Essential Insight.

mesh

Wireless Condition Monitoring for Essential Assets

Why Wireless?

Part 1
Basic operating principles
Bearing failures
REB related frequencies

Integrated Condition Monitoring Program

Rotating Machines
Online - Continuous

Online Periodic

Offline Periodic

monitoring & protection

(scanning) monitoring

walk-around monitoring

3500 & TDI

3300 &
TDXNet
or TDE

Wired

Wireless
Snapshot
PDC

BOP Assets

Critical Assets

Essential Assets

Gas Turbines

Fans

Vibration

Steam Turbines

Pumps

Portable Devices

Compressors

Blowers

Lube Oil

Main line Pumps

Etc

Thermography

MCA, etc

Selecting the right CM Solution

Focused on early detection of Failure modes that have a P-F life of
30 days or less but greater than 30 minutes.
Detection of Potential
Applicable scenarios for use include:
P
failure using predictive
technology
Failure modes that can be detected
Using Casing vibration
Using Temperature
Rule of Thumb:
Sample interval no
greater than P-F

Risk = probability of failure

x
Consequence of failure

P-F Interval

Functional
Worst Case Lead Time

Failure

P F Interval

Time

Asset Criticlity Distribution

10%

5%
15%

Highly Critical
Critical
Mid Criticality
Low Criticality

40%

No Impact

30%

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.

Essential Insight.mesh
DCS, MMS, ERP, Historian

Protection

Essential Insight

(Critical Assts)

(Essential & General Purpose Assets)

Rack-Based
Monitors
3300
3500 Encore
3500
Distributed
Monitors
1701
1900
2201
3701

Essential Insight . mesh

Clipboard

Snapshot
Trendmaster

How it works

Essential Insight .mesh

Wireless Condition Monitoring

wSIM

System 1 server

Repeater

Essential Insight .mesh

Manager Gateway
Vib

Vib
TC

TC

Wireless Mesh - Network Topology

50 m

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

Wireless mesh network

Reliable/Redundant Data Routes

Legend
wSIM
repeater

Manager Gateway

Wireless mesh network

Self-healing

Alternate
data route

legend
wSIM
Repeater

Active
node

Manager Gateway

Alternate parent node

Different frequency

Wireless mesh network

Low power consumption

legend
wSIM
Repeater

Active
node

Manager Gateway

Wireless mesh network

Scalable and Self-healing

[Node added]

legend
wSIM
repeater

[Node removed]

Manager Gateway

[Node moved]

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

Components of the Essential Insight.mesh

TM)
Wireless
Sensor
Interface
Module
(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

Global Solution 2.4 GHz frequency

communication (IEEE 802.15.4) - low
rate long battery life

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

wSIM

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

Components of the Essential Insight.mesh

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)

External Line Power

Enhanced performance to match application needs without

worrying about battery life

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

Hazardous Area Approvals

wSIM - Repeater

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

IP 67

Components of the Essential Insight.mesh

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

System
1 DAQ
Plant network
TCP/IP protocol

Wireless Mesh Network

TSMP 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

25 m
50 m

Horizontal
transmission
range (50 m)

Wireless mesh network

Battery Life

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

Battery Life vs. Temp

Battery Life vs. Collection Interval

New Features

Part 1
Basic operating principles
Bearing failures
REB related frequencies

New features flexible mounting

Mounting options:
Mount for Unistrut
Stud mount
Magnetic mount

mounting example with Unistrut

mounting Bracket for Unistrut

mounting Nut for Unistrut

New features On-Demand Data

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)

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

Node provisioning / deprovisioning

Support for multiple Manager Gateways

Firmware update over the air

Configuration Tool

Simplified configuration
Full System 1 toolbox available for wireless data
Status on remaining battery life-time

Network management functionality

Alarming functionality

Network
management

Plant Map

New features more diagnostics

Acceleration Enveloping is an overall value and a dynamic
variable consisting of a waveform and its associated spectrum.

Waterfall spectrum

AE overall value are

trended to identify
early bearing faults
Upgrade wSIM
firmware only as a GE
Service

Acceleration Enveloping
Spectrum

AE spectrums help
diagnose what is failing
inner race, outer race,
cage, rolling element
Acceleration
Enveloping
requires 200157 probe

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)

Stand-Alone - Essential Insight.mesh

Plant Integration
DCS & other
systems

Plant diagnostic platform

System 1

Essential Assets / BOP

EI.mesh Mgr
Gateway

Handheld
data collector
Clipboard

Essential Insight.mesh

Continuous
monitor
SnapshotTM

DSM

Trendmaster

Standard 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 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
Cisco
Management
SW

Cisco controller

Cisco
LWAP

System 1

Wi-Fi
Ethernet bridge/mesh

Cisco Aironet 1520

Wi-Fi mesh network/
Wireless Bridge

Essential Insight.mesh

RJ45

EI.mesh Mgr
Gateway

Motor

Pump

Essential Insight.mesh over Honeywell

OneWireless (wireless mesh ethernet backhaul)
Plant diagnostic platform
System 1

OneWireless Server
Or
Experion PKS Server

OneWireless
Gateway

Essential Assets / BOP

Handheld
data collector

Onewireless
Multinode

OneWireless
mesh
network

RJ45

Clipboard

Essential Insight.mesh

EI.mesh Mgr
Gateway

Continuous
monitor
SnapshotTM

DSM

Trendmaster

Defend against SKF Wireless

Essential Insight.mesh with Honeywell

(continued, GE Bently Nevada advantage)
OneWireless Server

Plant diagnostic platform

System 1

Or
Experion PKS Server

OneWireless
Gateway

Wi-Fi
Ethernet
mesh

OneWireless
mesh
network

802.11
Wi-Fi Client

Onewireless
Multinode

SKF + HON
VT monitor

Essential Insight.mesh

RJ45

EI.mesh Mgr
Gateway

Motor

Pump

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

Defend against SKF/HON Wireless

Essential Insight.mesh Over Cisco

(wireless mesh Ethernet backhaul)
Cisco controller

Cisco
Management
SW
Cisco LWAP

Plant diagnostic platform

System 1

Essential Assets / BOP

Handheld
data collector
Clipboard

Essential Insight.mesh

Continuous
monitor

RJ45

Cisco Aironet
mesh network

EI.mesh Mgr
Gateway

SnapshotTM

DSM

Trendmaster

Defend against CSI SmartWireless

Essential Insight.mesh Over Cisco

supporting Emersion SmartWireless/CSI
Cisco Management
SW
Cisco controller

Plant diagnostic platform

System 1

Cisco
LWAP

SmartWireless
Gateway
CSI 9420

Wi-Fi
Ethernet
mesh

Essential Insight.mesh

RJ45
Cisco Aironet mesh
network
EI.mesh Mgr
Gateway

Motor

Defend against CSI & SmartWireless

We provide waveforms with similar architecture

Pump

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)

EI.mesh certified ISA 100 (1H2011)

ISA100
Certification

System 1
ISA 100
Manager

DCS

Static from S1

Proprietary Static and waveform data flow

ISA 100 Gateway

(GE pass-through or 3rd party)

EI.mesh_ISA 100

Motor

Use existing ISA 100 certified gateways

Pump

EI.mesh certified ISA 100 (1H2011)

ISA 100
Manager

DCS

ISA100
Certification

System 1

Static from S1

Proprietary Static and waveform data flow

WirelessHART
Gateway

ISA 100 Gateway

(GE pass-through or 3rd party)

WirelessHART only
supports overall
values.
It DOES NOT
support complex
data and tunneling.

EI.mesh_ISA 100

Motor

Pump

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

EI.mesh certified ISA 100 (2012)

ISA 100
Manager

ISA Static from

ISA GW

DCS

ISA100
Certification

System 1

Proprietary Static and waveform data flow

ISA 100 Gateway

(GE pass-through or 3rd party)

EI.mesh_ISA 100

Motor

GE Bently Nevada data served to directly to DCS

through other vendor gateways

Pump

Target Applications

Target application

Aux seal oil pump

Circulation water pump

Vertical water pump

Target application

Condenser pump

GT turnning gear motor

Turbine vent fans

Target application

Tank Farm Pumps

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

Moto
r

x x
x x

Pum
p

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:

Pump Motor Sets

Monitoring of vibration and temperature at

key points several times per day major
improvement over traditional methods.

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)

Latim America (1)

BP @Naperville

Int.Paper @Brazil

BP @Houston

Asia (4)

Colmac Energy x 2

PetroCanada
ConocoPhillips@WoodRiver
Cytec concession
SDG&E @ San Diego

Petronas @Malaysia
Shell @Malaysia (Pilot)
Shell @Miri
Prai Power

NextEra

Middle East (4)

Entergy

Saudi ARAMCO @Turaif

NV Energy Yerrington

UAE pilot

Inland Empire

Aramco @Al-Jouf

Europe (2)

Qatar Petroleum @Dukhan

Turow Poland

China (2)

DUBLIN BAY

SECCO (reference site)

CNOOC

Case Study