faults.
•Thermography
•Ultrasound
•Partial Discharge
•Lubrication analysis
•Insulation Resistance
Testing
16 /
GE /
November 9, 2018
PdM/AnomAlert LEGEND
T – Temperature
L – Lubrication
V – Vibration
M – Motor
V/I Analysis

Program Comparison Th – Thermography

- Anomaly Event
U – Ultrasound

• Anomaly focuses attention on Bad

• Increased Demand on Support Today Actors – Maintenance Optimization
Resources
• Reduced need for amount of
• Increased Capital Investment in
Equipment purchases – Decreased
Collection Equipment
CapEx
• OPEX budget to retain
• Decreased need for field visits –
consultant support
Increased Safety, decreased Opex
• High Resolution PdM

Scheduled Monthly Routine Predictive/Proactive Routine

T T T T T T T T T T T T T T
V V V V V V V V V V V V V V ………………………..
L L L L L L AnomAlert shows when PdM
Th Th Th Th Th attention is required to correct a
Mechanical or Electrical anomaly on
M M the motor driven train.

Sample PdM Program AnomAlert Predictive

17 /
GE /
November 9, 2018
 AnomAlert and Equipment Energy Efficiency
Power Factor,
Misalignment Active Power,
Reactive
~ 0.5%
Power and
Apparent
Power
Loose belt
consumption
~ 5% ~ up to 20%
Voltage supply
over or under
by 10% cause
alarm.

Voltage
imbalance of
2.5% can
cause 1.4%
efficiency.
Supply voltage
harmonics
cause
excessive heat
and lost
efficiency up to
1%.

18 /
GE /
November 9, 2018
Part 3 – How does it work?
 Voltage and Current
Connections
Note: may already be installed for monitoring or metering purposes.

Potential (Voltage) Transformers “PTs”

Class 0.5
Secondary Voltage 100V,110V,120V

Metering Current Transformers “CTs” Hall Effect Current Sensors

Class 0.5, Secondary Current 5A for use with (inverter)
Note: Protection CT cannot be used variable frequency drives

20 /
GE /
November 9, 2018
 AnomAlert Model Types
Low Voltage – up to 480V Inverter – Low Voltage
Measurement CTs Hall Effect Current
required, but voltage sensors need to be fitted.
can be a direct Voltage can be directly
connection to the connected to the monitor.
monitor
3X
3X
Ct Power supply Hall Effect Sensor

High Voltage – above 480V Inverter – High Voltage

Measurement CTs and Hall Effect Current
Voltage PT are usually sensors and Voltage
already installed. Connect PT need to be fitted.
to the extra secondary
winding.
3X
3X 21 /
Hall Effect
Pt GE /
Ct Pt Sensor November 9, 2018
AnomAlert Installation AnomAlert Installation Checklist
Version 9/2/2010)

CT/PT HARDWARE INSTALLATION [more detail to be added later following first installation]

NFPA70e safety Standard consulted: 

(See Attached NFPA tables)
CT/PT Location (e.g. Motor Control Cabinet): AnomAlert cabinet (if separate):
Voltage Level: Voltage Level:
Distance/Proximity: Distance/Proximity:

Installation Checklist! ….
Hazard Risk Category: Hazard Risk Category:
PPE Required: PPE Required:

Connections made with 14 AWG wire:  TBD

Install PT fuses/breakers:  TBD
Install shorting block:  TBD
CT lines and shorting block shorted to ground:  TBD
Loop checks:  TBD
Include PT and CT parameters?

22 /
GE /
November 9, 2018
Technology – Model Based Fault
Detection
Compares ACTUAL motor behavior with Threshold Overlay
Extensive motor database
on PSD Plot
PREDICTED behavior to detect Anomalies is used to set threshold
and diagnose type of fault. envelope for Current PSD
OUTPUT at 8 standard deviations.
INPUT
MOTOR
Measured Current

Frequency (Hz) + Fault

Voltage Σ Diff Identification

-
Frequency (Hz)
Predicted Current
AnomAlert MODEL Fault type is identified
Three assessments are made: from frequency
• Inputs (Line voltage analysis) content
• Outputs (Motor current, Power factor)
• Power Spectral Density difference.
23 /
GE /
November 9, 2018
 How AnomAlert Works

Motor acts
as a sensor
1. Install & Commission

Electrical and
2. Train – 10 days 3. Run Mechanical Power Spectral
Density
anomalies (PSD)
AnomAlert automatically models automatically
electric and mechanical load detected
influences
24 /
GE /
November 9, 2018
AnomAlert Clustering Algorithm
•During the learning
period AnomAlert Power Factor
Motor Operating
treats each operating Curve
point of the motor as a
cluster in the three C3

MOTOR LOAD
dimensional space
(power factor, gain,
supply frequency). C4
C2
Each cluster is a C1
component of the
overall model Gain (A/V)
MOTOR LOAD
•The model predicts Frequency
the Dynamic Current
output for any motor
operating point.
25 /
GE /
November 9, 2018
Motor status display
MONITOR Examine 2 (Second level alarm)
OK MONITOR After this alarm, maintenance action is
required.

WATCH LINE ( Abnormal changes in Examine 1 (First level alarm)

supply voltage )
Temporary changes in supply voltage cause
this alarm. If alarm is persistent check ;
harmonic levels – capacitor - isolation of
cables- motor connector or terminal slackness -
contacts of the contactor
Maintenance should be scheduled. Check imbalance –
misalignment – bearing/ bearing housing – motor shaft -
broken rotor bar - isolation of stator windings- over
lubrication and lubrication leakages through oil belt
Driven equipment mechanical problems (gear box,
compressor, fan, pump, press, conveyor etc.) - friction
and breakdown of fan blades - breakdown of pump sealing
– incorrect conveyor chain tension problem -.....etc

WATCH LOAD ( Changes in process is observed )

If process is not altered deliberately, check; leakages – valve & vane
misadjustments - Pressure gauge fault – Manometer – filters getting 26 /
GE /
dirty (fans, compressors) November 9, 2018
 27 /
GE /
November 9, 2018
 1 2

Equipment
Status

4 5
28 /
GE /
November 9, 2018
Power Spectrum and Alert threshold

Power spectrum
shows the
difference
Standard deviations

(residuals)
between an ideal
motor and the
motor being
monitored.
Thresholds in red
show the limits of
acceptance for
each of the
differential
components.

29 /
GE /
November 9, 2018
 Part 4
Bringing it all together.
Stand alone Software or
System 1
AnomAlert Architecture
Media Converter
Typical arrangement is
RS485
RS485 multi-drop with
Ethernet media
converter connection to
AnomAlert monitoring
software.
Ethernet

RS485

31 /
GE /
November 9, 2018
 Motor AnomAlert small network – up to 31 Motors

System 1 AnomAlert
Or for large 100 per DAQ server.
system network
System 1 AnomAlert
AES OPC 100 per DAQ server.
Server 32 /
700+ motors GE /
November 9, 2018
View groups of motor driven assets

33 /
GE /
November 9, 2018
View individual motor driven assets

34 /
GE /
November 9, 2018
View trends of each variable

35 /
GE /
November 9, 2018
View accumulated run time & energy

36 /
GE /
November 9, 2018
 System 1 Condition Monitoring Emerson
Honeywell
Platform GE Mark Vie
Invensys
Yokogawa, etc ….
OSI PI Multilin Protective Relay
Motor Dynamics Cimplicity PLC or ESD system
Plant Distributed
Rotor Dynamics Wonderware Unit or Motor Control Control System
Thermo Dynamics Process Data Protection
Process Dynamics Historian

Fast Scanning
Portable Wireless Vib / Temp Trendmaster 3500 Rotating & Reciprocating
AnomAlert
Data Sensor Mesh Network Machinery Condition Monitoring
Collector Phase II any dynamic data & Protection
HSCT

HSCT

HSCT

37 /
GE /
November 9, 2018
Case Histories
AnomAlert technology and opportunity,
Case Study 1, Sea Water Lift Pump
39 /
GE /
November 9, 2018
 Case #1 Sea Water Lift Pumps – Trial Results.
Mark Pellow, Engineering Superintendent for BP Shipping.

“As with all new technology in the marketplace, there is a degree of

skepticism when embarking on an initial R&D and trial period,” he said.
“To prove a useful and worthwhile tool we needed to determine whether
the AnomAlert unit could accurately detect a fault prior to catastrophic
failure and ultimately, provide us with a non-intrusive monitoring process
with cost saving benefits.”

“It was agreed that our validation trial would run up to the point where a
specific failure was predicted and maintenance recommended, so that the
prediction could be compared with the subsequent maintenance report.
The units were then installed by the ship power specialist,”

40 /
GE /
November 9, 2018
Cross-sectional view of seawater pump, showing the shrouded double-
suction, six-vane impeller. The directly-coupled drive motor is not shown in
this drawing.

41 /
GE /
November 9, 2018
AnomAlert (MCM) trends showing increase in “other” frequencies
identified using the Power Spectrum Density plot (not shown) as
related to vane passing frequency.

Simultaneous increase in
“other” parameters

42 /
GE /
November 9, 2018
 Power Factor Basics
Power Factor : A measure of efficiency. The ratio of
Active Power (output) to Total Power (input)

Active Power (kW) Power Factor = Active (Real) Power

 Reactive Apparent (Total) Power
Power
(KVAR)
= kW
Apparent (Total) Power (kVA)
kVA
= Cosine (θ)

A power factor reading close to 1.0 means that

electrical power is being utilized effectively, while a
low power factor indicates poor utilization of
electrical power. Asset performance & operation
optimization indicator.
43 /
GE /
November 9, 2018
 Initial conditions
Irms= 84 Amps
Active Power = 63kW
Reactive Power = 27 kVAR
Power Factor = 0.92
Later conditions
Irms= 82 Amps
Active Power = 58kW
Reactive Power = 31 kVAR
Power Factor = 0.88

4.5%
2.3%
8%
13%

44 /
GE /
November 9, 2018
Trend plot showing a gradual progressive decrease in both active power
and power factor parameters for Main Cooling Seawater Pump 1.

45 /
GE /
November 9, 2018
Flow vanes (fins) had suffered significant metal loss due to erosion. The impeller
had light fouling, and the wear rings had eroded, causing a reduction in
performance by allowing recirculation flow.

Flow vanes
(fins)

46 /
GE /
November 9, 2018
Upon disassembly, it was discovered that erosion had produced a hole in the pump
casing, at the point where a wear ring retaining screw caused a localized flow
disturbance.

Hole in casing – surrounding the wear

ring retaining grub screw

Wear ring

47 /
GE /
November 9, 2018
Pump Repairs
• The impeller was in good condition, so it was simply
cleaned and reused (next slide).
• The eroded wear rings were replaced, restoring normal
clearances and pump efficiency.
• The hole in the pump casing was repaired using cold resin
techniques, preventing further deterioration of the casing at
that location.
• Although the casing fins were heavily eroded, they were not
significantly impacting performance, so the casing cover
was reused without repairing the fins.
• Cost of repairs was approximately 10% of the “normal” cost
of pump replacement associated with the previous Run-To-
Failure (RTF) regime.
48 /
GE /
November 9, 2018
Pump impeller cleaning.

49 /
GE /
November 9, 2018
 AnomAlert alarms and data point to pump
performance degradation and abnormal vane
passing frequency

Vane erosion
Hole in casing

Wear rings
excessive
clearance

50 /
GE /
November 9, 2018
Case #2: Compressor bearing

In this case, AnomAlert had been installed on various items of equipment at an

automotive battery manufacturer, including this compressor.

AnomAlert started giving intermittent alarms on September 2005, and a

bearing problem was diagnosed by AnomAlert. Deterioration in the condition of
the machine was kept under review until January 2006, during which time
maintenance action was safely deferred. When carried out, maintenance and
repair actions verified the diagnostic assessment of AnomAlert.

On later examination of the AnomAlert trends, it was found that the bearing
problem was detected even earlier that 13 September 2005, but the assessed
severity was not sufficient to give rise to an alert. This demonstrates the
capability of AnomAlert to indicate developing faults at a very early stage.

51 /
GE /
November 9, 2018
Case #2: Compressor bearing

5 Jan 2006

13 Sep 2005

15 Aug 2005

Equipment status 2

Equipment status 1

52 /
GE /
November 9, 2018
Case #3: Cooling Tower fan
attachment
In this case, an automotive manufacturer had installed AnomAlert on a number
of tower fans which had proved expensive and difficult to monitor in any other
way because of they were inaccessible. AnomAlert first gave a warning of a
problem on 16 October 05, and diagnosed a looseness problem. However, the
severity level remained low, and over the next few days went away altogether.
It was decided to take no action based on the AnomAlert diagnosis, but to
watch out for further occurrences.

Gradual deterioration in condition led to a renewed alert from 14 November

05, which remained consistently on after that time. Continued moderate
severity allowed deferment of inspection until 14 February 06, when a loose
attachment bolt was found and the fault corrected (verifying the AnomAlert
diagnosis and severity assessment). Following this action, the system remained
in alert, accurately identifying a continuing imbalance which may have been
related to the original problem.

53 /
GE /
November 9, 2018
Case #3: Tower fan attachment

16 Oct 2005 14 Feb 2006

Gradual imbalance
Looseness event

Equip status 2
Equip status 1

54 /
GE /
November 9, 2018
Case #3: Tower fan attachment

Loose bolt correctly

identified

55 /
GE /
November 9, 2018
Case #4: Pump internal electrical failure

Thermography
validates internal
electrical anomaly

56 /
GE /
November 9, 2018
 57 /
GE /
November 9, 2018
Summary
The GE BN Motor Condition Monitoring
Solution is
• Innovative solution
• Simple
• Increases availability
• Detects Mech and Elec Anomalies
• Detects anomalies on motor AND load.
• Complements other CM technologies
• Optimizes CM programs with PdM equipment
58 /

used to manage by exceptions. GE /

November 9, 2018
Thank You