Reliability and condition
monitoring solutions forthe wastewater 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
Water and wastewater plants are an indispensable part of a country’s infrastructure. Areas with growing populations
face the difficulty of meeting increased demand for services with shrinking staffs and budgets. They may also find that
increased demand has transformed formerly spare machinery into non-spared with little or no “back up” capacity
when an asset fails. In contrast, other plants may find themselves in areas of declining population, but still face theirown formidable challenges. Such plants are often required to meet demand with aging systems that must be kept up
and running without the option of major capital investment in new assets.
The “more with less” challenge isn’t unique to the water and wastewater industries, but that doesn’t make it any less difficult.
In an age of “lean” operations, most feel they’re already asked to do too much with too few resources. How to meet these
seemingly contradictory requirements?

Reliability: the key to a successful future
Unreliable assets have enormous consequences. What if
your assets could consistently operate at or above theirrated capacities, for a greater percentage of total hours
each year, 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 typicallyinvolves the following three categories:• Processes:	
Our comprehensive services help customers
assess their goals, identify the reliability gaps in theircurrent operations, and then implement the appropriate
corrective actions.
• Tools:	
Our Bently Nevada product line is world-renowned
for unsurpassed quality in rotating machinery condition
2

monitoring. Everything needed to address the assets inwater and wastewater treatment plants is available, fromsensors to continuous monitoring systems to wirelesssensor systems to portable data collectors and analyzers.
And, it’s all brought together in a unified platform for
asset condition monitoring and diagnostics—Bently
Nevada’s System 1* software. We also assist customers
in integrating and using their already installed tools, suchas computerized maintenance management systems(CMMS) and reliability software.
• People:	Reliability is about more than just technologies
and processes. Armed with even the most sophisticatedtools and effective strategies, companies can fail to reach
their reliability goals unless they are able to successfullychange the way they work. Reliability is a company-wide
effort that touches operations, maintenance, planning andscheduling, purchasing, management, and engineering.
Bently Nevada is able to help customers change the way
they work by addressing the organizational culture issues
that keep companies mired in ineffective processes,
helping them transform their businesses and balance
sheets.
Because Bently Nevada is able to fully address each one ofthese, we are able to solve the whole problem—not just bitsand pieces.

Condition monitoring

While condition monitoring may not be the only element
in a successful reliability program, it is nonetheless anessential element. For years, we’ve been taught thatthe older an asset 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.

Process DataAnalysis

Consequence of failure

HigherPortables

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
reasons that many companies are overspending on
maintenance. In other cases, the asset may fail before it
reaches its scheduled maintenance interval. Frustrated,Maintenance & Reliability staffs are left to wonder "whatwent wrong?"

Wireless,scanning

On line,continuous CM
or Protection

On linecontinuous CMand Protection

High Critical

CriticalMedium toLow Critical

Lower3

Today we understand that the probability of an asset
failure is often highest just after it has been placed inservice (or undergone maintenance). Following this“infant mortality” period, its probability of failure becomes
constant and does not rise linearly over time. This meansthat running hours and calendars are poor “predictors”
of failure. How do you know when such assets will fail if
the time-based intervals can’t be trusted? By measuring
the mechanical condition of the asset, using vibration,
temperature, efficiency, oil chemistry/particulates, andother physical parameters. In other words, condition
monitoring.
This approach results in maintenance being performed
only when the condition indicates the asset is failing.
Further, failure progression can often be trended quite
accurately, allowing maintenance intervention at exactly
the right time—not too soon, not too late. And, condition
data can be remarkably precise, indicating not just that theasset is failing, but exactly what is wrong, even identifying
root cause and mitigating failure completely.

Different assets, different approaches
Not all assets are created equal. Some, such as aerationblowers, are highly critical to operations. Other assets areless critical. And still others have little impact on safety,
environment or production, with only maintenance costs as
the primary consideration. As such, a variety of condition
monitoring products and approaches are required.

Services
Reliability improvement: Whether your facility has all
the tools it needs or is just getting started, BHGE can add
value through far more than just a collection of condition
monitoring products. In fact, our Reliability Consulting
Services offering is designed to function independently of
the condition monitoring products you may have chosen—
whether our own or someone else’s. It provides a holistic
approach to your reliability efforts by reviewing your entire
program and benchmarking you against world-classperformance. Where gaps exist, we show you what to doabout them and the financial benefit you can expect via aclear ROI.
We also go beyond just making recommendations andactually help you implement the improvements you’vechosen. For example, perhaps a gap has been identified
that you aren’t using your Condition Monitoring Systems
to its full potential. We’ll help you get there with training
and system integration support. Or, perhaps you are using
interval-based maintenance on assets where run-tofailure is actually a better strategy. Or, you may find thatmost of your time is spent “reacting,” leaving insuffcient
time to be proactive in your maintenance—and you don’tquite know how to get out of this vicious cycle.
44Or, your spare parts inventory may be problematic andyou need help developing a rational strategy for whatparts to stock and what quantities. Every one of these canbe addressed through our comprehensive portfolio ofreliability services.

•S cope based on your needs, from 100% turnkey tocoordination with and use of internal plant resources forselected functions—design-only services also available
upon request• Compliance with plant IT standards including cybersecurity, hazardous area requirements, and countryspecific certification agencies

Finally, we help you change the way you work. Manyorganizations invest in technology and have excellent
strategies, but neglect the most important factor: thehuman factor. When people understand the role ofreliability and can feel the difference it makes in not justtheir jobs, but the balance sheet, they are better able toembrace new ways of doing things. We understand how totackle these often difficult, but vital, organizational culture
issues in ways that get everyone playing on the same teamand working towards common goals.

• Outstanding record for safety, timeliness, and adherence
to budget
Machinery diagnostics: Since 1972, we have been helping
customers interpret their condition monitoring data,
helping them isolate not just machinery problems, butroot causes. These services are available globally througha team of more than 150 specially trained engineers, andcan be delivered either locally or via remote access using
System 1® software.

Installation: Our extensive project capabilities combine
our services with our hardware and software to deliver fully
installed, fully engineered solutions in your plant—solutions
that are tailored to your specific requirements, tested,configured, commissioned, and completely ready to use.
And, they’re available for every product we offer.

Training: We believe in helping customers help themselves.
Each year, we train thousands of customers worldwide on
topics ranging from operation and maintenance of our
instrumentation systems, to machinery balancing andalignment, to reliability awareness and improvement, tomachinery diagnostics.

Condition monitoring applications in wastewater
Headworks

Collection
systemMain lift
pump station

MM
M

Bar
screenM

Biological treatment

Gritchamber Mixer motors
 Sludge pumps

Primary
clarifierM

M Lift station
pumps

 Main Lift
Pumps
Stormwaterbasin

Landfill

Effluent
Secondaryclarifier
M

AerationFilter

Chlorination
DeCl2 orUV Disinfection

MSolidsGrit Grit blowers
 Grit pumps
 Grit classifiers

Return Activated Sludge (RAS) Aeration blowers
 Sludge pumps
 Scum skimmers/Sludge collector motors

 Sludge pumps
 Secondary clarifier motors
 Recycle water pumps

M

Waste Activated Sludge (WAS) Bar screen motors
 Conveyors

MSludgethickener

CMMSRiverBlowers

PrimarySludge (PS) Sludge pumps
System One®
Software Continuous on line monitoring Centrifuges
 Belt filter presses

Gas

M

Incinerationor landfillDigester Sludge pumps

Solids processing

SludgeDewatering Scanning on line monitoring Off line route based

portable data collection

Orbit 60

3500 Series

2300

ADAPT 3701/40

1900/65A

AnomAlert

vbonline Pro and Ranger Pro
VB7/VB8 and Scout products5• 50 technical training centers around the globe—on-site training
also available• Hands-on training using real-world case histories—ensures underlying
theory and practice are mastered• Students consistently rate their Bently Nevada training as “outstanding”
and “exceptionally practical”

You can rely on us
For more than 40 years, we’ve been supplying condition monitoring
solutions to machinery-intensive industries. We also bring two decades ofexperience conducting reliability improvement projects. Customers turnto us for a simple reason: lasting value. Our solutions demonstrate theirworth, day in and day out. We combine the highest quality products andresponsive customer support with a service team that takes the time tounderstand the uniqueness of your plant, your personnel, and your goals.
Our products can be found in many of the world’s water and wastewater
treatment plants, often supplied as standard by the OEM on highly criticalequipment such as aeration blowers. Today, many of those same plants
are turning to GE for a more comprehensive solution to their needs, moving
beyond just machinery protection instrumentation on a few assets to plantwide strategies and systems for improved environmental compliance, safety,
asset production, quality and reduced operation and maintenance costs.

6

7

Copyright 2020 Baker Hughes Company. All rights reserved.
BHCS14599D (05/2020)

bakerhughes.com