System 1® - Condition Monitoring Software
Condition Monitoring Software and Diagnostics Software Platform
Widely used across many industries, GE's System 1 condition monitoring software enables plant personnel to quickly identify important events, evaluate the situation, and respond, leading to increased equipment availability, reliability, and reduced maintenance costs.
System 1 is GE Energy’s patented condition monitoring software platform for real-time optimization of equipment and selected processes, condition monitoring, and event diagnostics. Similar in concept to a process control system which allows users to understand, diagnose, and control their process conditions in real time, the Bently Nevada System 1 platform provides this capability for the assets that drive your process.
- Increased safety
A single “miss” on safety or the environment can be disastrous. Proactive capabilities mean fewer, less severe mechanical failures that could impact people and the environment.
- Improved reliability and availability
Healthy assets are assets you can depend on when they are needed. Problems can be identified and dealt with early in the progression of symptoms – before they translate to expensive downtime.
- Optimized maintenance costs
System 1 helps you plan maintenance by allowing you to base decisions on actual condition – so you can fix only what really needs fixing and address problems when they are small and less expensive.
- Lower energy costs
Energy costs are often a plant’s single largest operating expense. System 1 helps assess and correct the conditions that waste energy.
- Fewer forced outages, less lost production
Even the most expensive repair and maintenance costs are often eclipsed by the enormous costs of lost or reduced production. System 1 can generally save one or more days of lost production due to mechanical failures in the first year alone, often paying for the entire system in a single “event.”
- Increased thermal efficiency/optimized heat rate
System 1 can provide the information you need to understand and correct degradations in these important parameters, and optimize the balance between energy costs, maintenance costs, and production revenues – often translating to significant financial benefits.
- Increased employee productivity
In today’s “lean” environment, people are already spread too thin. Instead of using people to hunt for problems, System 1 allows your people to work on identified problems, armed with relevant information on the identified symptoms and root causes.
- Move data, not people
With its remote access capabilities, System 1 can reduce travel costs, minimizing the need for people to move from place to place collecting data, and leaving them extra time for completing more meaningful activities. Data can not only be collected remotely, it can be analyzed remotely, allowing users to more easily manage assets from various locations – whether across an entire globally dispersed enterprise, or simply another process unit elsewhere in the plant.
- Easier collaboration
Key information can easily be shared between all relevant parties – employees, contractors, suppliers, or consultants – in real time. Enhanced collaboration means more relevant expertise can be applied to problems for faster, better resolution.
- Faster response, reduced human variance
Abnormal situations can be stressful, making it difficult for people to respond both quickly and properly. System 1 delivers Actionable Information* advisories that tell your people exactly how to respond to events – you decide in advance and embed these details right in the software. Instead of deciding how to respond, personnel can respond with predetermined actions – and at the speed your business demands.
- Sophisticated alarm management
System 1 enables true “management by exception” with its sophisticated alarm handling capabilities for the entire enterprise, ensuring that only relevant events and alarms are delivered to your operations and other personnel. No more overwhelming alarm lists, nuisance alarms, and cryptic messaging with insufficient details – you control the level of attention given to each event, the type of notification, the people notified, and all other details.
- Configurable data acquisition and storage resolution
Data capture can be individually configurable for each point and can be triggered by an event, by the state of another variable, by predetermined time intervals, or any combination of these parameters. “Dead band” capabilities ensure that data which is not changing within user-configurable limits for each point can be suppressed from storage – helping keep database sizes compact without missing important information and events or disrupting trend resolution.
- Powerful analytic and diagnostic capabilities
Data can be manipulated and presented using an extensive library of tools and functions – data can even be exported to spreadsheets and imported again for special calculations. Advanced plot management tools – such as plot grouping – make it easy to create, save, access, and duplicate plots of common interest. Users can quickly see what happened before and after an event using intuitive “zoom in/zoom out” capabilities on plot time ranges.
- Support for Virtual Private Network (VPN) technologies
VPN technologies are being increasingly used by many of our customers for accessing their corporate networks via a public Internet connection – without compromising security. System 1 fully supports this technology, providing the most convenient remote access capabilities we’ve ever been able to offer.
- Fully customizable displays
Just as you configure and personalize your Windows® desktop, System 1 users can individually configure their display capabilities, ensuring that only those assets and portions of the enterprise relevant to them are presented.
- Enhanced IT management and support capabilities
System 1* has been designed for highly secure and robust operation without the need for extensive support from your company’s Information Technology Department, while still providing powerful tools and capabilities for them to centrally manage the PCs across your enterprise.
- One database
System 1 integrates numerous data sources into a single system, reducing the need for learning and maintaining multiple systems. Portable data collectors, online wired and wireless continuous and intermittent measurement systems, manually entered data and notes, and many other data sources – all are now brought together in a single system.
- Highly scalable
Your System 1 implementation can start small and build through an architecture and pricing structure that has been deliberately designed for scalability and affordability. Pay for what you need today, add what you need tomorrow.
- One user interface
System 1 accepts data from multiple sources but eliminates the need for learning and navigating multiple user interface environments – providing a consistent, intuitive look and feel for viewing data and information. When you need access to external systems and user interfaces, its built-in DocuView* features provide consistent, easy-to-use access to supplementary programs, data, drawings, documents, web pages, and any other information that you can link to from your computer.
- Root cause analysis
System 1 provides unrivaled root cause diagnostic capabilities by allowing users to “drill down” and examine the sequence of events leading up to a problem, analyze the data using powerful graphical and tabular presentation formats, and then document this learning, either by posting notes in the database or by generating new rules, capable of automatically analyzing future events with the same root cause.
New System 1 Bundling
System 1 for Power Generation
Our new condition monitoring platform System 1 for Power Generation is a pre-licensed System 1 package (point size and interfaces) that is designed to meet the needs of power generators.
Application Packages provide the ability to view the plots relevant to a specific type of asset or application. There are a number of software packages available that address many of our customers' most often-requested applications.
Lubricant Analysis Data Import
Bently Nevada System 1 Lubricant Analysis Data Import Application Package allows customers to work with their existing labs to receive lubricant analysis data in a “.csv” (or Excel) format that we have defined for easy lubricant data import into System 1. Once the data is in system 1, general trending, easy correlation of lubricant analysis data with other condition monitoring data, alarm and event trigger configurations, and Decision Support rules can be performed and implemented to provide a better overall picture of machinery health and to help make better decisions regarding plant performance. Correlating lube data with other condition monitoring and process readings reduces missed failures and enables optimization of overall maintenance expenses with minimized negative impact to from an equipment failure mode.
System Extender modules are designed to work in conjunction with one or more types of System 1 applications, providing extended functionality applicable to a particular asset type, data collection method, or optimization task. Available System Extender modules include:
Dry Gas Seal Monitoring
The Dry Gas Seal System 1 RulePak enables customers to understand their seal health and take appropriate action ranging from “run to next outage” to “immediate shut down and repair. This new capability increases the ability to reduce process gas leakage during production runs and reduce flare events due to leakage. It also enables Condition Based Maintenance for compressor dry gas seal system and provides proactive advisories on the most common failure modes enabled at levels below control or protection alarms and trip setpoints. Additionally, machine availability is improved via more intelligent planned maintenance and fewer unexpected outages.
Corrosion and Erosion Monitoring
This extender detects and reports on piping system wall thickness, enabling you to trend and mitigate degradation from corrosion and erosion. Managing wall thickness and other fixed assets presents a costly challenge to most plants. Rightrax with the System 1 platform can integrate the most critical piping and vessel assets into a condition-based maintenance program. Such a program can typically produce a one year ROI based on moving time based inspection costs to an on-line condition monitoring infrastructure and management program.
GEnyus System 1® System Extender
Combines the domain expertise derived from an installed fleet of 6,500 GE Oil & Gas reciprocating compressors, with more than 40 years of Bently™ Nevada condition monitoring experience on recips, to create a powerful package that harnesses all of this knowledge – and available in a tightly integrated component of System 1 software.
Traditionally, protection bands from the Bently Nevada 3500/70M monitor and threshold alarms from other 3500 monitors alert users to the problem areas within these data sets. The Impact/Impulse RulePak builds on this proven foundation to provide powerful real-time analytics on your reciprocating compressor data, integrating synchronized pressure, load, and vibration measurements.
Interfaces to many of today's most common maintenance management platforms including:
- SAP** R/3** plant maintenance module
- MAXIMO** system from MRO Software and others
Allows users to generate and maintain their own custom rules for use by System 1's standard decision support and notification capabilities.
Pre-configured rules that embed GE mechanical diagnostic expertise for specific machinery types. Individual RulePaks are available for the following:
- Steam Turbines
- Reciprocating Compressors
- Industrial Gas Turbines
- Aeroderivative Gas Turbines
- Electric Motors and others
|System Minimum Computer Requirements||
For demanding online DAQ (Data Acquisition) installations, we strongly recommend that you use an approved and tested server grade computer. For a list of approved servers, please contact your local Sales and Service representative.
For limited online, portable, or Display/Configuration installations, the following requirements are the recommended minimum for the System 1 software to operate. If your system does not meet these requirements, the performance of the application may not be acceptable, and in some cases the software will not run properly. We strongly recommend that you contact your local Sales and Service representative for a list of tested and approved workstations.
2.83 GHz Intel Xeon processor
2 GB RAM
250 GB hard disk drive
Available USB port
256 MB video card
Data Acquisition; Database (Microsoft SQL 2005, 2008) Software
Windows Server® 2003 SP2
Windows Server® 2008 SP2
|Display; Configuration; Data Acquisition (Small Snapshot Only) Software||
Windows XP SP 3
Windows Vista SP2
Windows Server 2003 SP2
Windows Server 2008 SP2
Note: When ordered from GE, server operating systems come with 5 Client Access Licenses (CALs). Further, server operating system licenses are restricted to only be used for GE applications or in support of GE applications.
Number of simultaneous Display/Configuration clients for Data Acquisition /SQL Server Station :
Windows Server® 2003
|Virtually unlimited simultaneous clients restricted by licenses/CALs|
|Windows XP / Vista / Windows 7||10 simultaneous clients restricted by licenses/CALs|
Systems may support the following hardware depending on the ordered Application Packages. System limitations are listed below.
|Supported Monitor Systems and Communication Processor Types||
3500, 3300, 2201, 1701
TDI, TDXnet, TDIXconnX™, TDe
|Supported Portable/Scanning Types||
Trendmaster® Pro DSM
Snapshot Clipboard™ via PDA
Note: See Snapshot Clipboard data sheet, part number 162458-01, for additional devices.
|Maximum number of Communications Processors (CP)/ Equivalent FieldMonitor™ units per data acquisition station||12|
|Maximum number of TrendMaster® Pro DSMs per data acquisition station||150|
|Maximum number of nodes in an Essential Insight.mesh network||100|
|Maximum number of points ( 100 nodes X 4 points per node) in an Essential Insight.mesh network||400|
|Maximum number of Essential Insight.mesh networks supported per DAQ (without exceeding 2500 total points per DAQ limit)||5|
|Maximum number of Modbus® devices per data acquisition station||150|
|Maximum number of FieldMonitor units per data acquisition station||36 (3 FieldMonitor units = 1 TDXnet CP)|
|Maximum number of Snapshot devices per data acquisition station||Unlimited
Note: 1 Snapshot DAQ per Enterprise
|Maximum number of configurable machine trains||Unlimited|
|Maximum number of configurable portable points per data acquisition station||20,000 portable points|
|Maximum number of configurable online/scanning points (includes Trendmaster Pro and communication processor points) per data acquisition station||2500 total combined online/scanning points|
|Maximum number of configurable points per enterprise||45,000 (Limited only by the maximum number of points per data acquisition station)|
|Maximum number of lube test results||
portable points + lube results may not exceed 20,000
|Data Historian Maximum Limits (Process Data Only) Mid-Range Server||5,000 configured tags/DAQ server|
|SQL Server on Mid-Range Server||5000 events/second|
|High Range Server (requires 4GB RAM)||25,000 tags/DAQ server|
SQL Server on High Range Server (requires 4 GB RAM)
Maximum trend file length
|Unlimited; dependent on available system hard drive space.|
|Maximum number of system/alarm events per data acquisition station||Unlimited; dependent on available system hard drive space.|
|Maximum number of concurrent viewable events||10,000 events viewable within event list.|
|Network Transport Protocols||TCP/IP|
System1 clients – Display, Configuration, Smart Notifier and DAQ Connection manager – have been translated into 10 non-English languages. A language license is per Enterprise.
The supported operating system for non-English translations is the English version of Microsoft Windows. The Online Help system is available only in English.