Post on 10-Apr-2018
The Prescriptive Promise Next Generation Asset Management
Turning industrial trends and patterns from noise into action
2 The Prescriptive Promise
11/26/2013
Time series
Sensor devices
High velocity Temperature
Pressure
Speed
Sampled down to the microsecond Millions streamed into storage
Available for modeling, statistics and analytics
Definition 1 Example
data sources 2
Sampled and captured 3 Stored and analyzed 4
Industrial Data What Is It?
3 The Prescriptive Promise
11/26/2013
Data generated from one of many machines at one of many plants producing a specific personal care product
Industrial Data How does it get Big?
4 The Prescriptive Promise
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Industrial Big Data The Three V’s of Big Data
Velocity Volume Variety
PLC DCS
PAC
LIMS
ERP
CMMS
Operators
Loop
Controllers
HMI
SCADA
5 The Prescriptive Promise
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Line-level Trend Data with Historical Storage
Common Configuration
One-Click Historization
Enhanced Visualization
Embedded Ultra High Speed Writes (1MM+ writes/sec)
Small footprint
Intelligent collection
Site / Plant Data w/ Model Context
N-Way Distributed (One Server View)
• Always available
• Scales with Hardware
Centralized Administration
What We’re Doing about it
6 The Prescriptive Promise
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1 mo 2 mo 3 mo 1 yr 5 yr 10 yr
Why Hadoop based Historian
Operational Data Warehouse
SAN Redundant
Fault tolerant Fast
Expensive
Hadoop Shared Data
Shared Compute Scalable
Inexpensive (commodity Hardware)
$$$$/TB $/TB
7 The Prescriptive Promise
11/26/2013
Historian HD Cloud Enabled
Proficy
Historian
Proficy
Historian
Proficy
Historian
Proficy
Historian
Historian HD
8 The Prescriptive Promise
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Processor
Map to where data it resides and parallel process
An
swe
r
Processor Processor Processor
Processor
Processor Processor Processor
Processor
Have I seen this start up sequence
across my fleet of assets in the last 10 years?
Historian HD Cloud Enabled
Historian HD
9 The Prescriptive Promise
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Analytics Maturity Steps Insight to Action
Monitor
Analyze
Predict
Optimize
Learn
Va
lue
Time
10 The Prescriptive Promise
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Prognostics
Know Current State
Understand Causes
Operations
Predicting Problems
Today
Monitor
Diagnose
Predict
Optimize
Learn
Va
lue
Time
11 The Prescriptive Promise
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Underlying cause? Energy consuming systems like lighting were left on when production stopped. Value to the customer? Customer achieved up to 7 times the amount of return over their investment to implement the SCADA system to tie production to supporting ancillary systems.
Automotive company saves on energy costs
Monitor
6
Payback on energy cost savings
months
12 The Prescriptive Promise
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Automotive company saves on energy costs
Monitor
6
Payback on energy cost savings
months
Infrastructure required Control Networks SCADA and Historians Threshold based alarming Control charting
13 The Prescriptive Promise
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Diagnose
Underlying cause? Poor concentrator performance as a result of changes in feed material properties, de-tuned control and inconsistent operator intervention. Value to the customer? Understanding reasons for poor performance enabled corrective actions. Continuous performance monitoring and troubleshooting helps sustain performance.
Performance monitoring in a mining concentrator
$2M Productivity improvement
14 The Prescriptive Promise
11/26/2013
Diagnose
Infrastructure required Historical and real time data Equipment performance monitoring Process performance monitoring Data driven troubleshooting
Performance monitoring in a mining concentrator
$2M Productivity improvement
15 The Prescriptive Promise
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Single-sensor analysis or equation based models using traditional thresholds & rules
Bearing Temp
Real-time, multi-variable analysis
Bearing Temp
Load
Ambient
Normal Operation Early Stages of Damage
ALARM / TRIP
ALARM / TRIP
Predict
16 The Prescriptive Promise
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Applying Equipment Knowledge Combustion Turbine Example
Wheel Space Model
Fuel System Model
Combustion Model
Compressor Model
Mechanical Model
Lube Oil Model
17 The Prescriptive Promise
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Ambient Temperature
Gross Load
Inlet Guide Vane Position
Compressor Air Flow
Compressor Discharge Temperature
Compressor Discharge Pressure
Compressor Inlet Temperature
Compressor Inlet Pressure
Inlet Differential Pressure
Inlet Bleed Valve Position
Compressor Pressure Ratio
Inputs Outputs
Internals Calculation
Applying Equipment Knowledge Combustion Turbine Example
18 The Prescriptive Promise
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Applying Failure Knowledge Combustion Turbine Example
• Sensor Issues • Bearing Failure Modes:
• Bearing Cooling Loss
• High Radial Preload
• High OA, 1X, 2X, 1/2X Vibration
• High Axial Thrust
• Sensor Issues • IGV Control • Icing • Bellmouth Problem • Inlet Bleed Heat
• Inlet Filter blockage • Performance
• Pressure Ratio • Temperature
Ratio
• Sensor Issues • Filter Pluggage • Temperature
Control • Cooling Side
Fouling • Vapor Pressure
Lock
• Sensor Issues • Fuel Inlet Supply • Gas Inlet Valve Control
• Inlet Guide Vane Control
• Fuel Manifold
• Sensor Issues • Compressor Bleed
Problem
• Wheelspace Seal Problem
• Sensor Issues • Combustor Cold Spot • Combustor Hot Spot • Performance
Degradation • Exhaust Thermocouple
Sensor Issue • Inlet Bleed Valve • Turbine Cooling Issues • High Exhaust Emission
Wheel Space Model
Fuel System Model
Combustion Model
Compressor Model
Mechanical Model
Lube Oil Model
19 The Prescriptive Promise
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Predict
Underlying cause? Increased vibrations indicated damaged blades on combustion turbine. Value to the customer? The blade was 3-5 days from liberation. Scheduled outage avoided production loss and turbine repair costs.
Avoided catastrophic damage to combustion turbine at O&G facility
$30M Potential lost production
20 The Prescriptive Promise
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Predict
Infrastructure required Similarity Based Modeling Neural Networks Rule Induction Engines Random Forest Industrial Large Data Analytics as a Service
Avoided catastrophic damage to combustion turbine at O&G facility
$30M Potential lost production
21 The Prescriptive Promise
11/26/2013
Process Optimization + Asset Health Advanced Process Control
Pro
cess
7 Catches 1 Catch
Increase yield / throughput
Monitor
Analyze
Predict
Optimize
Learn
Va
lue
Time
22 The Prescriptive Promise
11/26/2013
Optimize
Underlying cause? Conservative and inconsistent operation in the drying section was constraining plant production Value to the customer? Optimized control increased dryer productivity by 10%
Productivity optimization in a mining smelter
$20M Productivity Improvement
23 The Prescriptive Promise
11/26/2013
Optimize
Infrastructure required Equipment performance monitoring Process performance monitoring Data driven troubleshooting Model predictive control Process Simulation Industrial Big Data
Productivity optimization in a mining smelter
$20M Productivity Improvement
24 The Prescriptive Promise
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Learn V
alu
e
Time
Leverage Big Data
Industrial Big Data
Pattern match deviations Faster analytic
deployment
25 The Prescriptive Promise
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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
Heat Exchanger
HRSG
Incinerator
Jet Engine Level Control Valve
Mill
Motor
Pulverizer
Pump Steam Turbine
Tower
Transformer
TRVL Screen