Enhancing Business Performance using Integrated Visibility and Big Data

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1 Enhancing Business Performance using Integrated Visibility and Big Data Manish Sharma Marketing Leader GE Energy Management Photograph of Speaker ARC Advisory Group

2 GE Energy Management GE s roots in electrification go back 130 years, beginning with our first transformer and electric motor Revenue ($B) $7.3 Today Energy Management is built upon the same legacy and innovation culture that Thomas Edison founded in More than ever, we enable utilities and industry to efficiently manage electricity from the point of generation to the point of consumption. $1.4 $0.7 $0.7 $0.7 $0.7 $0.2 $3.0 Generate Protect Transmit Automate Distribute Control Convert Optimize

3 Applications What we do Grid Modernization that span the energy Electrical Distribution, Protection & Control value chain Electric Transformation 2014 Revenu e ($B ) Digital Energy $1.4 How we do it Industrial Solutions $3.9 W orld class products Integrated systems Flawless Delivery Power Conversion $2.1 Broad electrical domain expertise & technology leadership

4 From advanced equipment to complex solutions Motors & Generators Power Delivery Electrical Equipment Protection and control Software Variable frequency drive Critical power High performance automation Services & Consulting we deliver outcomes that make the world work better

5 Operational Challenges & Cost Pressures

6 Throughput COGS Desperate Systems Lack of Integration Poor Access to Historical Data & Plantwide Visibility Process Variations & Emissions PID loops Quality rejects Goo d batch v/s Bad batch Prevention of Equipment Failures Person Centric Operations Lack of Integration with Business Systems Integrated Visibility Advanced Analytics & Predictive Diagnostics Value Chain Integration Operating Margins GET CONNECTED Fixed Costs

7 Model > Site > Equipment My Notifications MAP Solution Approach.. Modular, Integrated & Scalable Integration with Business Systems Analytics and Decision Support Integrated Data Visibility Central Data Repository Proficy RTIP Proficy Trouble shooter Proficy SCADA CAPTURE ANALYZE & RESOLVE DIGITIZE SOP s Site Contact Maintenance Operator Historian Operator Analyst Expert Shift Supervisor DATA to ERP

8 Performance Monitoring Through Integrated Visibility

9 Performance Visibility & Monitoring What Does Proficy Do? Monitors Defined KPIs Access from anywhere & everywhere.mobility Creates treasure of past & current performance Makes the past data available at finger tips Creates a benchmark from the past performance Proficy Integrated Visibility & Central Repository Visibility of variations in COGS Identification of Optimum COGS

10 Delivering Actionable Information

11 GE Proficy provides Manufacturing Intelligence for One of the Largest Steel Producer in India Blast Furnace Information Management System 2MM ton Blast Furnace Pain Area : Variance in output & avoidance of failure Need : Real Time Visibility & Analytics Value to Customer Integrated KPI Monitoring & Benchmarking Root Cause Analysis Avoidance of Downtime : SMS & alerts Open Technology PLANT NETWORK BLAST FURNACE Process Analytics Web SCADA Central Reporting Central Data Repository BLAST FURNACE CENTRAL CONTROL ROOM Notification PLC/DCS Alarm Condition Data Collector & Alarm Service SMS Notification

12 Enhancing Performance using Predictive Analytics

13 People The time is now Data..Zero Unplanned Downtime Machines GE Intelligent ARC Platforms Advisory Group

14 GE Connected Assets Today 200,000+ assets connected 21,000 aircraft engines 10,000 gas & steam turbines 15,000 wind turbines 110,000 medical equipment 12,500 locomotives Process Industry stores more data than any other sector close to 2 Exabyte's(10 18 ) of new data stored in McKinsey & Company Plus Power transformers Motors Water treatment Pumps, Valves Turbo Machinery Compressors Millions of analytics run daily 2013, General Electric Company 14 Global Footer Research appears here 14 Date appears here GE Intelligent Platforms 7/20/2015

15 Challenge: going from Reactive Maintenance to Predictive Time to Plan and Prevent The Challenge Difficult to achieve without advanced technology or extremely intensive analysis Very first precursors plenty of time to plan Prevent significant damage and unplanned outages Reactive Scramble Easily observed effects, but failure already in progress More damage, higher O&M, more downtime ARC Advisory Group

16 Decision Support & Predictive Diagnostics What Does Proficy Do? Compares the benchmark with current performance Identifies the gaps Interprets the Cause of benchmark Determines the cause of the gaps Suggests corrective action to close the gaps Implements the corrective actions Increases Throughput with APC Predicts Diagnostics. Where & why Proficy Advance Analytics & Decision Support Identifies Unclear Root causes of variations Reduction in COGS Increase in CM Repeatability of Optimum Throughput Predicts Failures Reduction in Fixed Cost Increase in OM Waste Reduction

17 Early Warning Multiple sensor, dynamic empirical analysis in real time Single-sensor equipment protection: traditional thresholds & rules Axial position Alarm / Trip Axial position Gas pressure Δ Speed Bearing Temp Normal operation Early stages of damage

18 SmartSignal : How it Works FROM YOUR DATA Modeling across related sensors Dynamic alerting on deviations from expected Comparing deviation with known failures TO DIAGNOSTICS Solution managed by seasoned staff ARC Advisory Group

19 Value Predictive Diagnostics Life cycle Optimize Learn Predict Operations Predicting Problems Prognostics Diagnose Monitor Understand Causes Know Current State Time

20 Some Examples Avoided catastrophic damage to combustion turbine at oil & gas facility Avoided liquid seal failure on water injection pump on offshore oil platform $30M Potential lost production $7.5M Potential lost production Surging compressor identified at oil and gas facility Rubbing turbine blades detected on jet engine $1M Potential production & maintenance loss Passenger Safety

21 Model > Site > Equipment My Notifications MAP Major Private Power Generation Company in India standardizes GE Proficy for Remote Monitoring & Diagnostic Remote Monitoring & Diagnostics Ultra Mega Power Project. Pain Area : Visibility & High Availability Need : Real Time Visibility & Predictive Diagnostics Value to Customer Centralized Monitoring & Reporting Avoidance of Failures : Auto escalation of critical alarms through SMS & Mobility Predictive Diagnostics.. Proficy Smartsignal CENTRAL CONTROL CENTER CEO Dashboards President Operations Dashboards Proficy Smart Signal Proficy RTOI Field Expert Dashboards Plant Operational Dashboards Centralized Proficy Portal 9 - REMOTE SITES PLC/DCS Alarm Condition Data Storage & Alarm Service Alarm Notification

22 Pioneers in Renewables standardizes on GE Proficy for Remote Monitoring & Control Remote Monitoring & Control Wind, Solar, Hydro. Pain Area : Remote Sites & cost of manpower Accurate Reporting Accurate Forecasting to avail incentive Need: Remote Monitoring & Control Past Data to enable forecasting Value to the Customer Web Based SCADA with SMS & alerts Robust web based Reporting Robust Historian for securing storage & Retrieval of Past data Analytics..

23 Transition to Brilliant Machines ARC Advisory Group

24 Industrial Performance & Reliability Center Our experienced equipment and software engineers monitor thousands of assets 7 days/week for more than 70 sites globally in Mining, Oil & Gas, Power Generation, and Aviation. Each month: 3000 customer advisories 500 cases 200 catches Air Heater Blower Chiller System Compressor Condenser Cooling Tower Engine Fan FCC Feedwater Heater Gas Turbine Gearbox Generator HRSG Incinerator Jet Engine Level Control Valve Mill Motor Pulverizer Pump Steam Turbine Tower Transformer TRVL Screen ARC Advisory Group

25 Thank You