1. GE EnergyPower Generation: Combined CycleBently Nevada* Asset Condition Monitoring

2. IntroductionThe first industrial gas turbine power plant went onpioneering achievements do not stop there. For moreline in 1939, in Neuchatel, Switzerland. The simple-than 50 years, our Bently Nevada systems have alsocycle turbine generated 4 MW of electrical powerbeen monitoring the condition of machinery in powerat an overall efficiency of 17%. Today, gas turbine plants, using sophisticated technology that waspower plants generate 30% of the worlds powerinvented in our own labs by our rotor dynamicists.with combined-cycle efficiencies three times greaterthan the original simple-cycle plant. Whether its turbine supervisory instrumentationon the main turbine-generator trains, portableWhile renewable technologies form an increasing data collection systems on numerous low-criticalitypercentage of generation capacity, combined-pumps and motors, wireless vibration monitoringcycle plants will continue to play a vital role for the on cooling fans, or software to monitor theforeseeable future in meeting the worlds demand forthermodynamic efficiency of the entire generationelectrical power. cycle, we have a comprehensive portfolio of systemsand services that help you protect your machinery,GE has been there since the inception, with Edisonsmonitor its condition, and optimize its operation andfirst light bulbs and the necessary mechanicalmaintenance.equipment such as turbines and generators. But our 3. Your ChallengesWith the complexity of a modern combined-cycle inimizing unplanned outages and downtimeMpower plant, unplanned downtime is exceedingly educing fuel costsRcostly, whether from lost revenues, O&M costs,contractual penalties, or regulatory fines. As such, rotecting critical machinery against catastrophicPyour mechanical assets need to run ator even mechanical failuresbeyondoriginal design capacity, reliably and educing unnecessary maintenanceRpredictably.In the pages that follow, we will show you exactlyOur asset management solutions can help you meetwhere our solutions can be applied and the benefitsmany of your most critical challenges, such as: that they deliver in a typical combined-cycle facility, xtending the time between planned outagesE whether applied at a single plant or across an entireenterprise. educing the duration of planned outagesR aximizing an assets useful life while optimizing itsMmaintenance and operating costs 4. The Business CaseMachinery protection and asset condition monitoring systems are an investment that pays back quickly and innumerous ways. Today, such systems have moved from simply good engineering practice to good businesspractice. And for good reasonthey have proven their value time and again in not just the power generationindustry, but nearly every industry that depends upon its machinery as part of the production process. Payback through Protection Our solutions help protect your machinery from catastrophic failures and their costs. For more than 50 years, the Bently Nevada name has been recognized for its industry leadership in machinery protection and condition monitoring. Today, with more than one million channels of machinery protection installed worldwide, customers have made us the proven choice for machine protection. We not only protect your machinery, but our legendary product quality, deep application expertise, and highly competent locally available service help protect your condition monitoring investment as well. Payback through Mechanical Validation Our solutions let you capture baseline machinery conditions, pre- and post-maintenance, giving you a reference for optimal decision making. One of the most crucial times in the life of a machine is immediately after maintenance has been performed. We can tell you if all is well with systems that capture relevant data both before and after maintenance. You can instantly see if problems are present and make decisions accordingly. For many customers, the ability to knowledgeably continue with or abort the startup of a turbine-generator train can more than pay for their entire system in a single event. Payback through Predictive Maintenance Our solutions deliver information that allows you to perform maintenance when conditionsnot calendarsdictate. The results of a predictive maintenance program enabled by our condition monitoring solutions speak for themselves. Consider this European power generation customers findings when they benchmarked the 25 years they have been using condition monitoring as the basis for their maintenance decisions versus the calendar-based approach they relied on previously: Time between outages increased by 80% Outage durations decreased by 60% Fleet availability increased by 3.5% 5. Integrated Condition and Performance Monitoring ApplicHeat Recovery Steam Generators Remote Monitoring and Diagnostics Center Machinery Health Thermodynamic Performance Condition Monitoring System Health Performance and Optimization Software Efficiency /Heat Rate Optimization Supervisory Control MV/LV Electrical Distribution Equipment Gas Turbines Cooling Towers and Fans Cooling Water Pumps Boiler Feed Pumps Machinery Diagnostic Services Problem Identification Root Cause Isolation Baseline Data Collection Field Balancing and Alignment Steam Turbine GeneratorCondenser Failure Analysis Rotor ModelingSite Installation Services CMMS/ERP System Plant Data Network Turbine Supervisory Instrumentation (TSI)Protection Protection and condition monitoringOnline, continuous machinerySystem 1* Software measurements specifically for large turbine- protection generator sets; includes bearing vibration and temperatures, differential expansion, case expansion, rotor eccentricity, rotor acceleration and speed, overspeed, valve position, zero speed, and more 6. cations in Combined-Cycle Power Plants Demineralized Water System Training Gas Turbine-Driven Generators Condensate PumpsTransformers Lube and Hydraulic Oil PumpsCondition MonitoringOnline continuous Performance Online, thermodynamicOnline periodic (wired or wireless) performance monitoring andOffline periodic (portable instrument) optimization 7. Measurable Results, Tangible ValuePlant-wide value through condition monitoring occurs asset-by-asset. Our solutions for combined-cycle plantsencompass not just your critical equipment where downtime is the dominant economic driver and can reduceor even halt plant output, but also your less critical assets where maintenance and labor costs are of primaryconcern. Below are just a few examples of the dozens of different asset types we can address.Gas TurbinesPerformance monitoring can be just as critical as condition monitoring whenit comes to maximizing the efficiency of your gas turbines. GEs EfficiencyMap*software delivers continuous thermodynamic performance information thatenables you to identify and correct root causes of efficiency losses.A combined-cycle power plant uses EfficiencyMap performance monitoringsoftware, and employs GEs services team to review the data and generatea monthly Performance and Optimization Report. One report uncovered MWlosses in the gas turbine and diagnosed the root cause as a measurement errorin the barometric pressure instrumentation, causing the gas turbine to under-fire. That insight enabled the services team to quickly correct the offendingpressure instrumentation and provided a substantial savings in fuel cost for theplant. All totaled, the plant is currently saving over $500,000 USD per year as aresult of optimization opportunities identified by EfficiencyMap software and thePerformance and Optimization Reports.Steam TurbinesOur comprehensive suite of Turbine Supervisory Instrumentation (TSI)measurements combined with our thermodynamic performance monitoringcapabilities provides a total solution for protecting and monitoring steamturbines and the entire steam cycle.When a steam turbine exhibited sustained high vibration, concerned plantpersonnel consulted a Bently Nevada Machinery Diagnostics Engineer whoremotely accessed the monitoring system, identified looseness in a bearingassembly, and confirmed that the unit could stay online, deferring repairs until amore convenient time. By conducting planned versus unplanned maintenance,$900,000 USD of lost production was averted.GeneratorsBearing vibration and winding temperatures are key measurements for detectingeverything from shorted windings to misalignment to bearing instabilities. Wemonitor thousands of generators worldwide.Using System 1 software and Bently Nevada machinery protection systems, aplant was able to diagnose shorted rotor bars on a generator, yet keep the unitonline by balancing vibration levels and VARS to keep the thermal bow of thegenerator rotor to a minimum. VARS were shared across the other four units untilthis particular generator could be rewound during a planned outage. Since this isa baseload plant, the economic benefits accrued were substantial. 8. Boiler Feedwater PumpsCritical to operating your plant at full capacity, loss of a boiler feedwater pumphas significant economic consequences. Bearing vibration/temperaturemeasurements on these pumps and their prime movers are essential forprotecting against catastrophic failures and for assessing mechanical health.Increased vibration levels were detected on a boiler feed pump being returnedto service at the end of a major planned outage. The Bently Nevada conditionmonitoring system enabled plant personnel to diagnose and fix the problemwithout delaying the startup schedule and declaration of full plant availability.$90,000 USD in contract penalties were avoided, as well as potential damage tothe machine.Cooling Water PumpsCooling water pumps are a critical part of a plants cooling system and requireperiodic inspection of the bearing and seals to avoid failures. Of course,inspections can be costly due to downtime and maintenance expenses. Further,unexpected problems such as leaks often occur when the pump is returnedto service. Clearly, increasing the interval between inspections can result insubstantial savings.When this combined-cycle plant went into commercial operation, the OEMrecommended mechanical seals and bearings on four Cooling Water Pumpsbe inspected every two years. Instead, on the recommendation of GE, the plantused their System 1 software to closely monitor the bearing and seals, collectingvibration data in three-month snapshots, and found no sign of deterioration. Thisallowed for the maintenance period to be extended by 11 2 years, and inspectionsto be conducted on a 3 1 2 -year cycle versus the OEM-recommended 2-year cycle.Cooling Tower FansWhen operating at or near design performance limits, loss of even a singlecooling tower can curtail plant output. Even when curtailment is not a concern,repair costs can be substantial. The speed-reducing gearbox is a particularlyvulnerable failure location that warrants vibration monitoring.A plant lost more than $300,000 USD to cooling tower fan problems beforeinstalling permanent monitoring. In one instance, a blade sheared off completely.The resulting unbalance destroyed the entire fan assembly and parts of the tower,even though simple vibration switches were installed and a portable data collectorwas being used to check the fans monthly. After permanent monitoring systemswere installed, no further failures have occurred. 9. Comprehensive, Globally Available ServicesTechnical Support AgreementsA one-year renewable Technical Support Agreement (TSA) is automatically includedwith every product we sell. Its structure consolidates all products installed at your siteunder a single agreement for ease of administration and entitles you to phone, e-mail,and web-based support from our global network of experienced support experts.Machinery Diagnostic ServicesOur more than 70 machinery diagnostic engineers around the world are recognizedglobally for their expertise in gathering and analyzing data to document baselineconditions and troubleshoot even the most vexing machinery problems.Remote Monitoring and DiagnosticsIn many cases, traveling to the site to perform machinery diagnostics and assessmachinery health is a thing of the past. We can even work with your IT department toengineer remote connectivity solutions that are fully compliant with your corporatedata network requirements.Supporting Services AgreementsA Supporting Services Agreement (SSA) is a custom-tailored combination of individualremote and site-based service offerings that addresses the unique needs of your siteand your installation. We work with you as a partner to keep your instrumentationperforming optimally at all times and to provide hands-on assistance that helps yourealize the full potential of your condition monitoring system.TrainingWe provide in-depth technical training that is routinely praised by customers forits highly effective learn by doing labs coupled with classroom-style instruction. Acomprehensive suite of product training courses is augmented by courses that teachthe fundamentals of rotating machinery behavior and diagnostic techniques. Our coursescan be provided at any of our global training centers or at your site.Design and Installation ServicesWe can provide comprehensive project management services to install and configureour solutions, document the installation, contract and manage site craft labor, andmore. You determine the scope, from simple installation consulting to full turnkeyservices to everything in between.Reliability ServicesWe provide our customers with the tools, processes, and methodologies toidentify and implement the proper condition monitoring technologies, strategies,and predictive services for all maintainable assets required to meet their specificmaintenance and operational goals. 10. lobal ExperienceG ocalL eep Application ExpertiseD 4/7/365 Technical Support2 hermodynamic and Rotordynamic ExpertiseT emote Service Capabilities Move Data, Not PeopleR omplete Turnkey Installation CapabilitiesC 0+ Years of Condition Monitoring Innovations5 11. For more information about Bently NevadaAsset Condition Monitoring solutions forcombined-cycle power generation, contactyour local GE sales professional or visit usonline at www.ge-energy.com/bentlyGE Energy1631 Bently Parkway SouthMinden, Nevada 89423 USA+1 775.782.3611energy.bnsales@ge.com Boiler feedwater pump photo on page 8 courtesy of Sulzer Pumps Ltd. Used by permission. All rights reserved. * enotes trademarks of Bently Nevada, LLC, a wholly owned subsidiary of D General Electric Company. 2010 General Electric Company. All rights reserved. GEA18239 (07/2010)