AI Detects Early Warning of Erratic Bearing Vibration on a Gas Turbine at an African Oil & Gas site

An unusual pattern in in the operation of a gas turbine at an oil and gas facility was detected by GE Vernova's SmartSignal Predictive Analytics software. SmartSignal employs digital twin technology, which serves as an intricate virtual model of the turbine, allowing for detailed monitoring and predictive analysis.

The digital twin indicated that the vibration probe at the turbine's drive end had shown instances of flatlining and subsequently spiked to concerning levels. These fluctuations in vibration levels are noteworthy as they can suggest potential mechanical issues or inefficiencies that require prompt investigation.

Acknowledging the significance of this finding, GE Vernova's Industrial Managed Services (IMS) team included this issue in their detailed weekly report. This report acts as an essential communication tool, fostering discussions and strategic planning with the customer.

Following the alert issued by GE Vernova's IMS team, the customer took decisive action to mitigate the risk of an unplanned shutdown of the gas turbine unit. To begin, the customer promptly adjusted the control logic to stabilize the unit's operation. This strategic adjustment was crucial in ensuring the continued functionality of the turbine without interruptions, thereby safeguarding operational efficiency and preventing potential production losses.

Next, the customer scheduled the replacement of the faulty vibration sensor for the next available maintenance window, four months from the anomaly detection. This forward-thinking approach allowed for a structured response to the issue, minimizing disruption and aligning maintenance activities with operational priorities.

Upon replacing the defective sensor, the vibration readings returned to levels consistent with the model's estimated values. This successful intervention not only restored the system's performance but also validated the effectiveness of the predictive analytics in identifying and addressing equipment anomalies.

Due to the timely alert provided by GE Vernova's IMS team, the oil and gas customer was able to effectively avert an unplanned shutdown and the associated production loss. They accomplished this by promptly adjusting the unit's trip logic and scheduling the replacement of the faulty vibration sensor at the earliest possible opportunity. The proactive approach ensured that the turbine continued to operate smoothly, maintaining production levels and minimizing potential disruptions.

Furthermore, the IMS team played a key role in verifying the success of these maintenance actions. By closely monitoring the equipment's performance, they confirmed that the actual vibration values had returned to the anticipated levels, thereby validating the effectiveness of the interventions. This foresight and collaboration are estimated to have saved the customer approximately $261,680 in costs that might have arisen from operational downtime and equipment inefficiencies.

The incident underscores the importance of timely alerts and the collaborative relationship between GE Vernova and its customers. By engaging in strategic planning and providing advanced monitoring, GE Vernova supports its customers in maintaining excellent operational standards. Such partnerships are vital in extending the lifespan of critical equipment and ensuring asset reliability in energy production. Through continued cooperation and innovative solutions, GE Vernova is a trusted ally in energy management, helping customers achieve their performance targets and operational resilience.


*Avoided costs are based on North American average production loss.