GE Energy Measurement & Control Solutions · PDF fileAll GE Measurement & Control Solutions product training is conducted by our ... Fundamentals of Vibration and Transducer...

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IntroductionAll GE Measurement & Control Solutions product training is conducted by our core group of customer training instructors, or certified regional Field Service Engineer instructors to provide a world-class training experience for our customers. Measurement and Control Solutions offers comprehensive, self-paced, and hands-on instructor led courses designed to help you protect and manage all your machinery.We provide a training curriculum, and consulting services for applications involving all facets of power generation, mechanical drives and petrochemical industries. Our services include needs and gap analysis, objective development and skills based training solutions.

ContentsCondition Monitoring .............................................................................................................................2Systems and Instrumentation ..........................................................................................................3Machinery Diagnostics .........................................................................................................................5Thermodynamic Performance ..........................................................................................................7Computer Based Training (CBT) ........................................................................................................8Legacy Products, Systems and Services ......................................................................................9Skills Development Program ........................................................................................................... 10

Condition MonitoringFundamentals of Vibration & Transducer Operation( 2 days )

Fundamentals of Vibration and Transducer Operation course provides an overview of the theory of operation, applications, installation, and troubleshooting of vibration transducers, including displacement (proximity), velocity (moving coil & piezoelectric), acceleration (piezoelectric), and optical phase reference sensors. The workshops are designed for maximum interaction with the equipment, and provide an opportunity for the students to work hands-on with the transducers.This hands-on course provides practice that will help participants understand what vibration is, the different types of transducers and how each transducer works. Upon completion of the course, the student will be able to:• Understand measurement parameters and concepts• Take vibration and position measurements• Take non-vibration & other position measurements• Understand velocity seismoprobe transducer installation system operation• Perform accelerometer, velomitor and miscellaneous transducer installations• Understand transducer orientation• Identify noise, errors, & shaft bow (runout)

3500 System Operation & Maintenance ( 3 days)

A hands-on course for anyone involved with operating and maintaining a 3500 Monitoring System. Topics include overview of hardware components, rack configuration, operator display software, data acquisition software, and system troubleshooting and maintenance. Workshops include practice with ‘live’ monitors and racks. Class sizes are kept small to ensure that students have the opportunity to fully explore the capabilities of the system.The student will be able to use 3500 Rack Configuration software to configure, maintain, and troubleshoot the transducers and 3500 Monitoring System used to protect monitored machinery.Upon completion of the course, the student will be able to:• Correctly assemble the components of a

Proximity Transducer System and verify the system meets specifications by use of a TK-3 and multimeter

• Properly connect field wiring for specific input signals to the 3500 Monitoring System

• Use a computer to make a connection to the 3500 Monitoring System, upload the racks configuration, download a configuration change to the rack, and save the configuration file to the computer hard drive

• Configure channels of a 3500 Monitoring System for Radial Vibration and Thrust

• Return the 3500 Monitoring System to proper operation and verify that all signals are being read correctly and that all relay logic is operating correctly

System 1* Fundamentals (3 days)

This instructor-led course teaches students to use the System 1* software in a variety of practical daily use situations. Workshops demonstrate how the platform can be used efficiently to minimize time spent looking at non-significant data, and to focus on the information that is needed to make good management

decisions. The course can be tailored to specific asset types: Hydro, Wind, Reciprocating Compressors, Motors, Turbines, Compressors, and other machinery.Upon completion of the course, the student will be able to:• Use various System 1* tools and plots to

detect subtle changes in asset condition• Retrieve and display data in bar graphs and

various plot formats• View alarms and events in the Event Manager• Enter observations and notes with the Journal

Editor• Create reports on monitored plant assets• Gain a practical understanding of how Bently

Nevada communication processors such as TDI or TDXnet collect transient data

Getting the most from Trendmaster* Pro ( 2 days)

Similar in scope to our Trendmaster* 2000 course, the Trendmaster* Pro course covers the specific components used by the newer Trendmaster* Pro system including Dynamic Scanning Modules, programmable Transducer Interface Modules (TIMs), and System 1* software. Workshops demonstrate how the customer can minimize ‘down-time’ by effectively using the Trendmaster Pro system for Plant Asset Management.Upon completion of the course, the student will be able to:• Use System 1* Display software to verify

communication with the periodic online scanning system

• Utilize the features of the Dynamic Scanning Module

• Take advantage of the features in the programmable TIMs

• Use the DSM Initialization utility for performing analysis tests with proTIMs

• Learn techniques to ensure Trendmaster* Pro is providing good data

Systems and Instrumentation

Getting the most from ADRE* and the 408 ( 3 days)

This hands-on course teaches the skills necessary to ensure the highest quality of data acquisition and presentation using the ADRE* diagnostic system. The course begins with the basics in system configuration and continues through advanced database manipulation tools. The skills you learn will help you get the most value from ADRE* Sxp software and the 408 DSPi.Upon completion of the course, the student will be able to:• Display vibration and other data types using

various plot types for machine condition analysis

• Configure the ADRE* system to collect machinery data

• Acquire data effectively for real-time analysis• Edit, document, and store databases for future

use

Snapshot* IS Portable Data Collector ( 2 days)

This course teaches students how to use the Snapshot IS portable data collector to gather data, configure and download routes and upload data once it has been collected. Workshops demonstrate how portable data collection can be used to augment and supplement the online monitoring that may already be present in a plant. Upon completion of the course, the student will be able to:• Use the Snapshot* IS portable data collector• Use the Application Manager to navigate

through the various Snapshot applications• Explain how to download a Snapshot route

from System 1* to the Snapshot* IS portable data collector

• Practice uploading collected data from a Snapshot unit to System 1* software and displaying the collected data

• Explain how to find a starting point for selecting band-pass filter settings

Decision Support SM ( 3 days)

This course shows students how to use the Decision Support tools within System 1® software to enhance their ability to manage their plant assets. Examples and case scenario discussions help students apply Decision Support to their needs. Workshops give hands-on practice in creating rule logic and sending notifications with recommended action advisories.Upon completion of the course, students will be able to:• Create rule logic that calculates new data

values or custom events.• Create user-defined recommended action

advisories for delivery when events occur.• Use notification tools to send automatic

notifications and recommended action advisories via cell phone, pager, email, XML, Smart Notifier, or other delivery means.

• Use Decision Support Studio to create advanced rule logic, test them, and bundle them into custom RulePaks for fleet distribution.

Machinery Diagnostics ( 5 days)

This course builds upon what was learned in the Data Acquisition computer-based training, providing the foundation for machinery diagnostics. The hands-on approach gives students the experience they need to feel confident when taking action at their plant. This is a “must have” course for those who interpret or plan on interpreting machine vibration and position data to determine machine condition.Upon completion of the course, the student will be able to:• Understand how the fundamentals of machine

design and behavior are reflected in the vibration measurements

• Learn how to reduce machine vibration data into usable plot formats. Learn which plot formats are best to use in the different stages of machine diagnostics

• Learn the causes, affects and indicators of the typical machine malfunctions; including recognition of problems such as unbalance, misalignment, rubs, shaft cracks and fluid-induced instabilities

Machinery Fundamentals and Applied Diagnostics( 5 days)

Students will review the different machine types commonly encountered in industry as well as the characteristics of design and construction that influence behavior under both normal and malfunction conditions. This course helps new machinery diagnosticians gain knowledge and confidence. Experienced diagnostics people gain additional insight needed to efficiently solve complex machinery problems. This course is an advance-learning course; full of case histories intended to sharpen diagnostic skills by leading participants through the common malfunctions of many machine types using multiple case histories.The Applied Diagnostics Workshop is designed to be very flexible. Students can select which machines they would like to focus on, and then

diagnose problems specific to those machines.Workshops are the main focus of this course wherein each student analyzes actual machine case histories using the most advanced diagnostic tools available. The Data for these case histories have been collected by Bently Nevada Machinery Diagnostic Engineers while solving customer’s machinery problems. The student organizes data in plot formats believed to be indicative of the machinery fault. The students will present their conclusions and make recommendations to resolve the problem.Finally, the students compare their findings to the actual results of the case history. In classroom demonstration will also be done for some of the malfunctions analyzed.

Advanced Machinery Dynamics ( 5 days)

Designed for engineers who are responsible for managing rotating machinery assets, this course includes presentations of advanced rotor dynamic turbo machinery concepts. Hands-on workshops using the latest monitoring and diagnostic tools, portable rotor test rigs, and case histories from actual field studies complement the practical aspects of the analytical techniques used in this course. At the conclusion of the course, students shall be capable of conducting root cause analysis through the understanding of the fundamental forces and stiffnesses that are evident in machine malfunction behavior.Upon completion of the course, the student will be able to:• Discuss rotating machinery dynamics in terms

of forces, stiffnesses and responses• Develop a rotor model and use the

fundamental relationships• Conduct modal perturbation testing• Identify dynamic stiffness parameters in real

machines• Conduct multiplane balancing using polar

plots and static and couple balancing techniques

Machinery Diagnostics

• Analyze case histories (misalignment, unbalancing, rubs, instability, etc.)

• Control rotor system stability• Analyze shaft cracks emphasizing detection &

prevention• Discuss how condition and performance

monitoring provide a complete picture of machine behavior

Reciprocating Compressor Condition Monitoring& Diagnostics ( 3 days)

In this instructor-led course, students will learn how to properly instrument a reciprocating compressor, interpret data plots and identify reciprocating compressor malfunctions. The course includes hands-on workshops with actual case histories.Upon completion of the course, the student will be able to:• Relate reciprocating compressor components

to various failure modes• State how crank angle measurements affect

the reciprocating compressor data plots• Interpret PV Plots: Use cylinder pressure

versus volume plots, as well as performance monitoring to determine throw condition

• Calculate rod load conditions (reversal)• Discover the full applications and benefits of

rod drop and rod position measurements• Conduct compressor vibration analysis

Unlocking your plant’s potential

GE offers several different software products to help you maximize the efficiency of your plant. Whether you are looking for increased profitability, better environmental compliance or to maximize raw material usage, we have a training course designed to show you how to achieve any or all of these benefits.

Gate Cycle - Plant Thermodynamic Modelling ( 5 days)

This instructor-led course is designed for students who have little or no experience using GateCycle thermodynamics modeling software. By the end of the course, students will be able to use GateCycle to make both basic and sophisticated models of thermal plant cycles. Students are strongly encouraged to bring their own project data and their own computer for use in the workshop, allowing them to apply the skills they learn to actual field applications. Facilitated workshops can also be conducted, tailored to a specific plant or project.Upon completion of the course, students will be able to:• Create and troubleshoot plant models.• Analyze thermodynamic case histories.• Create design and off-design cases.• Manage databases and create reports.• Effectively use mass flow control and pressure

feedback.• Enhance plant models using custom

calculations, macros & linking.• Effectively use complex equipment models.• Use convergence & damping factor.• Complete plant-specific workshop sessions.

EfficiencyMap - Plant Performance and Optimization ( 3 days)

Plant Engineers, owners, operators, and managers responsible for thermal performance understand that fuel is the single largest annual cost. Knowing how to get the most from every BTU is not just a good idea - it’s absolutely

essential in today’s competitive environment. In this course, students learn how to use the EfficiencyMap online system to continuously monitor a plant’s overall and equipment efficiencies.Upon completion of the course, students will be able to:• Discuss the practical aspects of combined

cycle thermodynamics.• Relate how different plant configurations

affect the heat balance.• Determine how on and off design affects the

plant.• Discuss how controls & combustion affect

performance.• Discuss how condenser & vacuum systems

affect performance.• Understand how plant & component testing

are used in model validation.• Detect and determine how to recover from

performance degradation.• Learn how to evaluate economic payback

from managing performance.

Bently PERFORMANCE™( 3 days)

This instructor-led course begins with a review of basic thermodynamic concepts. Students then learn to use Bently PERFORMANCE and System 1® Software to evaluate the condition of steam turbines, centrifugal compressors, and other machines/assets as their performance degrades due to various causes.Upon completion of the course, students will be able to:• Derive maximum benefit from the Bently

PERFORMANCE software in your plant.• Interpret and use thermodynamic calculation

results and plots.• Gain the skills necessary to evaluate the

condition of steam turbines and centrifugal compressors based on their thermodynamic performance.

Thermodynamic Performance

Data Acquisition CBT

The Data Acquisition application is a self-paced tool designed to introduce the use and proper application of vibration transducers. This provides the foundation to the science and methodology behind our Bently Nevada™ rotating machinery diagnostics. This tool uses a multi-media environment to demonstrate concepts and challenges the student through interactive animations and quizzes.Product Features• Understand how data is used to create plots and other graphical representations of machine

behavior.• Learn how to properly install a proximity probe or casing-mounted transducer.• Explain and identify the causes and corrections for noise and other error sources• Learn the conventions used by our own technicians and engineers.

Machine Library CBT

The Machine Library is a collection of machine behavior and reference material covering the field of machinery diagnostics. Included are interactive animations demonstrating the physics of machine response, as well as presentations and papers that provide insight into Bently Nevada™ machinery diagnostics. This tool should be considered the next step after attending one of our machinery diagnostics instructor-led courses.Product Features• Learn complex topics such as Fundamental Synchronous Rotor Response.• See simulations of Full Spectrum, Orbits and other data presentation methods.• Easy access to instruction at any time to reinforce a concept or principle of machine behavior

Computer Based Training

3300 Operation & Maintenance ( 3 days)

This hands-on course provides practice that will enable you to fully benefit from your 3300 Monitoring System. Topics include system maintenance and troubleshooting, self-test capabilities, jumper installation, monitor calibration, and common options and features. Workshops include practice with ‘live’ monitors and racks. Class sizes are kept small to ensure that students have the opportunity to fully explore the capabilities of the system.Upon completion of the course, students will be able to:• Identify the different hardware components of

the monitoring system• Successfully identify a matched and

mismatched system, installation pitfalls, proper installation procedures, and running a probe curve verification using the TK-3

• Explain all of the standard programmable options and their uses in detail

• Successfully setup the programmable jumper options of the 3300/16 monitor, calculate input signals, and verify the monitor using test equipment (function generators, power supplies, DMM)

• Successfully setup the programmable options for the 3300/20 monitor, calculate the input signals, and verify the monitor using test equipment (power supply, DMM)

• Successfully identify an error code in the system and perform the necessary steps to clear the error

• Identify an indication of potential problems within the 3300 monitoring and/or Proximity Transducer system and how to go about the troubleshooting process

Trendmaster 2000 ( 3 days)

This hands-on course covers the configuration, installation, and use of the hardware and software components in the Trendmaster 2000 system. Students will set up and configure a Trendmaster 2000 system using the actual

hardware and software, and then use the software to display machine data, and create reports and other documentation. Students will verify the operation of monitors, make changes to their configurations, collect static and dynamic data, evaluate alarms and system events and practice remote and networking capabilities.• Explain the difference between and typical

applications of online, online periodic and offline monitoring systems.

• Plan, install, and configure the measurement points for a Trendmaster 2000 system.

• Configure, gather and view data using the Trendmaster 2000 software.

• Display vibration and other data types using various plot types for machine condition analysis using the Trendmaster 2000 software.

• Troubleshoot TIM failure and communication problems.

ADRE for Windows® and the 208 DAIU ( 3 days)

This hands-on course teaches the skills necessary to ensure the highest quality of data acquisition and presentation using the ADRE diagnostic system. The course begins with the basics in system configuration and continues through advanced database manipulation tools. The skills you learn will help you get the most value from ADRE for Windows software and the 208 DAIU.Upon completion of the course, students will be able to:• Display vibration and other data types using

various plot types for machine condition analysis.

• Configure the ADRE system to collect machinery data.

• Acquire data effectively for real-time analysis.• Edit, document, and store databases for

future use.• Operate various ADRE tools to manipulate

data and perform advanced analysis.

Legacy Products and Systems

In addition to scheduled training programs, GE also works with you to develop a comprehensive skills development program specifically designed to address your needs. A comprehensive Skills Development program will help you to build sustainable competencies and maximize your return on investment on Condition monitoring technologies.

The first step in our skill development program is establishing a role based competency matrix. This will be achieved by combining your organization’s job descriptions and Condition monitoring best practices from GE. All members of team will be assessed against competency matrix specific to their role to identify skills and competency gaps. Based on the skill gaps identified, Condition Monitoring technologies deployed at site and site operational constraints a roadmap to build sustainable competencies will be developed.

By using customized training content and state of art training aids our certified instructors will conduct learner centered training sessions at your site. Later employees will work on identified on-job training opportunities under the mentorship of our subject matter experts to acquire valuable practical skills and build confidence in facing key challenges in your facility.

As we progress through the program, our subject matter experts from the regional offices and factory will mentor key personnel from your organization as “Power Users” of the products and systems. These power users equipped with plant specific knowledge and advanced awareness of the systems will be able extract maximum benefit from the systems deployed and improve the ROI.

If you think this would be of interest to you, we can start working on defining the competency matrix and developing the plan to make sure your teams are equipped with all the knowledge and confidence to efficiently manage your plant assets.

You can contact our regional contacts at the phone numbers listed below for inquiries on Skills development program.

Skills Development Program

SME’s

“Collaboraate”

“Empower”

“Experience”

Diagnostics

Systems

Assessment

Software

“Aware”

Technology

Awareness

Sessions

Performance

Monitoring

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