Reliability and condition
monitoring solutions for thesugar production industry

Why partner with Bently Nevada?
We have earned your trust. For six
decades the Bently Nevada product line
has supported the most demanding
applications in multiple industries. Andeven as we protect and monitor yourmachinery, we constantly strive to refine
and improve our offerings—and help
enable your success.
We design and deliver solutions for allof your monitoring needs—including
sensors, distributed and rack-based
monitors, software, and supporting
services—with the following goals:• Increased availability and production• Lowered maintenance costs• Reduced risk in terms of safety,environmental, and asset upsets
Quantifiable, proven results:• Over 60 years of innovation in asset
protection and condition monitoring• Over 85,000 3500 Series monitoring
systems installed globally• Over 4 million sensor
monitoring points• Services support globally• Over 1,600 System 1 software
users worldwide• More than 240 international patents
issued, including over 150 in the U.S.
• More than 360 international patents
pending, including over 95 in the U.S.

Industry challenges
Sugar is virtually in everything we consume, including alternative fuels in many parts of the world. Table sugar is extracted
from the roots of sugar beets and the stalks of sugarcane. It’s a big business: The world produces more than 78 million tons
(71 metric tons) of sugarcane annually [source: The Sugar Bureau]. It can take up to 18 months for new cane stalks to be readyfor harvest, and harvesting is often done now by machines on large plantations. Processing and packaging often occurs very
close to the harvest location to prevent the harvested cane or beets from rotting.
Harvesting also typically occurs September to February, requiring the factories to be extremely reliable during this criticalseason. Consequently, a sugar refinery’s production reliance upon its machinery has never been more important. Downtime
is more expensive. Uptime is more valuable. Operators need to know if they can push machinery to its design capacity andbeyond while remaining safe and maximizing the balance between useful life and capacity. And, as always, operators need toremain safe—for their families, for their communities, and for the environment.

Reliability: the key to a successful future
Unreliable assets have enormous consequences. What if yourassets could consistently operate at or above their rated
capacities, for a greater percentage of total hours eachyear, all while spending less money on maintenance? That’s
exactly what today’s best companies have discovered how
to do. Industry studies show that the average facility spends
approximately 5% of its Replacement Asset Value (RAV) on
maintenance each year. In comparison, best performers
spend 60% less—just 2% of RAV—while enjoying better uptime,efficiency, and profitability. It’s not about simply spending
less on maintenance, it’s about working differently—working
smarter—to achieve more reliable production operations.

Benefits with Bently Nevada
Closing the gap between your reliability “goals” and what
you are actually obtaining from your efforts typically involves
the following three categories::• Processes: Bently Nevada can help customers assess theirgoals, identify the reliability gaps in their current operations,and then implement the appropriate corrective actions.
• Tools: Our Bently Nevada product line is world-renowned
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for unsurpassed quality in machinery condition monitoring.
Everything needed to address the assets in sugar refinery
plants is available, from sensors to continuous monitoring
systems to portable data collectors and analyzers. And,
it’s all brought together in a unified platform for asset
condition monitoring and diagnostics –System 1® software.
We also assist customers in integrating and using theiralready installed tools, such as computerized maintenancemanagement systems (CMMS) and reliability software.
• People: Reliability is about more than just technologies andprocesses. Armed with even the most sophisticated tools
and effective strategies, companies can fail to reach theirreliability goals unless they are able to successfully change
the way they work. Reliability is a company-wide effort thattouches operations, maintenance, planning and scheduling,purchasing, management, and engineering. Bently Nevada
is able to help customers change the way they work byaddressing the organizational culture issues that keepcompanies mired in ineffective processes, helping themtransform their businesses and balance sheets.
Because Bently Nevada is able to fully address each one ofthese, we are able to help you solve the whole problem—
not just bits and pieces. Our tailored condition monitoring
solution can help you close the gap.

Condition monitoring
While condition monitoring may not be the only element in a
successful reliability program, it is nonetheless an essentialelement. For years, we’ve been taught that the older anasset is, the more likely it will fail. As such, many plants have
evolved elaborate and finely tuned maintenance schedules
based on calendar intervals or running hours.
There’s just one problem with that approach: time- or
usage-based maintenance strategies alone are only valid
for 10 to 15% of the assets in a typical industrial facility.
In other words, if you have applied a time or usage
based only maintenance strategy to the majority of yourequipment, most are getting “maintained” when they don’t
need to be. That’s wasteful, and it’s one of the major reasonsthat many companies are overspending on maintenance.
In other cases, the asset may fail before it reaches
its scheduled maintenance interval. Frustrated, plantmaintenance staffs are left to wonder “what went wrong.”.

Different assets, different approaches
Not all assets are created equal. Some, such as mills andventillation fans, are highly critical to operations. Other assets
are less critical. And still others have little impact on safety,

Process Data
Analysis

Consequence of failure

HigherPortables

environment or production, with only maintenance costs as
the primary consideration. As such, a variety of condition
monitoring products and approaches are required.
Today we understand that the probability of an asset failure
is often highest just after it has been placed in service (orundergone maintenance). Following this “infant mortality”
period, its probability of failure becomes constant and does
not rise linearly over time. This means that running hours andcalendars are poor “predictors” of failure. How do you know
when such assets will fail if the timebased intervals can’t betrusted? By measuring the mechanical condition of the asset –vibration, temperature, efficiency, oil chemistry/particulates, andother physical parameters. In other words, condition monitoring.
This approach results in maintenance only when the conditionindicates the asset is failing. Further, failure progression canoften be trended quite accurately, allowing maintenanceintervention at exactly the right time—not too soon, not
too late. And, condition data can be remarkably precise,indicating not just that the asset is failing, but exactly what iswrong, providing vital input to a root cause investigation thatcan help to prevent a similar failure in the future.

Wireless,scanning

On line,continuous CM
or Protection

On linecontinuous CMand Protection

High Critical

CriticalMedium toLow Critical

Lower3Bently Nevada service menu
Key benefits
Get it right the 1st time

Implementationservices• Ensure your assets are protected andmonitored when you’re ready to startup• Avoid costly delays and rework• One source to design, plan, manage,and execute the installation• Avoid startup trips due to improper
installation and configuration
Keep your system healthy and optimized• Prevent instrumentation related false trips

Proactivesupport• Prevent and minimize potential data loss events• Keep up to date and compliant with the best
technologies available• Access the expert support you need when you
need it most
Actionable insights you can trust

Asset healthand consulting• Understand your asset health to optimize
outage and maintenance planning• Plug in to our global network of machinery
experts with remote monitoring• Professional OEM agnostic machinery
diagnostics when and where you need it• Custom analytic development and tuning
to pinpoint specific conditions
Stay ahead of evolving cyber threats• Ensure your system is up to date and protected
as threats continually evolve

Cybersecurity

1Trainingand education• Identify and mitigate cybersecurity risks
to your operation• Keep your system both secure and accessible
with advanced security technologies andarchitectures leveraging data diodes anddatabase replication
Critical skills that amplify yourmachinery management capabilities• Enable your personnel to operate and maintainyour monitoring and protection system• Enable your operation to maximize the valueof your system leveraging expert product andapplication training and knowledge

Up to$1M/day

100%

Avoided costfrom lost
production,
secondaryprocess &equipment
damageService workguarantee
1 year warranty
standard on
all service work

80%

Industry widemachineryalarms & eventsare due toinstrumentation>90%

Typical reduction
in non-actionable
alarms & events

100% ROI

5-10X

A single machinesave often resultsin completemonitoring
contract
payback andmore

Cost reduction
for well planned
maintenanceoutage vsunplanned reactive
outage29%

243 days

Patchmanagement
can reduce
your attack
surface up
to 29%

Average time
before detectionthat a system iscompromised

400+

Customer courses delivered each yearin 10 languages and over 45 global
locations1. https://www.us-cert.gov/sites/default/files/documents/Seven%20Steps%20to%20Effectively%20Defend%20Industrial%20Control%20Systems_S508C.pdf

4You canrely on us
For more than 50 years, we’ve been
supplying condition monitoring
solutions to machinery-intensive
industries. We also bring two decadesof experience conducting reliability
improvement projects. Customers
turn to us for a simple reason: lastingvalue. Our solutions demonstrate
their worth, day in and day out. We
combine the highest quality products
and responsive customer support witha service team that takes the time tounderstand the uniqueness of yourplant, your personnel, and your goals.
Our products can be found in manyof the world’s sugar refinery plants.
Today, many of those same plants
are turning to Bently Nevada for amore comprehensive solution to theirneeds, moving beyond just machinery
protection instrumentation on a few
assets to plant-wide strategies andsystems for improved environmental
compliance, safety, asset production,
quality and reduced operation andmaintenance costs.

5Sugar production

Process can vary depending on
facility and feed stock used

Preparation –Shredding,Crushing & MillingShredders
Crushers
Mill Stands(Tandem, typically 6)
Process Pumps
Conveyors

Receiving & Unloading
Conveyors

Cane Juice

Cane Juice
FilterSediment
Tank

Filter CakeRoller
Cane Juice
Holding Tank
Sugar Boiling
Process Pumps

Sugar Boiling
Process Pumps

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System 1 – One Platform, Endless Possibilities
Improve Equipment Reliability, Uptime and Efficiency

System 1 represents Bently Nevada’s flagship condition monitoring solution that seamlessly
integrates with our industry leading products including online and portable devices. System
1 provides scalability by adapting to the condition monitoring requirements at your facility,
as well as flexibility by connecting to any Bently Nevada’s field devices.

Boiler Station (Steam forelectricity & processing)
Boiler Feed Pumps

Power Island (Heat Recovery)
Steam Turbine / Generator
Cooling Tower Fans

BagasseTreated/ClearedCain Juice

Molasses

Syrup
Tank
Vacuum Pan

Separation
Centrifuge

Raw Sugar
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BHCS34337A (06/2020)

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