Plantwide asset health
Optimize and scale your asset health andcondition monitoring programFrom the 5% to the other 95%
For more than sixty years, asset-intensive industries have experienced the benefits
that continuous vibration protection and condition monitoring deliver for theircritical assets. Today, these disciplines are so well-entrenched that they have
moved beyond merely “best practice” to standard operating practice. Indeed,
many customers will not even consider operating their critical machinery without
such systems in place.
But in most plants, only 5% of total assets are considered “critical”. What about
the other 95%? The combined impact of these “non-critical” assets can still besignificant.

Steel plant

LNG tanker

Coal-fired plant

Mine

Cement plant

Refinery

Cargo ship

Pulp and paper$235,000/hr in losses
due to an unavailable
overhead ladle crane$192,000/hr due to failureof a non-critical asset
impacting a single‑stream
mineral process

Nuclear plant$13M for one week of lost
generation due to ripple
effects of failure of anon‑critical pump

$90,000 in losses toreplace rather than repair
a seawater pump

$75,000 for each restart of
the kiln due to failure of anon-critical asset$40,000 for each
additional hour to sit
dockside due to nonworking support assets

Every industry, every asset$300,000 to restart aboiler due to failure of anon-critical asset$140M due to a fire fromfailure of a non-critical
asset$1.8M to interrupt pulp
production and replace adigester cooling booster
pump bearing

With good reason, operators in every industry are turning their attention fromonly the “critical few” to the wider population of assets and the opportunities
they present for improvement. This holistic, plantwide approach is fueled both by
the benefits it yields and the market forces that are forcing operators to adopt
proactive asset management strategies across their entire population of assets.

90%

of failures are nottime‑based+25%

production

50%

of workforce to retirein the next 5 to 10years. Knowledge
and experience is not
being transferred

60%

-70%

machinery breakdowns

A move towards
plantwide
predictive
maintenanceestimated increase in
EHS spending among
global E&P companies-40%
downtime-50%

maintenance costs6x

the cost for unplanned eventsvs. planned maintenance inprocess industries

Eight key considerations
for plantwide success

4In your journey to plantwide asset health management success, who you choose
to work with has never been more important. Will you end up with fragmented
islands of technology or a uniform, integrated solution landscape that works
cohesively and seamlessly? Will you be on your own when guidance and support
are needed, or will you have a trusted, expert partner with decades of experience?

1. The right hardware

You need a partner with a comprehensive
hardware portfolio capable of addressing every
asset—whether those needs are machinery
protection, condition monitoring, or both.

2. The right software

You need a partner with a unifying software
infrastructure that eliminates silos andpoint solutions without sacrificing power orfunctionality.

3. The right expertise

You need a partner that understands more thanjust instrumentation and software—you need onethat understands machinery.

4. The right service and support

You need a partner that can deliver
knowledgeable, 24/7 support no matter whattime zone you are in, no matter what languageyou speak.

5. The right approvals
and certifications

You need a partner capable of fully satisfying thecertifications and approvals requirements of thelocations in which you operate.

6. The right embedded intelligence
You need a partner that knows how to answer
the challenges associated with embedded
intelligence. At the edge? In the cloud? Howmuch? How little?

7. The right cybersecurity

You need a partner with products that comply
with modern security concerns and protocols if
it’s going to be allowed through the door by yourIT and OT gatekeepers.

8. The right all-inclusive subscription
You need a partner that is fully equipped todeliver plantwide condition monitoring outcome
as a service, delivering end to end plantwide
health management as a subscription.

5

1. The right hardware
Plantwide condition monitoring necessitates sensors anddevices that can properly address every asset, from the least
critical to the most. Nobody offers the breadth of hardwarethat Baker Hughes brings to the table. One-size-fits-all
approaches sound good on paper, but they simply can’t
scale to fit the different needs of each machine, the differentdetection technologies warranted, the optimal channel
granularity, and the unique place each must fill in thespectrum from continuous to intermittent measurements,protection to condition monitoring, online to offline, wired
to wireless. Our hardware portfolio addresses every part ofthis spectrum with thoughtfully engineered solutions thatare right-sized for the application, providing exactly the rightfeature set, measurement technologies, and functionality.

6

Although we’re perhaps best known for our Baker Hughes
protection and condition monitoring systems, such as
Orbit 60 and 3500 Series, every part of our hardware portfolio
is world‑class. The SCOUT200 series portable vibration datacollectors and analyzers combine innovative technology
and decades of domain expertise in machinery diagnostics,
bringing simplicity and dependability when it is most needed.
The Ranger Pro™ wireless system was built from the groundup and supports not one, but both of the leading industrial
standards—WirelessHART and ISA100—giving you unmatched
flexibility and choice.
The Orbit DCM platform provides highly tailored condition
monitoring at user-configurable intervals with high-speed
data collection, processing on the edge, and synchronous
data acquisition across all 16 channels. The 2300 Series
monitors offer affordable protection for high‑consequence
assets like pumps that may number in the hundreds but
still warrant reliable monitoring. The 3701 ADAPT™ platform
delivers machinery protection in a high-performance
package that can be skid-mounted on the machine for
reduced cost.

Continuous

Measurement frequency

Periodic

Bently Nevada portfolio

Orbit 60 Series

3500 Series

3701 ADAPT ESD

2300

Orbit DCM

Ranger Pro

Portables

Process
dataSensors

HighestAsset criticality

Lowest10 million+
installed vibration sensors

Some would argue that sensors are commodities.
But operators know all too well that when it
comes to making the right call, everything restson the integrity the sensor. For six decades,
Baker Hughes sensors have been trusted todeliver the highest quality and accuracy in theindustry, across every part of the measurement
portfolio: acceleration, velocity, displacement,pressure, speed, and position. The breadth of
our sensor portfolio (over 20,000 catalog items)
means you don’t have to spend precious timelooking elsewhere for what you need.
We have it. We designed it. We stand behind it.

7

2. The right software
When we first developed asset health software over 20 years
ago, we had a simple vision: one system for linking all of yourasset monitoring field devices together, resulting in a unified
asset management dashboard. Cordant™ Asset Health, built
on System 1, delivers on that promise, bringing every asset
in your plant together into a single, powerful ecosystemaccessed from a single user interface.
With others, plantwide means a patchwork of software thatdelivers little more than a collection of silos. That may notmatter when you’re only concerned with a subset of assets
in your organization, but when a plantwide approach is thegoal, integration matters. With Cordant™ Asset Health, built on
System 1, you have only one system to configure. One system
to learn. One system to maintain. And we deliver that unity
without asking you to compromise analytic capabilities. Our
powerful suite of diagnostic tools is best-in-class for not justfluid-film bearings but rolling element bearings as well, withpowerful spectrum-based tools to complement all of theother tools we deliver, allowing you to analyze gear problems,belt problems, foundation and piping problems, electricalproblems, and every other problem—not just bearing
problems.

OnlineWireless

Surveillance

Portable

Turbomachinery

10,000+installations
globally

8

Reciprocating compressors

12

remotemonitoring
centers100+

certified fieldengineers

Other assets

3 million+

plantwidemeasurement
points monitored

Cordant™ Asset Health, built on System 1, does more than just unify
your assets under a single umbrella. It unifies your monitoring
technologies by combining conventional diagnostic, visualization,
and alarming tools, thermodynamic performance, and automateddecision support. Alarms can be set on any incoming data
stream—including process data.

Core alarming, analytics,and visualization

Decision support

Thermodynamic
performance monitoring93. The right expertise
It’s nothing special to expect your provider to have expertise on their own softwareand instruments. But what about on the machinery those instruments monitor? Weunderstood early in our history that it wasn’t enough to possess merely instrument
expertise. We also needed application knowledge, allowing us to be users of ourown products and helping our customers interpret the data our systems provide.
To that end, we launched our machinery diagnostics team in 1980 and have neverlooked back.

18,000+completed machinery
diagnostic projects

30+

machine and component
types where we possess
deep expertise

10

150+

machinery diagnostic
engineers globally

1,200+

cumulative years ofmachinery diagnostic
expertise• Fluid-film bearings• Seals• Foundations• Rotor dynamics—lateral and torsional• Gas turbines—industrial• Compressors—integrally geared• Compressors—screw• Compressors—centrifugal• Hydro turbines—Kaplan• Pumps—centrifugal• Gears—helical• Gears—worm• Motors—induction• Motors—variable speed• Pelletizers• Conveyors• Fans• Turbo-expanders• Separators• Pulverizers• Pulp refiners• Rolling Element Bearings• Couplings• Piping• Steam turbines• Gas turbines—aeroderivative• Compressors—axial• Compressors—reciprocating• Hydro turbines—Francis• Hydro turbines—Pelton• Pumps—positive displacement• Gears—planetary• Generators• Motors—synchronous• Wind turbines• Crushers• Extruders• Blowers• Centrifuges• Ball mills• Agitators• Cooling tower/heat exchanger fans11

4. The right service and support
When you need help, you need somebody responsive.
Somebody knowledgeable. Somebody experienced.
Somebody that speaks your language. And you need morethan one way to reach them—chat, phone, email, Zoom.

50+

global training
centers

How we help
• Installing instruments• Modifying your machine to accept transducers• Troubleshooting a problem• Verifying and calibrating your instruments• Designing your condition monitoring and asset
management program• Outsource your condition monitoring program, including
hosting your software

15+

remote andeLearning course
offerings

500+

servicesand support
professionals
globally• Training with flexible delivery, format, and language options30+

18,000+400+

60,000+course topics tochoose fromtraining courses
delivered eachyear

20,000+
customers
trained globally

12machinery anddiagnostics
projects

field service
projects
completed5. The right approvals and certifications
We take great care to make certain our products feature the global approvals
and certifications needed by our customers. It’s a never-ending journey involving
a myriad of standards—each undergoing regular updates and revisions. Our
dedicated team of approvals engineers makes certain we’re always current,
re‑testing and re-certifying our offerings on an ongoing basis.

13

6. The right embedded intelligence
Embedded intelligence and expert systems can increase the efficiency ofcondition monitoring and provide enhanced insights for more proactive assetmanagement. However, to be effective, these systems need to be capable ofcapturing, processing, and analyzing enormous amounts of data. And there’s
a misconception that unguided AI can help cut through the noise to deliver
meaningful insights.
Baker Hughes helps organizations overcome these challenges and realize thebenefits of embedded intelligence with Decision Support, a purpose‑built AI
solution for condition monitoring. The solution includes Decision Support Analytics—
powerful software plug-ins for more than 15 specific asset types, capable ofdetecting and identifying more than 30 different malfunctions.

14You can distill your own
intelligence, too, by developing
your own analytics using simple,
powerful configuration tools
as part of Decision Support’s
suite of tools and capabilities.
These can then be deployed
across your organization, justlike any other Decision Support
Analytic, ensuring that what you
know about your own machines
is shared across your entire
organization and is continuously
being used to automatically
identify similar problems.

Machine
dataAcquire

Analytics allow staff
to use their time
more efficiently

Process

Analyze

Diagnose
Failure mode
detection

Operations
dataDecision Support Analytics perform real-time analysis and diagnostics to detect failure modes15

7. The right cybersecurity
Remote access to data has never been more important.
Travel restrictions, a shrinking pool of machinery expertsthat may not even be located at your own facility, and otherfactors mean that moving data, not people, is non-optional.
But it’s far more complex today than simply connecting yoursystems to a network and giving out a password. How do you
make such connections securely, allowing access to dataover business networks without creating vulnerabilities?

For more than a decade, we have been at the forefront ofindustrial cybersecurity:• The first condition monitoring company to achieve
Achilles’s certification for our flagship protection system• The first company to develop architectures thatfully insulate the protection system from thecondition monitoring system via inherently secure
analog connections• The first company to successfully employ data diodetechnology to replicate condition monitoring server datafrom the control domain to the business domain

16

We take cybersecurity extremely seriously so that it
doesn’t have to get in the way of your condition monitoring
objectives. Our solutions were designed by consultingour customers’ OT and IT professionals to understand theenvironments they operate in, the constraints they face, andthe technology stacks they employ. Cordant™ as well as ouredge appliances and monitoring hardware are designed
from the ground up with cybersecurity as a primary
design criteria.

$8T

12023 global annual costof cybercrime$4.78M

2

Average cost of a data breachin the energy industry

$350M

3

Loss for Maersk after WannaCry attack,due to significant business interruption(no data loss or physical destruction)

Every 5 hours

4

the US power grid is struck by a cyberor physical attack

1234

https://cybersecurityventures.com/cybercrime-to-costthe-world-8-trillion-annually-in-2023/
https://www.ibm.com/downloads/cas/E3G5JMBP

https://www.csoonline.com/article/567845/rebuildingafter-notpetya-how-maersk-moved-forward.html

https://www.politico.com/news/2023/09/10/powergrid-attacks-00114563#:~:text=According%20to%20a%20
report%20on%20grid%20security%20compiled,to%20
outages%2C%2071%20percent%20more%20than%20in%20
2021

178. The right all-inclusive subscription
If you prefer ensuring your comprehensive solution iscompletely taken care by a trusted partner, Baker Hughes
is fully equipped to deliver plantwide condition monitoringoutcome as a service, delivering end to end plantwide
health management in a convenient and cost-effectivesubscription.

Technology
Cordant™ Asset Health is built around decades of subject
matter expertise and constant technology advances andengineered to provide a variety of machinery insights to a
cloud asset performance management environment. Our
experts utilize physics‑based models, machine learning,and AI technology to identify malfunction and healthindicators and combine with application domain knowledge
to drive attention where it is needed with actionable
recommendations.

Seamless integration
Direct cloud connectivity to Cordant™ Asset Health allows
high-resolution dynamic analysis on fast occurring events ormachine startups/shutdowns. Secure integration to existingdata sources in premise or on cloud allows a complete
picture of asset health and improved analytics models.

18Security
The architecture and operations processes are based onstandards including, but not limited to ISO, IEC, NIST, NERC
CIP, and other elements as described by the Center forInternet Security (CIS) controls. This foundation is furtherenhanced by applying the lessons learned through decadesof experience by Baker Hughes systems integrationengineers working in OT and IT security in the mostdemanding industries.

Remote Analysis & Advisories

Diagnostics and application experts

Goals achieved

Our vibration
monitoring devices

Focus just on what contributes to organizations’ success

AI + knowledge-based
failure mode analytics• Minimize infrastructure and software cost of ownership• Unlock benefits from a scalable and future-proof condition
monitoring program• Get predictable costs and measurable value fromthe investment

Connectivity

Secure VPN over internet

Plantwide Assets

Sensors and monitoring19

Learn more
Contact us to learn more about
Cordant™ Asset Healthbakerhughes.com/cordant

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