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GE Energy

Power Generation: Coal-FiredBently Nevada*Asset Condition Monitoring

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IntroductionCentralized generation of electric power dates backto 1882 with New Yorks Pearl Street Stationacoal-fired facility. More than a century later, thetechnology and thermal efficiencies of the coal-firedcycle have improved dramatically, and the basic idea

of converting the stored energy of coal into electricityaccounts for more than 40% of the worlds power.

While renewable technologies form an increasingpercentage of generation capacity, coal-fired plantswill continue to play a vital role for the foreseeablefuture in meeting the worlds demand for electricalpower.

GE has been there since the inception, with Edisonsfirst light bulbs and the necessary mechanicalequipment such as turbines and generators. But our

Renewables

Coal

Natural Gas

Nuclear

Liquids

40

30

20

10

02006 2010 2015 2020 2025 2030

TrillionKilowattho

urs

World Electricity Generation by Fuel, 2006-2030

Sources: 2006:Derived from Energy Information Administration (EIA),International Energy Annual 2006(June-December 2008),

website: www.eia.doe.gov/iea.Projections:EIA, World Energy Projections Plus(2009).

pioneering achievements do not stop there. For morethan 50 years, our Bently Nevada systems have alsobeen monitoring the condition of machinery in coal-fired plants, using sophisticated technology that wasinvented in our own labs by our rotor dynamicists.

Whether turbine supervisory instrumentation onthe main turbine-generator trains, portable datacollection systems on numerous low-criticalitypumps and motors, wireless vibration monitoring oncooling tower gearboxes, or software to monitor thethermodynamic efficiency of the entire generationcycle, we have a comprehensive portfolio of systemsand services that help you protect your machinery,monitor its condition, and optimize its operation andmaintenance.

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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 ProtectionOur 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 industryleadership in machinery protection and condition monitoring. Today, with morethan one million channels of machinery protection installed worldwide, customershave made us the proven choice for machine protection. We not only protect yourmachinery, but our legendary product quality, deep application expertise, andhighly competent locally available service helps protect your condition monitoring

investment as well.

Payback through Mechanical ValidationOur solutions let you capture baseline machinery conditions, pre- andpost-maintenance, giving you a reference for optimal decision making.

One of the most crucial times in the life of a machine is immediately aftermaintenance has been performed. We can tell you if all is well with systems thatcapture relevant data both before and after maintenance. You can instantly seeif problems are present and make decisions accordingly. For many customers,the ability to knowledgeably continue with or abort the startup of a large turbine-generator train can more than pay for their entire system in a single event.

Payback through Predictive MaintenanceOur solutions deliver information that allows you to perform maintenance

when conditionsnot calendarsdictate.

The results of a predictive maintenance program enabled by our condition monitoringsolutions speak for themselves. Consider this European power generation customersfindings when they benchmarked the 25 years they have been using conditionmonitoring 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%

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Remote Monitoring and Diagnostics Center Machinery Health

Thermodynamic Performance

Condition Monitoring System Health

Machinery Diagnostic Services Problem Identification

Root Cause Isolation

Baseline Data Collection

Field Balancing & Alignment

Failure Analysis

Rotor Modeling

Site Installation Services

Coal Conveyor Pulverize

Condenser

Integrated Condition and Performance Monitoring App

CMMS/ERPSystem

Plant DataNetwork

System 1*Software

Turbine SupervisoryInstrumentation (TSI)Protection and condition monitoringmeasurements specifically for large turbine-generator sets; includes bearing vibrationand temperatures, differential expansion,case expansion, rotor eccentricity, rotoraccelleration and speed, overspeed, valveposition, zero speed, and more

PA FansCooling Towers and Fans

Condensate Pum

Circulating Water Pumps

MV/LV Electrical Distribution Equipment

ProtectionOnline, continuous machineryprotection

Steam Turbine Generator

Performance and Optimization Software Boiler Optimization

Efciency / Heat Rate Optimization

Slagging Mitigation

Supervisory Control

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Boiler TrainingDeaerator and Drum

tions in Coal-Fired Power Plants

Condition MonitoringOnline continuousOnline periodic (wired or wireless)Offline periodic (portable instrument)

Boiler Feed Pumps

TransformersFeedwater Heater

PerformanceOnline, thermodynamicperformance monitoring andoptimization

FD Fans

ID Fans

Slurry Pumps

Air Preheater

Economizer

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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.

Following a boiler restart, a 400 MW turbine exhibited sustained high vibration.Concerned, plant personnel consulted a Bently Nevada Machinery DiagnosticsEngineer who remotely accessed the monitoring system, identified loosenessin a bearing assembly, and confirmed that the unit could stay online, deferringrepairs until a more convenient time. By conducting planned versus unplannedmaintenance, 900,000 USD of lost production was averted.

Measurable Results, Tangible ValuePlant-wide value through condition monitoring occurs asset-by-asset. Our solutions for coal-fired 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.

GeneratorsBearing vibration and winding temperatures are key measurements fordetecting everything from shorted windings to misalignment to bearinginstabilities. We monitor thousands of generators worldwide.

A 2 GW plant monitors all five of their main T-G sets with System 1 softwareand Bently Nevada machinery protection systems. In one incident, the plantwas able to diagnose shorted rotor bars on a generator, yet keep the unit

on-line by balancing vibration levels and VARS to keep the thermal bow of thegenerator rotor to a minimum. VARS were shared across the other four unitsuntil this particular generator could be rewound during a planned outage.Because this is a base-load plant, the economic benefits accrued were substantial.

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 at a 735 MW coal-fired facility.The Bently Nevada condition monitoring system enabled plant personnel todiagnose and fix the problem without delaying the start-up schedule anddeclaration of full plant availability. 90,000 USD in contract penalties wereavoided, as well as potential damage to the machine.

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FD/ID/PA FansVital to the combustion process, loss of a fan can constrain plant capacity.Blade unbalance is a common problem that can destroy bearings, foundations,and even the entire fan. Energy loss is another common problem whenoperating too far from the Best Efficiency Point.

A steady increase in FD fan vibration was monitored for two months until aninspection could be performed during a planned outage. Loose foundation boltsalong with unbalance from accumulated blade dust were found and correctedwithout impacting power production. In contrast, because no monitoringsystem was installed, similar problems with an FD fan at a sister plant led tocatastrophic failure and more than 1MM USD in losses.

PulverizersUnder certain conditions, loss of even a single pulverizer can impact production.A particularly common failure mode is broken gear teeth. Vibration monitoringis effective in detecting this and other problems, enabling proactively plannedmaintenance that minimizes production impact.

An Asian power plants pulverizers suffered from poor availability (below 90%).Within months of installing an online condition monitoring system, availability

had reached 93% and was steadily climbing. In one incident, five broken gearteeth were detected before catastrophic failure could ensue with elevatedrepair costs. A temporary fix was implemented until a planned outage, savingthe plant more than 90,000 USD and averting considerable lost production.

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 aconcern, repair costs can be substantial. The speed-reducing gearbox is aparticularly vulnerable failure location that warrants vibration monitoring.

A plant lost more than 300,000 USD to cooling tower fan problems beforeinstallingpermanent monitoring. In one instance, a blade sheared offcompletely. The resulting unbalance destroyed the entire fan assembly andparts of the tower, even though simple vibration switches were installed anda portable data collector was being used to check the fans monthly. Afterpermanent monitoring systems were installed, no further failures have occurred.

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Comprehensive, Globally Available Services

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.

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 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.

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.

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.

Technical Support AgreementsA one-year renewable Technical Support Agreement (TSA) is automatically includedwith every product we sell. Its structure consolidates all products installed at your site

under 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.

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 instrumentation

performing optimally at all times and to provide hands-on assistance that helps yourealize the full potential of your condition monitoring system.

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Outstanding Saety Record

Global Experience Local Presence in 40+ Countries

Deep Application Expertise

24/7/365 Technical Support

Thermodynamic and Rotordynamic Expertise

Remote Service Capabilities Move Data, Not People*

Complete Turnkey Installation Capabilities

50+ Years o Condition Monitoring Innovations

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Photo pages 2-3 courtesy of Mirant Pagbilao Corporation.Used by permission. All rights reserved.

Boiler eedwater pump photo on page 8 courtesy o Sulzer Pumps Ltd.Used by permission. All rights reserved.

FD an photo on page 9 courtesy o Howden Group Ltd.Used by permission. All rights reserved.

* Denotes trademarks o Bently Ne vada, LLC, a wholly owned subsidiary oGeneral Electric Company.

2009 General Electric Company. All rights reserved.

GEA17603 (09/2009)

For more information about

Bently Nevada Asset Condition

Monitoring solutions for coal-fired power

generation, contact your local GE sales

professional or visit us online at

www.ge-energy.com/bently

GE Energy

Bently Nevada Asset Condition Monitoring

1631 Bently Parkway South

Minden, Nevada 89423 USA

+1 775.782.3611

energy.bnsales@ge.com