Customer Success Story: Bently Nevada Asset Condition Monitoring


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A case study on Oil & Gas Vessel Equipment - Petroleum Refining

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Customer Success Story: Bently Nevada Asset Condition Monitoring

  1. 1. GE Energy Oil & Gas – Petroleum RefiningCustomer Success Story Bently Nevada* Asset Condition MonitoringBig Savings Realized Before System is Fully Commissioned“ he Bently Nevada Trendmaster* system is like having an operator standing T next to each pump 24 hours per day. Catastrophic pump failure prevention was the basis for justification of this system, and before we even had it commissioned, it paid off big time.”ProblemA catastrophic pump failure that resulted in a fire totaling more than 12MM USD in losses motivateda large petrochemical facility to install online condition monitoring for hundreds of pumps and otherequipment assets to help avert another incident.SolutionThe plant deployed Bently Nevada Trendmaster* systems at several locations. Trendmaster canscan individual measurement points every few minutes, providing a cost-effective online vibration/temperature monitoring solution for pump alley installations where frequent data collection helpsprevent problems that could result in toxic or hazardous substance releases, fires, or explosions.PaybackThe system began to pay dividends early in the project as the first pumps were being brought on Trendmaster* Proline with vibration/temperature measurements. During normal rounds, which included a stop at the Asset Scanning Systemshelter housing the Trendmaster computer, operators were surprised to find a crude pump in thehighest level of vibration alarm. After verifying the reading, the pump was replaced. A subsequentinspection of the faulty pump confirmed that catastrophic failure was imminent, in fact only a fewminutes away. Motivated by this initial save, the plant accelerated the project schedule, quicklyintegrating alarms from Trendmaster into the process control system, giving operators continuousaccess without having to leave the control room. Within days after integrating these alarms, twoother pumps went into alarm and were quickly replaced.Trendmaster’s temperature monitoring capability also proved valuable by identifying several pumpsthat required additional coolers and/or piping alterations, and alerting operators to clogged waterlines. Clogged lines can cause pumps that normally run at 150˚F to rise to 220˚F within minutes.Trendmaster alarms on such conditions so immediate action can be taken. According to operatorsat the plant, “this level of surveillance would not be possible without the Trendmaster system.”Benefits• A bility to integrate alarms into the plant DCS creates an integrated condition monitoring/ process control environment for plant operators with continuous access to vibration and temperature data from a central location.• Improved and cost-effective condition monitoring for less critical assets can be applied in installations where manual data collection is dangerous due to environmental or physical constraints and remote or un-staffed facilities where manual data collection is impractical.• More frequent data collection than is possible with hand-held data collector routes, allows problems that develop quickly to be caught in time – before catastrophic failures occur. As seen in Learn more by reading the Synopsis of Savings article in ORBIT magazine Vol. 25, No. 3, 2005 at © 2008 General Electric Company, all rights reserved. * Trademarks of Bently Nevada, LLC, a wholly owned subsidiary of the General Electric Company. GEA17122 (08/08)