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GE Energy




                                                                                                                                                                      Oil & Gas – Petroleum Refining
Customer Success Story	
Bently Nevada* Asset Condition Monitoring


Big 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.”
Problem
A catastrophic pump failure that resulted in a fire totaling more than 12MM USD in losses motivated
a large petrochemical facility to install online condition monitoring for hundreds of pumps and other
equipment assets to help avert another incident.

Solution
The plant deployed Bently Nevada Trendmaster* systems at several locations. Trendmaster can
scan individual measurement points every few minutes, providing a cost-effective online vibration/
temperature monitoring solution for pump alley installations where frequent data collection helps
prevent problems that could result in toxic or hazardous substance releases, fires, or explosions.

Payback
The system began to pay dividends early in the project as the first pumps were being brought on                                         Trendmaster* Pro
line with vibration/temperature measurements. During normal rounds, which included a stop at the                                        Asset Scanning System
shelter housing the Trendmaster computer, operators were surprised to find a crude pump in the
highest level of vibration alarm. After verifying the reading, the pump was replaced. A subsequent
inspection of the faulty pump confirmed that catastrophic failure was imminent, in fact only a few
minutes away. Motivated by this initial save, the plant accelerated the project schedule, quickly
integrating alarms from Trendmaster into the process control system, giving operators continuous
access without having to leave the control room. Within days after integrating these alarms, two
other pumps went into alarm and were quickly replaced.

Trendmaster’s temperature monitoring capability also proved valuable by identifying several pumps
that required additional coolers and/or piping alterations, and alerting operators to clogged water
lines. 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 operators
at 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.   www.orbit-magazine.com
                                                                                * Trademarks of Bently Nevada, LLC, a wholly owned
                                                                                        subsidiary of the General Electric Company.     www.ge-energy.com/ocsuccess
                                                                                                                  GEA17122 (08/08)

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Customer Success Story: Bently Nevada Asset Condition Monitoring

  • 1. GE Energy Oil & Gas – Petroleum Refining Customer Success Story Bently Nevada* Asset Condition Monitoring Big 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.” Problem A catastrophic pump failure that resulted in a fire totaling more than 12MM USD in losses motivated a large petrochemical facility to install online condition monitoring for hundreds of pumps and other equipment assets to help avert another incident. Solution The plant deployed Bently Nevada Trendmaster* systems at several locations. Trendmaster can scan individual measurement points every few minutes, providing a cost-effective online vibration/ temperature monitoring solution for pump alley installations where frequent data collection helps prevent problems that could result in toxic or hazardous substance releases, fires, or explosions. Payback The system began to pay dividends early in the project as the first pumps were being brought on Trendmaster* Pro line with vibration/temperature measurements. During normal rounds, which included a stop at the Asset Scanning System shelter housing the Trendmaster computer, operators were surprised to find a crude pump in the highest level of vibration alarm. After verifying the reading, the pump was replaced. A subsequent inspection of the faulty pump confirmed that catastrophic failure was imminent, in fact only a few minutes away. Motivated by this initial save, the plant accelerated the project schedule, quickly integrating alarms from Trendmaster into the process control system, giving operators continuous access without having to leave the control room. Within days after integrating these alarms, two other pumps went into alarm and were quickly replaced. Trendmaster’s temperature monitoring capability also proved valuable by identifying several pumps that required additional coolers and/or piping alterations, and alerting operators to clogged water lines. 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 operators at 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. www.orbit-magazine.com * Trademarks of Bently Nevada, LLC, a wholly owned subsidiary of the General Electric Company. www.ge-energy.com/ocsuccess GEA17122 (08/08)