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Essential Insight.mesh Wireless Condition Monitoring for Essential Assets

Why Wireless?

Part 1 Basic operating principles Bearing failures REB related frequencies

Rotating Machines

Online - Continuous monitoring & protection

Critical Assets Gas Turbines

Steam Turbines

Compressors

Main line Pumps

3500 & TDI 3300 &

TDXNet or TDE

Online Periodic (scanning) monitoring

Wired Wireless

Essential Assets

Fans

Pumps

Blowers

Etc

Snapshot PDC

BOP Assets

Vibration

Portable Devices

Lube Oil

Thermography

MCA, etc

Offline Periodic walk-around monitoring

Integrated Condition Monitoring Program

Focused on early detection of Failure modes that have a P-F life of

30 days or less but greater than 30 minutes.

Applicable scenarios for use include:

Failure modes that can be detected

Using Casing vibration Using Temperature

P-F Interval

Time

Functional

Failure

Detection of Potential

failure using predictive

technology

F

P

P F Interval

Rule of Thumb:

Sample interval no

greater than P-F Worst Case Lead Time

Can also be utilized for early detection of Failure modes

that have a P-F life of greater than 30 days where

financially justifiable: Assets where Criticality and potential of hidden

failures presents a risk.

Assets where Portable Data Acquisition presents a

EHS (Safety) risk to personnel.

Where cost of Portable Data Acquisition is high. Assets where a wired scanning solution is the best

solution but wiring is not practical.

Asset Criticlity Distribution

5%

15%

30%

40%

10%

Highly Critical

Critical

Mid Criticality

Low Criticality

No Impact

Risk = probability of failure

x

Consequence of failure

Selecting the right CM Solution

Essential Insight.mesh


Snapshot

Clipboard

Trendmaster

Rack-Based Monitors 3300 3500 Encore 3500

Distributed Monitors 1701 1900 2201 3701

Protection (Critical Assts)

Essential Insight (Essential & General Purpose Assets)

DCS, MMS, ERP, Historian

How it works

Essential Insight .mesh

wSIM

System 1 server

Vib

Essential Insight .mesh

Manager Gateway

TC

Vib

TC

Wireless Condition Monitoring

Repeater

Wireless Mesh - Network Topology

Mesh Topology advantages:

A wireless sensor network (WSN) consists of an array of wireless routers that form a multi -hopping, ad-hoc mesh network.

Time Synchronized Mesh Protocol (TSMP) self-joining, self-organizing, multi-hop networks, self-healing

>99% steady-state end-to-end reliability

Identical units no differentiation between sensors and repeaters simple and easy network structure

Highly scalable in terms of numbers of sensors joining the network as well as network reliability

Low power consumption

Dynamic load balancing

Hazardous Area Approvals

50 m

Wireless mesh network

Reliable/Redundant Data Routes

Legend wSIM

repeater

Manager Gateway

Alternate parent node

Different frequency


Self-healing

Manager Gateway

legend wSIM

Repeater

Active node

Alternate

data route


Low power consumption legend

wSIM

Repeater

Active node

Manager Gateway


Scalable and Self-healing legend

wSIM

repeater

Manager Gateway

[Node moved]

[Node added]

[Node removed]

System Components

Components of the Essential Insight.mesh

Accelerometers and Temperature

Wireless sensor interface modules (wSIMs)

Wireless repeaters

Energy harvester

Network Manager Gateway

System 1 Data Acquisition Server


Wireless Sensor Interface Module (wSIMTM)

wSIM

Transducers - 4 channels Accelerometer (200150-155-157)

Thermocouple (K-Type (200125) - J, T & E type)

Signal Processing Static - acceleration, velocity and enveloped values

Dynamic 2 Simultaneous of 3 Waveforms choices Acel, Veloc & Enveloped Acceleration

Power Options Lithium Battery (3-5 years) for typical use

Standard port for alternative energy sources

Energy Harvester - a resonant, mass energy-harvesting device

Line power - AC (110/220V 50/60Hz) to DC power supply (5 Vdc)

Optional alkaline battery

External power source - meets the input requirements (5Vdc)

Scan Rates (per channel) Static Data: 15 min to once per day **

Dynamic Data: Once per day to once per every 30 days

On-Demand: Anytime separate requests for Static and Dynamic data

Environmental performance

Global Solution 2.4 GHz frequency communication (IEEE 802.15.4) - low

rate long battery life

Zone 0, Intrinsically Safe hazardous areas; place it anywhere in the plant


Wireless Repeater A wireless router that forwards data packets on a wireless

mesh network

Can be powered by battery or Energy Harvester

Energy Harvester Power for life with a universal external power connector The nodes in a wireless mesh network are all self-powered

wSIMs and repeaters can be powered by either an internal alkaline battery or an external energy harvester

Safe area use only (not Zone 0 / Zone 2 certified)

Hazardous Area Approvals

wSIM - Repeater

External Line Power Enhanced performance to match application needs without

worrying about battery life

Safe area use only (not Zone 0 / Zone 2 certified)

ATEX & CSA Class-I, Zone-0/Div-0

IP 67


Manager Gateway

Supports up to 100 nodes (wSIM + repeaters) / maximum 400 sensors per wireless mesh network

(Up to 1000 sensor per network - future phase)

Up to 5 manager gateways per System 1 DAQ

Manages communication in the mesh network

Uses IEEE 802.15.4 radio mesh networking technology

Option for Redundant electronics for maximum reliability

Serves as a network interface between the mesh network and the plant network where the System 1 DAQ is connected

19 rack mount - control room

Remote mount - weather proved housing

Plant network

System 1 DAQ

Wireless Mesh Network TSMP protocol

TCP/IP protocol

Radio transmission considerations

Radiation pattern for the wSIM antenna All of the components in a wireless mesh

network use a 2dB omni antenna

Omni directional antennas radiate signals in a toroidal (donut) shape

The half angle power is a measure of the vertical propagation of the signal energy from horizontal

The half angle power for wSIM antennas is 60

Best practice - each node can see 3 other nodes within a 50m radius to avoid a single point failure taking down the mesh network

60

50 m

25 m

0

Horizontal

transmission

range (50 m)


Battery Life

Battery Life vs. Temp Battery Life vs. Collection Interval

Battery life depending on:

Type and frequency of the data collected waveform vibration transmission consumes more energy

Data collection interval faster rate means lower battery life

Dynamic data collection, integration, high-pass filter corners below 10Hz, high resolution spectrums and use of the 200155 low freq accel consumes additional power and reduces battery life

New Features

Part 1 Basic operating principles Bearing failures REB related frequencies

Mounting options:

Mount for Unistrut

Stud mount

Magnetic mount

mounting example with Unistrut

mounting Bracket for Unistrut mounting Nut for Unistrut

New features flexible mounting

On-Demand - Static and Dynamic Waveform Separate requests for Static and Dynamic

All parameters that are already configured for the channel are sent

Demand Function available as a System 1 menu item (in System 1 EI.mesh Utility and can be setup as a toolbar button in System 1 Display)

New features On-Demand Data

1. Select the wSIM

2. Select Data menu item.

3. Select which variable type you want to request (Dynamic or Static)

4. Select wSIM channel

5. A data demand is sent out for the WSIM channel

6. Data displays along with normal scanned data.

New features - System 1 Integration Wireless Utility

Network

management

Configuration Tool

Node provisioning / deprovisioning

Support for multiple Manager Gateways

Firmware update over the air

Simplified configuration

Full System 1 toolbox available for wireless data

Status on remaining battery life-time

Network management functionality

Alarming functionality

Plant Map

New features more diagnostics

AE overall value are

trended to identify

early bearing faults

Acceleration Enveloping is an overall value and a dynamic

variable consisting of a waveform and its associated spectrum.

AE spectrums help

diagnose what is failing

inner race, outer race,

cage, rolling element

Acceleration Enveloping Spectrum

Waterfall spectrum

Acceleration Enveloping requires 200157 probe

Upgrade wSIM firmware only as a GE Service

System Deployment

Three deployment Choices with Essential Insight.mesh

1. Stand-Alone: Deploy Essential Insight.mesh as a stand-alone sensor

mesh linked to System 1.

Deploy Essential Insight.mesh in long haul

2. Leverage 3rd party backhaul (Honeywell)

3. Leverage ISA100 gateways and backhaul (Yokogawa & Honeywell)

Essential Assets / BOP

Plant diagnostic platform

System 1

Handheld data collector

Continuous monitor

Essential Insight.mesh Clipboard

Trendmaster DSM

DCS & other

systems

SnapshotTM

EI.mesh Mgr

Gateway

Stand-Alone - Essential Insight.mesh Plant Integration

Standard Deployment

Essential Insight.mesh (point-to-point backhaul) Deployment Guidelines for long distance remote

What is the solution for long distance wireless bridging?

Use Wireless WAN for distances greater than 500M (~1/4 mile) between Manager Gateway and the wired Ethernet LAN System 1


Cisco controller

Cisco

LWAP

Cisco Aironet 1520

Wi-Fi mesh network/

Wireless Bridge

EI.mesh Mgr

Gateway

RJ45

Cisco

Management

SW

Wi-Fi Ethernet bridge/mesh

Motor Pump

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System 1


Continuous monitor


Trendmaster DSM

OneWireless Server

Or

Experion PKS Server

SnapshotTM

OneWireless Gateway

OneWireless mesh

network

Onewireless

Multinode

Essential Insight.mesh over Honeywell OneWireless (wireless mesh ethernet backhaul)

Defend against SKF Wireless

EI.mesh Mgr

Gateway

RJ45


System 1


OneWireless Server Or

Experion PKS Server

OneWireless Gateway

OneWireless mesh

network

Onewireless

Multinode

Essential Insight.mesh with Honeywell (continued, GE Bently Nevada advantage)

Defend against SKF/HON Wireless

EI.mesh Mgr Gateway

RJ45

SKF + HON

VT monitor

802.11 Wi-Fi Client Wi-Fi

Ethernet mesh

SKF/HON EHM solution uses less robust Wi-Fi vs. highly robust mesh technology Our solution uses mesh plus wired connection between gateway and Ethernet backhaul

Motor Pump



System 1


Continuous monitor


Trendmaster DSM

Cisco controller

SnapshotTM

Cisco LWAP

Cisco Aironet

mesh network EI.mesh Mgr

Gateway

Essential Insight.mesh Over Cisco (wireless mesh Ethernet backhaul)

Defend against CSI SmartWireless

RJ45

Cisco

Management

SW



System 1


Cisco controller

Cisco LWAP

Cisco Aironet mesh network

EI.mesh Mgr Gateway

Essential Insight.mesh Over Cisco supporting Emersion SmartWireless/CSI

Defend against CSI & SmartWireless We provide waveforms with similar architecture

RJ45

Cisco Management

SW

CSI 9420

SmartWireless

Gateway Wi-Fi Ethernet

mesh

Motor Pump


System 1

EI.mesh certified ISA 100 (1H2011)

ISA 100 Manager

DCS

Proprietary Static and waveform data flow

Static from S1

ISA100 Certification

ISA 100 Gateway (GE pass-through or 3rd party)

EI.mesh_ISA 100

Use existing ISA 100 certified gateways

Motor Pump

System 1

EI.mesh certified ISA 100 (1H2011)

ISA 100 Manager

DCS

Motor Pump

EI.mesh_ISA 100



ISA 100 certified solutions supports complex data and any data format via tunneling

WirelessHART only supports overall values.

It DOES NOT support complex data and tunneling.

WirelessHART Gateway


Static from S1

System 1

EI.mesh certified ISA 100 (2012)

ISA 100 Manager

DCS

EI.mesh_ISA 100



GE Bently Nevada data served to directly to DCS through other vendor gateways

ISA Static from ISA GW

Motor Pump


Target Applications

Aux seal oil pump

Vertical water pump

Circulation water pump

Target application

Target application

Condenser pump

Turbine vent fans

GT turnning gear motor

Tank Farm Pumps

Target application

Fin fan heat exchangers

Application Solution Tank Farm Assets

Current Practice: Walk-arounds @ 3 week intervals

Failure Modes: Undetected Failure occurs between rounds

Our Solution: System 1 Monitoring of vibration at key points several times per day with Essential Insight.mesh

Motor

Pump

x x

x x x x

Application Solution Steam Turbine/Plant Essential Assets

Current Practice: Bi-weekly walk-arounds with visual inspection

Failure modes: 1. Pumps/Motor bearings, couplings. 2. Early detection difficult due to rudimentary detection

methods (manual inspection - eyes, ears, touch)

Wireless solution: Monitoring of vibration and temperature at key points several times per day major improvement over traditional methods.

Pump Motor Sets

Boiler Feed

Circulation Water located 450 ft away at remote cooling pond

Condensate

Make-up water small bank of pumps

Lube oil pump

Motor Pump

Application Solution Fin Fan Heat Exchangers

Current Practice Monthly walk-arounds with portables

Failure modes Reduced efficiency from fouling or environmental conditions, undetected failure between rounds

Our solution System 1 analysis of essential measurements brought in daily by Essential Insight.mesh.

wSIM plots examples Timebase Waveform

Waterfall

Trend

Spectrum

Our installed base @ December 2010

North America (20)

BP @Naperville

BP @Houston

Colmac Energy x 2

PetroCanada

ConocoPhillips@WoodRiver

Cytec concession

SDG&E @ San Diego

NextEra

Entergy

NV Energy Yerrington

Inland Empire

Europe (2)

Turow Poland

DUBLIN BAY

Latim America (1)

Int.Paper @Brazil

Asia (4)

Petronas @Malaysia

Shell @Malaysia (Pilot)

Shell @Miri

Prai Power

Middle East (4)

Saudi ARAMCO @Turaif

UAE pilot

Aramco @Al-Jouf

Qatar Petroleum @Dukhan

China (2)

SECCO (reference site)

CNOOC

Case Study

EI.Mesh Case Study.ppt

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