SmartSignal: Predictive Analytics

12 Real Examples of Machines SavesMarch to May 2012

2 FAE Learning Review

04/10/2023

Predictive Analytics Drives Proactive Decisions, Improves Metrics

3 FAE Learning Review

04/10/2023

The SmartSignal DifferencePersonalized models, multiple sensors, residual (not actual) data –in real time

Axial position

Gas pressure Δ

Speed

Alarm Hi

Bearing Temp

Alarm / TripAxial position

Single-sensor equipment protection: traditional thresholds & rules

Early stages of damage

Detects problems before traditional alarms

Normal operation

Plugging Lube Oil Filter Found on a Water Injection Pump on an Offshore Oil Platform Availability & Performance Center  |  April 2012

What did the Proficy SmartSignal software find? On March 25th,

the Proficy SmartSignal solution identified a small increase in metal

temperature on a water injection pump thrust bearing. Metal

temperatures were expected to remain around 41degC, but had

risen to values around 46degC. A few days later, the Proficy

SmartSignal solution identified an increase in lube oil filter

differential pressure and a drop in lube oil supply pressure. This

particular client is taking advantage of the Proficy SmartSignal

Sentinel application and the proactive email notifications. The email

notification for high filter differential pressure went directly to the

client and they investigated the issue. The client and the Availability

and Performance center then discussed the issue, the clients

findings, and their planned corrective action.

What was the underlying cause? After investigation, the client

was able to confirm that the lube oil filter was showing signs of

plugging.

What was the value to the client? If left unchecked, a plugged

lube oil filter could deprive the pump bearings of oil and lead to a trip

of the pump or damage to the bearings. The client appreciated the

opportunity to proactively schedule a lube oil filter change before the

situation was critical. The ability to schedule a maintenance action

proactively means that the client can have the parts and labor on

hand to perform the maintenance action, thereby minimizing costs

and down time.

Screenshot depicting increases in actual thrust bearing metal temperature, lube oil filter differential pressure, and decreases in actual lube oil supply pressures

(blue) versus expected value (green).

Who found it? The Proficy SmartSignal solution directly notified the client.

Contaminated Seal Fluid at an Oil and Gas FacilityAvailability & Performance Center  |  April 2012

What was the value to the client? This particular notification

helped the client replace a clogged filter and prevent damage

to a pump’s seals. This is valuable to the client because a

plugged filter, or contaminated seal fluid, can allow debris to

enter into the seals, causing sudden seal failure for a pump.

In addition, the joint collaboration between the client, the

GEIP Availability and Performance Center, and the GE MCS

Bently teams helped to identify a seal system issue that was

affecting many pumps at the facility and allowed the client to

correct a condition that was potentially damaging or

endangering the seals for several pumps.

Who found it? Lonnie

McCollum

Screenshot depicting decreases in actual seal supply pressures (blue) versus expected seal supply pressures (green).

What did the Proficy SmartSignal software find? On March 28th, the Proficy SmartSignal solution identified a drop in the drive end seal

supply pressure for a pump at an oil and gas facility. Pressures were expected to remain around 62 BARG but were dropping to 54 BARG. The

Availability and Performance Center sent a high priority notification to the client. This client is taking advantage of a joint monitoring solution

between the GE MCS Bently and the GEIP Availability and Performance Center teams. This issue was discussed with Bently and the client on

the weekly call.

What was the underlying cause? A very similar seal supply issue occurred in mid-February on a sister pump whose seals were fed by the

same seal system that supplied seal fluid to this pump. After the notification in February, the client found a seal filter that was clogged and

replaced the filter for the first pump. After the second notification, the client investigated and found a clogged seal filter on this second pump.

Because this appeared to be a recurring condition, the client suspected that there was a seal system condition affecting multiple pumps. The

client sampled the common seal fluid that supplied both pumps and found that the seal supply fluid was contaminated. The client believes that

either they received a bad batch of seal fluid or that the seal fluid storage tank is corroded and releasing contamination into the seal fluid.

John Thibodeaux

Incorrect Hydrogen Pressure Level Found at a Combined Cycle Power Plant Availability & Performance Center  |  April 2012

What was the underlying cause? The client first investigated the

H2 scavenging line. When it was determined to be normal, further

investigation was conducted. It was found that an operator had

incorrectly set the hydrogen pressure set-point to a value that was

too high.

What was the value to the client? The initial detection of the

degradation in Hydrogen purity is important to the client, because

hydrogen in lower purity concentrations is combustible and presents

a significant safety danger. Subsequently, the Availability and

Performance Center helped identify that a corrective maintenance

action, conducted by the plant, had occurred incorrectly. In addition

to causing excessive loss of expensive hydrogen, over-pressuring

the hydrogen cooling system could damage the hydrogen seals,

which could lead to a loss of hydrogen purity and an increase in the

risk of a generator explosion.

Who found it?

Screenshot depicting changes in actual hydrogen purity (blue) and deviations between expected hydrogen pressure (green) versus actual

hydrogen pressure (blue).

What did the Proficy SmartSignal software find? On March 31st, the Proficy SmartSignal solution identified a slow degradation in the

hydrogen purity for a generator at a combined cycle power plant. The hydrogen purity had fallen below an alarm limit of 85%. The Availability

and Performance Center discussed the issue with the client during the regular weekly call. To correct the hydrogen purity issue, the plant

operator increased the hydrogen pressure set-point. On April 7th, the plant performed a test of the hydrogen cooling system and seals by

bleeding hydrogen and refilling the generator (a “bleed and feed”). The Proficy SmartSignal solution identified that the generator did not respond

to the hydrogen system test as it had in the past. The Availability and Performance Center discussed the new issue with the hydrogen system

on the next week’s call.

Eric Logis David Saad

Mike Reed

Broken Valve Bolt Found on a Reciprocating Compressor at an Oil and Gas FacilityAvailability & Performance Center  |  April 2012

What did the Proficy SmartSignal software find? On March 13th, The Proficy SmartSignal solution identified a sudden and sustained rise in

the rate of number impacts over time on a reciprocating compressor at an Oil and Gas Facility. Values for this sensor were expected to stay

near 0 for sustained periods of time. The Availability and Performance Center notified the client of this issue during the scheduled weekly call.

Lonnie McCollum

Screenshot depicting increases in actual impacts vs. time (blue) versus expected impacts vs. time (green)..

Peter Spedale

What was the underlying cause? When the

operators investigated this issue, they found that

valve center bolts had broken on 3 separate

valves. Parts of one of the bolts had fallen into the

cylinder head and were damaging the piston.

What was the value to the client? The debris

from the broken bolts could have caused a

catastrophic failure of this compressor and could

have resulted in the compressor needing a

complete overhaul. Because the issue was

detected early, the client was able to replace the

piston and valves and return the machine to

service.

Who found it?

Combustion Problem Found at a Combined Cycle Power PlantAvailability & Performance Center  |  May 2012

What did the Proficy SmartSignal software find? On March 6th, the Proficy SmartSignal solution detected an issue with three combustion turbine exhaust

thermocouples during a steady state run that was the turbine’s first run after a hot gas path Inspection. As this combustion turbine varied load between 100 and

155MW, intermittent deviations appeared in thermocouples 3, 4, and 6. The exhaust thermocouples were expected to have values between 1100 and

1200degF. Actual temperature measurements varied as much as 100deg below expected values.

Eric Logis

Screenshot depicting increases in actual (blue) versus expected (green) power for combustion turbine power [TOP], actual exhaust temperatures [SECOND FROM

TOP], and actual (blue) and expected (green) values for exhaust temperatures [BOTTOM THREE].

Combustion health is monitored using exhaust thermocouples and a swirl pattern that will vary with

airflow changes that are associated with load changes. Since the deviations in the thermocouples

were changing, as the load of the machine was changed, the Availability and Performance Center

performed a swirl analysis to assist in narrowing down a possible combustion issue. It was

suggested to the client that there was a possible combustion system issue associated with cans

11, 12, or 13.

What was the underlying cause? Since this hardware was just replaced, the client was very

interested in further evaluating this combustion issue with the OEM. The OEM investigated and

eventually replaced combustion nozzles 12 and 13 during a subsequent planned maintenance

outage. These 2 combustion nozzles have been sent out to be inspected and repaired as needed.

What was the value to the client? Finding this issue early, helped ensure that the client did not

take a forced outage during their summer run season. This particular client is under a long term

service agreement so they were not liable for the replacements costs of the combustion nozzles.

However, the client was very appreciative that we were able to find this issue now and allow them

to address it during a planned maintenance outage. The client estimated that by detecting this

issue now, and preventing this issue from affecting them during the summer peak season, the

client was able to avoid more the $350,000 in lost power production revenue..

Who found it? David Saad

Plugged Gas Recirculation Fan Air Filter Found at a Coal Plant Availability & Performance Center  |  May 2012

What did the Proficy SmartSignal software find? On April 26th, the Proficy SmartSignal solution identified a sudden rise in the motor

outboard bearing temperature and the motor stator temperature of a gas recirculation fan in a coal plant. The motor outboard bearing

temperature was expected to operate between 120 and 140degF, but values were detected as high as 180degF. Values for the motor stator

temperature were expected to operate around 80degC, but actual values were detected as high as 120degC. In addition, the motor inboard

bearing temperature was beginning to show early signs of overheating, with actual values 5 to 10 degrees above expected values.

Vanessa O’Malley

Screenshot depicting increases in actual temperatures (blue) versus expected values (green).

What was the underlying cause? After the Availability and

Performance Center notified the plant of the issue, the plant

operators wrote a work order and immediately inspected the fan.

This fan is air cooled and the operators found that an air filter had

plugged with debris, starving the fan of necessary cooling air. The

plant installed a new air filter. The Availability and Performance

Center was able to subsequently help verify that their maintenance

action was successful with a follow up notification on March 27th

showing that actual values had returned to expected levels.

What was the value to the client? The early warning provided by

the SmartSignal solution and the Availability and Performance

Center allowed the client to react to a situation before the gas

recirculation fan could trip off due to a high alarm limit, potentially

impacting power production. The early warning also allowed the

client to minimize possible damage or reduction in life of the motor

and bearings due to high thermal loading

Who found it? Mike

Reed

Missing Coupling Bolt Detected on a Reciprocating Compressor at an Oil and Gas FacilityAvailability & Performance Center  |  May 2012

What did the Proficy SmartSignal software find? On April 2nd the Proficy SmartSignal solution started identifying intermittent, small

increases in vibration over expected values. Overall, actual vibration values were increasing due to increases in load, which was expected.

However the Proficy SmartSignal solution detected that the vibrations were 1-2% higher than they should be given the increasing load. The

Availability and Performance Center continued to monitor this trend. Over the next two weeks, the vibration recursions become more consistent

and the customer was notified on April 18th.

Thomas Lowisz

Lonnie McCollum

Screenshot depicting increases in actual vibration (blue) versus expected vibration (green).

Peter Spedale

What was the underlying cause? When the

operators investigated this issue, it was found that

a throttle rod coupling was missing a bolt. The

operators installed the bolt to bring vibrations back

to expected values.

What was the value to the client? The client

appreciated the opportunity to correct this issue

when they simply had to install a bolt. If this issue

was not corrected, the throttle linkage or other

parts of the compressor could have been

damaged or destroyed, causing a loss of

production.

Who found it?

Combustion Turbine Startup Failure due to Wet Fuel at a Combined Cycle Power PlantAvailability & Performance Center  | May 2012

What did the Proficy SmartSignal software find? On March

30th, The Proficy SmartSignal CycleWatch solution monitored

the startup of a Combustion Turbine and identified an exhaust

thermocouple that was expected to operate around 800 degrees

Fahrenheit, but was actually operating approximately 20 degrees

lower than expected. After the plant completed the day’s run,

the unit was started up again the following day. During this run,

the same thermocouple showed a rapid degradation in

temperature and the exhaust spread showed a rapid increase in

temperature causing the unit to trip.

What was the underlying cause? After the trip, the plant

investigated and discovered that the unit had tripped because of

water in the fuel. Two exhaust thermocouples were replaced

along with damaged fuel nozzles.

What was the value to the client? The Proficy SmartSignal

solution and the Availability and Performance Center were able

to provide data and trends that aided the plant in their

troubleshooting efforts and helped to identify the nozzles

affected by the wet fuel. This aided the maintenance and

restoration process.

Who found it?

Mike Reed Alex Jenkins

Screenshot depicting actual and expected turbine speed [top], decreases in actual exhaust temperature (blue) versus expected (green) [second from top], increases in exhaust spread actual (blue) versus expected (green) [3rd from

top], and decreases in actual exhaust temperatures versus other exhaust temperatures [bottom].

Pinched Lube Oil Drain Line Detected at an Oil and Gas FacilityAvailability & Performance Center  |  June 2012

What did the Proficy SmartSignal software find? On April 5th, the

Proficy SmartSignal solution detected that the lube oil drain temperature

of a bearing on a gas turbine began reaching temperatures around 185

degrees Fahrenheit, while they were expected to remain around 175

degrees Fahrenheit. At the same time, the lube oil drain temperature of

the other bearings continued to track with expected values. The

Availability and Performance Center immediately notified the client and

began tracking this issue on the weekly calls.

What was the underlying cause? When the client completed their

investigation, they discovered that the lube oil drain line was being

pinched, thereby restricting the flow of lube oil to the bearing.

What was the value to the client? The client had the opportunity to

correct the pinched drain line before damage was caused to the bearing.

The Availability and Performance Center was able to provide verification

that their maintenance action was successful by showing actual values

returning to expected values on April 23rd. Had this issue not been

addressed, the restricted lube oil flow could have damaged the bearing

and potentially caused the gas turbine to trip.

Who found it?

Thomas Lowisz Peter SpedaleScreenshot depicting actual values (blue) and expected values (green). Increases in actual Lube Oil Drain Temp (blue) versus expected (green) shown second from top.

Incorrect HRSG Operation Detected at a Combined Cycle Power Plant Availability & Performance Center  |  June 2012

What did the Proficy SmartSignal software find? On May 5th, the Proficy SmartSignal solution detected that the exhaust gas stack

temperature on a Heat Recovery Steam Generator (HRSG) for a Combined Cycle power plant had increased to values around 240 degrees

Fahrenheit (115 degrees Celsius). Given the current loading conditions, stack temperatures were expected to operate around 180 degrees

Fahrenheit (82 degrees Celsius). The Proficy SmartSignal solution also detected that the low pressure super heater outlet steam flow was less

than expected.

Justin Whitty David Saad

Screenshot depicting actual values (blue) and expected values (green). Increases in actual HRSG Gas Temp and LP Main Steam Flow (blue) versus

expected (green) shown in bottom two graphs.Mike Reed

What was the underlying cause? The Availability and Performance

Center reviewed the issue and, on the normal weekly call, notified the

plant that there was either an unnecessary recycling of the preheater, or a

low pressure bypass valve that was open or leaking by. Immediately after

the call, the plant engineer reviewed the issue with the plant operator and

discovered that the operator had incorrectly set the bypass valve to 28%,

when it should have been at 0%.

What was the value to the client? The plant immediately closed the low

pressure bypass valve and the Availability and Performance Center was

able to confirm that the maintenance action was successful by showing

that actual values returned to expected values. Having the low pressure

bypass valve open reduced the efficiency of the plant, which was

immediately remedied by the corrective action. Also running with high

temperatures in the exhaust stack over an extended period of time will

eventually cause back end corrosion and degradation of the stack and

outer preheater tubes.

Who found it?

Damaged 1st Stage Nozzle and Cross Fire Tube at a Combined Cycle Power Plant Availability & Performance Center  |  June 2012

What did the Proficy SmartSignal software find? On May 8th, the

Proficy SmartSignal solution detected a high exhaust spread on a

combustion turbine.  Exhaust spread was expected to be around 50

degrees Fahrenheit (10 degrees Celsius), but the actual exhaust spread

was around 115 degrees Fahrenheit (46 degrees Celsius).  The Availability

and Performance Center analyzed the issue and suggested that there was

a possible cold spot that needed to be investigated.

What was the underlying cause? The client took the combustion turbine

offline and performed a borescope inspection.  The borescope inspection

found a first stage nozzle that was damaged and a cross fire tube that was

burned.

What was the value to the client? Early detection of this issue allowed

the client to only replace one cross fire tube and first stage nozzle.  If this

unit had continued to run, additional combustion turbine hardware could

have been damaged and the unit could have tripped offline, taking further

life out of the combustion turbine.  The client was able to avoid these

secondary impacts and costs and fix this issue without affecting their

summer run season.  The client estimated that this notification saved them

more than $68,000 in potential avoided power production losses alone.

Who found it?

Eric Logis David SaadScreenshot depicting actual exhaust spread values (blue) and expected exhaust

spread values (green) [Second from Top] and actual exhaust temperatures [Bottom].

Loose Belts on a Coolant Pump Detected at an Oil and Gas FacilityAvailability & Performance Center  |  June 2012

What did the Proficy SmartSignal software find? On May 8th,

the Proficy SmartSignal solution detected that the coolant supply

pressure on a reciprocating compressor was no longer operating as

expected. Values for coolant supply pressure were expected to

operate between 18 and 30 PSIG (225 – 305 kPA) but actual values

were dropping as low as 14 PSIG (198 kPa). The Availability and

Performance center discussed the issue with the client on the

regular weekly call.

What was the underlying cause? The coolant for this compressor

was supplied by a belt driven pump. Upon investigation, it was

discovered that the belts driving this coolant pump had become

loose.

What was the value to the client? The client was able to tighten

the belts driving the coolant pump and the Availability and

Performance Center was able to validate that the client’s

maintenance action was successful on the subsequent weekly call.

The client was able to perform a small maintenance action and

prevent the damage that could have occurred if the coolant system

had continued to degrade into functional failure.

Who found it?

Thomas Lowisz

Screenshot depicting actual values (blue) and expected values (green). Decreases in coolant pressures shown in bottom graph.

16 /GE /

April 10, 2023

SmartSignal with Bently Nevada System1

P1 P2

P5P6

P3P =Potential

F = Failure

P4

P6

• Look out before problems start• Based on sound Asset Management Vision• Reliability Training – Discovery Tools

Redefining the P-F curve

Foresight Insight

Bently Nevada + SmartSignal Benefits

System 1 and SmartSignal are collaborative.

• SmartSignal provides earliest warning of impending failures

• System 1 provides the deepest level of diagnostic needed for analysis of impending failures

Together, the two technologies provide:

• Earlier detection of alarm status

• More confidence you actually have an issue

It’s the combination of Foresight + Insight, delivering a world class solution.

The best solution is to use both.