asset performance management...human productivity. today, the technology of our time is digital....

GE Digital

Asset Performance Management


Throughout industrial history, technological breakthroughs ranging from the steam engine to a personal computer have propelled leaps in machine and human productivity. Today, the technology of our time is Digital.

Digital is flourishing and driving radical change. Industry is in transition. At the heart of industry are assets. Machines that output industrial goods and commodities. Some economists argue, that since 1970 we have been in a productivity slump. Many of the incumbent firms have been operating in a volatile macro-environment forced to compete based on efficiency coupled with high internal cost structures, aging infrastructure and workforce. Information technology advances provide a significant productivity lift, allowing companies to compete based on innovation. Digital has become indispensible and it is the future.

GE is going through a pivotal time, as are our customers. We are emerging as a Digital Industrial. Over the last five years, we made big bets in software. We created a market leadership position in Industrial Internet through aggressive investments in R&D, commercial capabilities, talent and a customer partner ecosystem. To further strengthen our software portfolio trajectory, we are integrating four companies within GE Digital. Our bold journey highlights the power of metamorphosis. At scale. It is also our differentiation.

Consuming and benefiting from innovation requires a mindset and a behavioral change. Becoming digital is profoundly about committing to change. Adopting new technology to reorganize the way we work and produce. This idea of productivity is inextricably linked to assets and people, which involves tricky calculus. We are in the pursuit of building GE’s killer app by infusing state of the art technology and market feedback. Asset Performance Management (APM) is a software application. It uses data management, pattern recognition, predictive analytics, artificial intelligence and machine learning to make asset centric organizations more productive. It improves machine reliability while reducing operational costs and risks, by getting ahead of failure and unifying the enterprise through data intelligence.

Customers seeking ways to make assets and people more insightful and productive can benefit from APM software; as well as lower their computing infrastructure and innovation costs by subscribing to services on Predix-GE’s Industrial Cloud Platform.

Benefitting from APM is as much about committing to change as it is about architecting a solution that maps to your current needs and future goals. It is about being our digital partner. It is about the promise of transformation.

Watch GE APM Video

Preface: Committing to Change“Be the change you wish to see in the world”- Gandhi

INTRODUCTION MARKETOVERVIEW

SOLUTION OVERVIEW

SOLUTION DEVELOPMENT

APPROACHCASE STUDIES PRICING GE ADVANTAGE

2

APM EXPERIENCEPREDIX

https://www.ge.com/digital/asset-performance-management


This interactive booklet is designed to provide a view of the Asset Performance Management (APM) industry, market dynamics, GE Go to Market approach, and APM offering. GE has created this solution booklet to help understand the value of optimizing asset performance while simultaneously minimizing costs and reducing operational risk.

Organizations invest in APM tools and technologies to:

• Increase asset availability

• Minimize the costs of maintaining assets

• Reduce the risks associated with operating the assets

The content enclosed will enable you to quickly understand:

• The Asset Performance Management solution with key capabilities, proof points, and outcomes delivered

• A competitive overview

“Asset performance management (APM) consists of the market of software tools and applications designed for the explicit purpose of optimizing the performance of operational assets (plant, equipment, and infrastructure essential to the operation of an enterprise).”

Implementing an APM strategy is key for transforming industrial operations to increase efficiency, reduce costs and get the most out of Big Data. Asset Performance Management (APM) from GE Digital enables intelligent asset strategies that balance three traditionally competing priorities—reducing cost, improving availability, and managing risk—to help optimize your overall asset and operational performance.

Introduction


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New levels of connectivity, advanced analytics coming from smart sensors and devices, and improved data storage economics which means more and more data is available. One of the most important changes is the cost associated with storing more historical data. This has been prohibitive in the past. Related technology advancements in predictive analytics are now making it possible to obtain insights from this vast amount of data.

The broad application of this technology in industry is commonly referred to as the Industrial Internet of Things, Industrial 4.0, Smart Manufacturing, Smart Connected Operations, and more. General Electric focuses on the Industrial Internet for very large or complex equipment and applies our expertise in these solution categories that are built on Predix.

• Asset Performance Management

• Brilliant Manufacturing

• Automation

• Cyber

This booklet focuses on Asset Performance Management (APM).

Data availability and analytics capability is rapidly changing how industry designs, makes, and services its products. The Industrial Internet is enabling businesses to reach new performance levels through optimized processes and productivity increases that are faster and less expensive than ever before.

Market and Technology Evolution

APM Market Overview


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APM MARKET IMPACT | MARKET INSIGHT | VALUE DRIVERS & GROWTH PLAYS | GE DIFFERENCE | APM OFFERS


Mean Time Between Failures (MTBF)

Reliability/Availability (Uptime %)

Mean Time to Repair (MTTR)

Unplanned Downtime

Maintainability (Downtime %)

Planned vs. Unplanned Work %

Mean Time to Failure (MTTF)

Work Order Backlog

Maintenance Cost per Unit of Production

Return on Net Assets (RONA)

Work Order Closure Rate

Labor per Planner

APM Metrics That Matter, Metrics by

Filter Settings vw_LNS_SurveyQuestions Responses - SurveyName: (2016 - 2017 Asset Performance Management Survey, 2016 - 2017 Demographic Survey, 2016 - 2017 Metrics that Matter Survey) Survey Questions Responses-Question1 - Question2: (Discrete, Government/Public Sector, Oil and Gas, Transportation)

APM Market Insights

What APM Metrics does your organization measure?

of asset-intensive organizations will rely on APM to help

them optimize the performance of their mission-critical assets.”

as one of their top priorities

analyticsMany customers of GE see

Gartner Strategic Planning Assumption: “By 2018,

50%

$300 BILLION by 2020

Gartner estimates the Asset Performance

Management market to hit

53%

41%

31%

31%

27%

27%

21%

19%

16%

13%

13%

4%


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Market Environment and Challenges

2.5%‘16 GLOBAL

GDP GROWTH

5~30%COST OUT

TARGET

29%CAPEX BUDGET

SHRINK

20%ASSET NEAR END OF LIFE

50%WORKFORCE TO RETIRE BY 2025

Business Challenges

1 Pressure to increase profit in a flat and volatile economy

2 Demand for agility in asset operations

3 Tighter regulation and increased compliance risk

4 Aging assets and increased operation risk

Competitive Environment1 GE named an IIoT leader (Q4, Forrester Wave)

2 Hot market fueling acquisitions : Mtell (AspenTech), MaxEAM (Schneider)

1 Sensitive and critical opportunity vs risk operating decisions with little margin for error

2 A lack of asset level visibility and insights - not knowing in advance when problems are about to occur

3 Unplanned downtime with lost productivity and high cost of emergency repairs

4 Costly and often unnecessary routine preventive maintenance that introduces risk and decreases availability

5 Delay in critical information reaching those that need to take action - maintenance technicians, operators

Operation Challenges

Market has dramatically changed how assets must be operated and industry is challenged to deliver with legacy processes and technology.

These figures represent the Oil and Gas industry. Relevant statistics will vary by industry vertical.


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Motivating Challenges

We want to be data-driven, but… 80% of the effort is in

gathering and normalizing the data

IT and OT data sources are diverse and siloed, resulting in limited visibility across an enterprise

We are a mature and proactive shop, but… 89% of failures are NOT time-based

We know asset failure is often random; however, we don’t have a

better set of mitigation tools

We need to cut costs, but… don’t know which cuts

push us over our risk tolerance

We don’t know where to cut or where the point of diminishing

returns resides

Big Data and automation are critical

but also disruptive to people and processes

We don’t know how to best leverage emerging technologies, with our people and processes.

Source: Nowlan and Heap study

Slow aging Best new Constant random failure Worst new

(Primarily random wear) 89%

5%

7%

68%

14%

Budget savings Highest value strategies Risk acceptance

Cumulative strategy costs

Cum

ulat

ive

stra

tegy

ris

k re

duct

ion

Amid macro and micro environment challenges, our customers are also challenged by conventional methods of running production operations.


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APM addresses challenges of customers through these value drivers• Comprehensive solution for monitoring, diagnosis, and reliability management

for asset and process intensive industries. Most comprehensive in this space

• Value to customers bottom line with less unplanned downtime, more predictable operations, and matching maintenance to budget; and lower TCO of APM Solution

• Ability to manage data once, but serve it up many times to multiple analytics, KPIs, and other performance views. One visualization to bring results together

• Cost effective solution from an IT spend perspective. APM is an end to end solution that will cut costs through landscape simplification compared to fragmented alternatives

APM Value PropGE APM maximizes customer outcomes by balancing traditionally competing priorities: Improving reliability & availability, reducing costs, and managing risk.

Key Take AwaysAPM is a subscription based business model with software as a service (SaaS) offerings. Our prescription is to move to cloud first. However, APM offers both cloud and on-premises solutions.

APM is comprised of 4 offerings: 1) Machine & Equipment Health2) Reliability Management

3) Compliance & Integrity Management 4) Asset Strategy Optimization

Value Drivers and Core Sales Messages

Cloud Advantage:Predix cloud offers continuous delivery of improved and proven analytics thereby drastically improving pace of innovation and reducing cost to maintain infrastructure. We are cloud first, targeting on-prem needs as well

Manage Risk

CustomerOutcomes

ImproveAvailability

ReduceCost

& Time to Value

Proven Predictive Analytics

Intelligent Asset Strategies


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APM Growth Plays

GE FOR GE GE FOR CUSTOMERS

GE FOR THE WORLD

Supplier Customer

APM has a three prong growth strategy.

1. GE for GE—We are using APM in our own factories and businesses to: • Drive productivity in GE M&D service

center operations.

• Define the “GE Way” for best-practice M&D across the market

• Increase referenceable productive usage by Power (Atlanta), O&G (Florence), and Aviation (Cincinnati) in 2017

2. GE for Customers—We are deploying APM for customers to:• Deliver outcomes that improve

operational productivity.

• Enable them to on-ramp to a digital transformation roadmap through collaborative partnerships.

• Consume or monetize analytic IP through new business models and content catalog

3. GE for the World—We are expanding to new market of original Equipment Manufacturer by:• Enabling better after market service for Equipment

Manufacturer’s customers

• Reducing warranty costs

• Shortening the product innovation cycle through the concept of digital twin and field usage feedback into product development

GE Business Productivity Backlog Support Service Productivity M&D Infrastructure Unification Showcases per GE business

Owner/Operator Productivity Operational Productivity Digital Transformation Partnerships

Digital Channel for CSAs Service expansion Analytic IP monetization New Business Models

Equipment Manufacturer Productivity After-Market Service Expansion Product Lifecycle Cost Out Service Collaboration Analytic IP Monetization New Business Models


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Although GE built APM, it’s now a race by market providers. GE is out in front leading this transition. We are consuming our own product, we have a position of strength because our:

• Remote Monitoring & Diagnostics expertise

• AI for Intelligent Data Management

• SmartSignal Predictive Analytics

• Machine learning

• End to End Digital Portfolio (Apps + Platform)

GE has deep experience in Industrial Software.

• Over 30 M&D centers worldwide

• Designed for any Equipment Manufacturer; GE and non-GE equipment

• 10,000 software professionals globally

• $1 Trillion in assets under management

GE offers the combination of:

• Algorithms for machine learning, reasoning, and advanced statistical analysis to identify if equipment is behaving anomalously.

• Physics-based modeling which predicts how the equipment should perform given its past and current operating conditions and environment.

• Predix, the cloud platform for the industrial internet, provides continuous data availability and through cloud technologies a dramatic reduction in time to value for customers.

+ + Operator A Operator B Part Temperature

Cruise Takeoff

Tem

pera

ture

Threshold

Altit

ude

(ft)

Climb

STATISTICS: Unlock trends

PHYSICS: Apply equipment

expertise

PREDIX™ Leverage

cloud platform

INDUSTRY BENEFITSBetter equipment reliability and availability, lower fuel, repair and maintenance costs

Physical + Analytical + Platform

Why GE? The GE Difference


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APM Solution MapGE Digital’s APM is a full end-to-end suite that is comprised of four modules designed to increase asset reliability and availability, while simultaneously reducing cost and risk.

Reliability Management Compliance & Integrity Management

Asset Strategy Optimization

Achieve less unplanned downtime by predicting equipment issues

before they occur.

• Predictive analytics

• Case and collaboration management

• Knowledge management

• Root cause analysis

• Reliability analysis

Anytime, anywhere, unified view of your assets’ current state, and health.• Connectivity• Data management• EAM integration

• Condition monitoring• Data analysis and visualization• Criticality analysis

• Event management• Recommendation management• Benchmarking

Ensure asset integrity and compliance by monitoring changing risk conditions.

• Hazard analysis

• Safety lifecycle management

• Risk based inspection

• Inspection management

• Thickness monitoring

Optimize across availability, reliability, risk, and costs through

intelligent asset strategies.

• Reliability centered maintenance

• Failure mode and effects analysis

• Strategy management

• Strategy library

• Lifecycle cost analysis

• Financial and risk simulation

Machine & Equipment Health


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MACHINE & EQUIPMENT HEALTH

Customer Challenges: GE APM Offers:

Obtaining a single, unified view of overall Asset Health, Status and Performance is challenging:• Data Disparity: data is isolated across islands of

information with no common understanding • Data Aggregation: Aggregating disparate data

usually results in data swamps with little consistency and reference-ability across assets, operations and processes

• Data Organization: Organizing data into canonical forms and standards is manual, time consuming and usually fit for purpose

• Data Analysis and Visualization: No unified view – single pane of glass - to visualize and present the variety of data

• Data relevancy: Identifying important and relevant data is usually ad-hoc, reactive and resource intensive

• Data Availability: Assets without sensors or online condition monitoring – difficult to collect health and condition information – manual tasks

Value by providing integrated performance data in the right context to identify opportunities for improvement based on facts• Asset Centric: Connect and integrate with multiple data

sources to and relate it to your assets• Digital Transformation - Enable edge to cloud and

multiple data source connectivity: Cloud-ready for APM, Predix , or third part data access.

• Data Modeling and Mapping and Organization: Automated AI driven integration,organization, and modeling of a variety of disparate data types to a canonical model.

• Complex Event Processing: use analytics to identify relevant data and events. Develop and execute strategies, actions and recommendations, based upon historical and dynamic data, which is obtained by monitoring conditions in real time. Core foundational tools like Queries, Graphs, GIS Mapping, Benchmarking and advanced search to view and find the right information fast.

• Accelerate Time to Value: Real time view of asset health status, provides pro active asset risk analysis and KPI’s


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Customers Need: GE APM Offers:

• Issue prediction to minimize unplanned downtime

• Downtime scheduling so it has the least impact on operations

• Issue notification and case management

• Mobile workforce support

• Asset history throughout its lifetime

• Past event insights to guide future analysis

• Real-time Executive-level operating and performance metrics

• Predictive analytics honed through decades of industrial experience

• Case Management and Root Cause analysis tools to maximize operating efficiencies

• Executive dashboards with visual and analytic diagnostics

• Mobile device support for greater workforce productivity and safety

• Diagnostic Workflows that guide operating staff through indicated actions

RELIABILITY MANAGEMENT


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• Real time insight and visibility into linear and fixed asset risk assessment – unmitigated, mitigated, and current

• Oversight to ensure safety and integrity risks are mitigated, managed, or controlled

• Ensure regulatory inspections are completed and compliance requirements met

• Optimization of inspection strategies and compliance with API standards

• Visibility and proper governance of safety system lifecycle management

• Eliminate multiple databases, reduce input errors, increase efficiency by removing typical organizational “silos”, which are perpetuated by use of non-integrated tools

• Rank linear and fixed equipment risk using globally accepted methodologies

• Develop and implement inspection plans using client-defined strategies

• Store thickness readings and carry out detailed corrosion analyses to determine remaining useful life

• Ensure compliance and manage risk at optimum levels using configurable reports, metrics, and key performance indicators (KPIs)

• Automatically re-calculate integrity risk, based on real-time data field information and intelligent actions executed on pre-defined conditions

• Fully integrate compliance and integrity initiatives across an enterprise with corporate asset hierarchy and EAM system integration

• Enable compliance with OSHA 1910.119 process safety management requirements

COMPLIANCE & INTEGRITY MANAGEMENT


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• Maintenance activities performed at the right time and at the right cost to avoid unnecessary work and resources

• More proactive maintenance to prevent incidents and costly repairs

• Balanced reliability, performance and operational costs

• Asset strategies that adapt to to match changing company goals

• Executive-level view into the financial impact of asset strategies

• Analysis of individual assets and entire asset systems to identify potential failures

• Risk-based asset strategy management to improve maintenance planning and efficiency – “Do the right work at the right time”

• Access to pre-defined strategies for 600+ equipment types to accelerate the development of intelligent asset strategies

• Insight into the true “whole life” costs of assets from procurement through salvage to make objective, informed decisions on when to repair vs. when replace

• Simulations to forecast the effect of strategy changes to risk and cost in order to develop optimal strategies

• Dashboards to communicate the financial impact of asset strategies across the organization

ASSET STRATEGY OPTIMIZATION


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Solution Overview

Asset Performance Management by GE DigitalGE Digital’s APM, the leading and most compete APM offering on the market, balances traditionally competing priorities—reducing costs, improving availability, and managing risk—to provide APM Intelligent Asset Strategies that maximize asset performance and productivity. These APM capabilities are directly related to the outcomes our customers need to achieve.

Reliability Management Compliance & Integrity Management



Achieve less unplanned downtime by predicting equipment issues

before they occur.

• Predictive analytics

• Case and collaboration management

• Knowledge management

• Root cause analysis

• Reliability analysis

Anytime, anywhere, unified view of your assets’ current state, and health.• Connectivity• Data management• EAM integration

• Condition monitoring• Data analysis and visualization• Criticality analysis

• Event management• Recommendation management• Benchmarking

Ensure asset integrity and compliance by monitoring changing risk conditions.

• Hazard analysis

• Safety lifecycle management

• Risk based inspection

• Inspection management

• Thickness monitoring

Optimize across availability, reliability, risk, and costs through

intelligent asset strategies.

• Reliability centered maintenance

• Failure mode and effects analysis

• Strategy management

• Strategy library

• Lifecycle cost analysis

• Financial and risk simulation


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CAPABILITIES | APM PRODUCT AND FEATURES


APM Offerings

Reliability ManagementCompliance &

Integrity ManagementAsset Strategy Optimization


OT Systems

Powered by:

IT Systems Asset Data

What’s New:• Bit Stew and Meridium capabilities are integrated into a unified APM• Maintenance Optimization —> Asset Strategy Optimization• Added Compliance & Integrity Management Offering• Each offering only requires M&EH

(M&EH vs. RM which is not required for ASO or C&IM)

GE Digital’s APM is an integrated suite of software and service offerings that works across all equipment, all Equipment Manufacturers, and all industries; across the plant and across the fleet. Combining GE Digital’s proven predictive analytics with Meridium’s Industry-leading APM solution and Bit Stew’s MIx Core platform; the new unified APM enables asset centric industrial companies to maximize outcomes by providing a comprehensive view of asset health and actionable insights.

Deployment Options: Cloud, on-premises, or Hybrid


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Machine & Equipment HealthMachine & Equipment Health

Data Management

Condition Monitoring

Data Analysis & Visualization

Criticality Analysis

Event Management

Recommendation management Benchmarking

Machine & Equipment Health (pr-requisite for pillars above)

OT Systems IT Systems Asset Data

Delivers Customers:• A single unified view across asset data, time series, GIS, alarms and

events, operations and work order data• Real-time analysis and tracking of operational environment

• Accelerated time to value of asset monitoring and diagnostics

Powered by: Deployment Options: Cloud, on-premises, or Hybrid

Machine & Equipment Health is not only the foundation of APM, but also the common enabler across all other APM solution offerings: Reliability Management, Compliance & Integrity Management, and Asset Strategy Optimization.

M&EH is required before customers can add other APM solution offerings.


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Reliability Management

Predictive Analytics Case and Collaboration Management Knowledge Management Root Cause Analysis Reliability Analysis



Helps Customers:• Reduce unplanned downtime by predicting equipment issues

before they occur and• Collaborate efficiently on issues, all the while automatically

capturing best practices

Reliability Management (RM) solution uses advanced predictive analytics to analyze data, detect and diagnose equipment problems before they occur.

Reliability Management



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Compliance & Integrity Management

Hazard Analysis Safety Lifecycle Management Risk Based Inspection Inspection Management Thickness Monitoring


Helps Customers:• Develop and optimize inspection strategies through risk-based inspection

methodologies (API 580, 581)

• Enables compliance with OSHA 1910.119 process safety management requirements and ISA/IEC safety standards

• Fully integrate compliance and integrity initiatives across an enterprise to maximize asset availability and lower catastrophic incident probability


Compliance and Integrity Management



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Reliability Centered Maintenance

Failure Mode Effects Analysis

Strategy Management Strategy Library Lifecycle Cost

AnalysisFinancial and

Risk Simulation


Asset Strategy Optimization (ASO) provides a common methodology to develop and manage asset strategies by using a risk based approach. It conducts rigorous analysis of individual asset and entire systems to anticipate failures and their causes.

Helps Customers:• Develop better maintenance strategies that balance reliability, performance and costs

• Improve ability to respond to market conditions as prices, demand and costs fluctuate





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CriticalityFailure Modes

Damage Mechanisms

Re-evaluate Risk (New DM)

Drive Work (Repair)

MobilityCloud Services

and ApplicationsIT Cyber Security

Software Development Kit

Optimized Plan(Inspect, Monitor, PM)

Change Strategy (Interval)

Connect & CollectSensor Data / Alerts / EventsInspection Data / Alerts / History Events

Engineer, Operate, and Maintain

Define Strategy (mitigation)

Assess Risk

Analyze + Action

Intelligent Asset Strategies

Continuous Learning and ImprovementGE Digital’s integrated suite of APM solutions enables customers to develop and refine intelligent asset strategies to collect and manage all the asset related data customers need to make decisions that maximize assets and overall operational performance – and to continuously improve and learn, automatically.


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APM Managed Services

The promise of IIoT comes with high volume of data and cutting edge analytics. To generate valuable insights, tracking and monitoring the right data becomes paramount. GE Digital’s experienced Reliability and Maintenance Engineers provide these services for customers. With over 250 years of subject matter expertise and over $10B in industrial assets under management, our team can help maintain critical machines from one of our remote locations around the world using model based predictive analytic technology.

We have managed services for M&EH, RM and ASO.

• Tier 1 Offering: We help customers incorporate our analytic capabilities into their core business processes to ensure value is maximized.

• Tier 2 Offering: We co-monitor customer assets with one of our Level 2 Certified Customer Reliability Engineers, so customers can get subject matter expertise on weekly support calls. We review potential issues and provide actionable notifications so production is always running and downtime is avoided.

• Tier 3 Offering: This service level is a co-monitoring engagement with our Level 1 and Level 3 Certified Customer Reliability Engineers. We give you 24x7 access to our analytics, complex model maintenance on request, monthly quality reviews, and ongoing blueprint optimization.

Tier 1 Tier 2 Tier 3

Complex Model Maintenance ✔ ✔ ✔

Monthly Quality Review ✔ ✔ ✔

24x7 Coverage ✔ ✔

Simply Model Maintenance ✔ ✔

Subject Matter Expertise ✔ ✔

Advisory List Management ✔

Services for Asset Strategy Optimization

Powered by Meridium*

Helps your staff optimize maintenance and operations spend

Helps your staff transition from reactive to proactive maintenance

Helps your staff manage and monitor alarms and data from the cloud

Services for Reliability Management

Powered by SmartSignal

Services for Machine & Equipment Health

Powered by Predix Cloud Data Storage Technology

P curve showing most failures have small signs of early warning prior to failure

Full Functionality Equipment offline (Trip)Functional Failure

Machines and processes are

running normally

Optimize Maintenance

TimeMac

hine

/pro

cess

efe

ctiv

enes

sProactive Maintenance React to alarms Break/fix

Early signs of failure exist in data Alarms reached

Equipment or processes are not

producing


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APM Product Development Approach

BUILDMEASURE

CUSTOMER PROBLEM CUSTOMER SOLUTION

PIVOT OR PERSERVE

PROTOTYPEFORM INSIGHTS

OBSERVE & INTERVIEW PEOPLE

DEFINE OPPORTUNITY SPACE

FRAME PROBLEMS GENERATE IDEAS

LEARN

FEEDBACK

DESIGN THINKING LEAN STARTUP AGILE SOFTWARE DEV

GE’s APM solution follows GE Digital’s Software Development Lifecycle, founded on Agile principles. It operates on a rolling four quarter planning model. We work in close collaboration with industry analysts, Customer Advisory Councils and collaborate with customers to continuously update and improve our solutions.

The figure below communicates our roll-in and release iterative model.

INTRODUCTION SOLUTION OVERVIEW



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APM EXPERIENCEPREDIXMARKET OVERVIEW



SOLUTION OVERVIEW



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BORD GAIS | CUSTOMER CASE RESOURCES

OBJECTIVE

Whitegate Power Station sought to increase plant efficiency and reliability, while reducing maintenance costs.

SOLUTION

Big Data analysis and predictive analytics based monitoring using 141 sensors

OUTCOME

• 24/7 monitoring of the plant’s hardware helps Whitgate’s engineers avoid operational issues by identifying them before they occur.

• Delivers operational recommendations and a single, consolidated view of plant performance.• Bord Gáis achieved 25 percent fuel savings as a result of their use of sensors, Big Data

and diagnostic analysis to engineer greater reliability into its operations.Whitegate Power Station, Ireland, owned by Bord Gáis EnergyBord Gáis Energy’s 445-megawatt gas combined cycle power plant at Whitegate, which is 25 miles east of the city of Cork, provides power to 10 percent of Ireland.

“The Software that GE’s developing is not just about collecting big data. It’s about turning that data into useful information, into intelligence, and it can help us to make better decisions.”

Chris Barry, Whitegate Project Engineer

Whitegate Power Station


SRP (Utility) SRP is using GE Digital software to achieve zero unplanned downtime

Customer Case Resources

WATCH VIDEO

VIEW ALL GE DIGITAL STORIES

READ CASE STUDY

READ ARTICLE 1

Ras Gas (LNG Producer)

Kraton Polymers

READ ARTICLE

SSE (Power Producer)

WATCH VIDEO

Gerdau (Steel Producer)

READ ARTICLE

Schindler (Elevator-Escalator Manufacturer)

READ ARTICLE 2READ ARTICLE


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BORD GAIS | CUSTOMER CASE RESOURCES

https://www.youtube.com/watch?v=juATErQ7R98&feature=youtu.be&list=PLnPw6yhGDFtkJ7D57Q87kA8oXVEtfCrHu

https://www.ge.com/digital/stories

https://industrial-iot.com/2017/01/salt-river-project-uses-iiot-to-prevent-losses/

http://www.reuters.com/article/ge-idUSnBw015076a+100+BSW20151102

http://reuters.com/article/ge-idUSnBw095279a+100+BSW20150609

https://www.youtube.com/watch?v=wVul44pA0yI&feature=youtu.be

http://www.reuters.com/article/gerdau-steel-plate-idUSL2N1BR048

http://www.albawaba.com/business/pr/rasgas-leads-first-global-ge-asset-performance-management-solution-built-exclusively-lng

http://www.gereports.com/elevator-maker-schindler-group-and-ge-digital-take-industrial-internet-to-the-next-level/


Value Based Pricing

GE Digital’s APM is offered as a subscription-based, pay-as-you-go pricing model, allowing users to easily access and scale with it as their business needs evolve over time.

Fewer forced outagesImproved Availability

Improved Reliability

Reduced Maintenance

Improved Operational

Reduced Operating/Infrastructure Costs

Fewer equipment failures

Reduced trips

Improved asset life

Increased production throughput

Reduce fuel costs

Improved worker productivity

Reduced hardware costs

Reduced SW costs & consolidationReduced PM

Reduced Break/Fix

1

2

3

4

5

APM value category and driver


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GE Advantage

GE is the only company that embodies multiple qualities of an industrial and a digital organization. The ability to combine these capabilities at scale makes us unique and differentiated.

Industrial Domain Expertise: GE has deep expertise in developing and servicing machines for industry – from turbines, to jet engines, to wind farms, to locomotives, to medical equipment and more. This gives our experienced team of 14K+ software professionals around the globe a deep understanding of real business operations and the insights to deliver on industry needs.

Industrial Scale & Security: GE has decades of cross industry experience securely monitoring and managing industrial assets and data at scale. Each day, GE monitors and analyzes 50 million data elements, from 10 million sensors, on $1 trillion of managed customer assets.

For Industry by Industry: GE is one of the largest users of technology in the world. Not only does GE manage and maintain $1 trillion in industrial assets sold to customers, we actively deploy technology to drive efficiency and process improvements in our 400+ factories.

Predix: GE’s cloud platform for the Industrial Internet, enables customers to benefit from a standard way to connect machines, data, and people and to run industrial-scale analytics. This cloud- based platform accelerates time to value for customers, enables interoperability of a wider range of assets, allows customers to easily scale and extend functionality over time, and gives end-users a consistent user-friendly experience.

To create and inhabit a new world at the intersection of dualities

Digital Industrial

By Evolving our Culture Being Open to Ideas from Inside & Outside.

Adopting Horizontal Thinking.

Physical Machine

HardwareSensors

OTMaterial Science and Physics

ProductDomain Experts

Century Old Industry IconValue Chain

VirtualHuman Mind SoftwareData & InsightsITData Science & AIPlatform +AppsDigital Natives MillennialsSilicon Cally Start-UpEcosystem

Transformation


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GE ADVANTAGE | TECHNOLOGY DIFFERENTIATORS


Technology Differentiators

Asset Connectivity: GE can help you get connected quickly. APM Powered by Predix combines proprietary technologies with global telecommunications partners to enable rapid provisioning of sensors, gateways and software-defined machines.

Scalability: APM Powered by Predix is built to scale easily as your needs grow. Businesses can focus on making better asset decisions; we’ll handle scaling the APM infrastructure as your needs change.

Security + Compliance: Predix, the underlying operating system for APM, leverages the advanced security protocols, including customized, adaptive security solutions for industrial operators and developers. With GE, businesses benefit from decades of experience in operational and information security.

Interoperability: APM Powered by Predix is built to operate seamlessly with applications and services running in a broad spectrum of cloud environments. Businesses will be able to take advantage of Predix’s security and data structure offerings while maintaining and interoperating within existing solutions.


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GE ADVANTAGE | TECHNOLOGY DIFFERENTIATORS


According to Seeking Alpha, not only does Predix provide a compelling value proposition to GE’s clients, it also serves to further augment the conglomerate’s competitive advantage by enhancing customer lock-in. GE has delivered exactly that with its Predix platform, which forms the core of the Industrial Internet. Simply put, GE installs sensors on their client’s assets. These sensors collect real-time environmental data which is then fed into GE’s software offerings. GE’s software then analyzes this data and produces actionable insights that its customers can capitalize on.

GE built Predix software platform to bring capabilities together so GE’s own businesses can deliver solutions on top of a platform. Customers can use the platform to drive more incremental value by leveraging those capabilities optimized for industrial data, understanding machines and other assets, and being able to participate in the next generation of the industrial revolution.

Predix is the Cloud Platform of the Industrial Internet. Predix enables Asset Performance Management and operations optimization by providing a standard way to run industrial-scale analytics and connect machines, data, and people. Deployed on machines, on-premises, or in the cloud, Predix combines an industry-leading stack of technologies for distributed computing and big data analytics, asset data management, machine-to-machine communications, and mobility. This platform extends beyond GE assets to connect machines from any vendor or vintage.

Predix:• Securely connects machines, data,

and people

• Performs Industrial Scale Analytics

• Allows customers to easily scale and extend functionality over time

• Gives users a consistent, user friendly experience

For GE, APM is part of a broader industrial Internet strategy of driving more efficiency.

Predix, GE’s Industrial Cloud Platform


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APM Experience—Monitoring Services and Catches


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APM EXPERIENCE—MONITORING SERVICES AND CATCHES


Detected Catches• Lube oil pump operational issue found at combined cycle power plant

• Faulty recirculation valve on a feed pump at a combined cycle power plant

• Wiped bearing detected on a feedwater pump at a combined cycle power plant

• Failed cooling fan detected on a condensate pump at a nuclear power plant

• High winding temperatures found on a hydro turbine

• Incorrect hydrogen pressure level found at combined cycle power plant

• Tripped purge valve on a hydrogen cooled generator detected at a combined cycle power plant

• Increased high frequency pulsation detected on combustion turbine at a combined cycle power plant

• Inlet bleed heat valve problem detected on a combustion turbine at a power plant

• Sump magnetic chip detector resistance drop at a combustion turbine peaker plant

…. And many more day to day issues faced by utilities

Power Generation APM Experience


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What did GE’s analytics software find?

In late March, the GE SmartSignal solution detected that a steam turbine control valve started reporting a value of 35% open when it was expected to be operating at 80% open, given the load on the unit. The Industrial Performance & Reliability Center sent a high priority notification to the plant and began tracking the issue on the weekly calls.

What was the underlying cause?

When the customer investigated this notification, they found that there was a problem with the valve positioner.

What is the value to the client?

The customer received early notification that a steam turbine valve positioner had failed. They were able to schedule a short outage, when it minimized their production losses, and repair this issue and address a secondary issue which arose shortly after this notification. The Industrial Performance & Reliability Center was able to provide the customer verification that their maintenance action was successful. If this issue had not been detected, this positioner failure could have caused a unit trip, resulting in a larger loss of production revenue.

Problem Detected:

Failed steam turbine control valve positioner detected at a combined cycle power plant


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Detected Catches• Faulty hydraulic valve in fuel delivery system

• Leading edge corrosion on combustion turbine buckets

• Damage/cracking of compressor blades from icing/FOD/DOD

• Misalignment of bearing and coupling

• Prognostic notification for tuning to prevent lean blow out trip and combustion damage

• Detect contaminates in gas fuel piping

• Damage of combustion liner, transition piece, fuel nozzles

• Slow responding compressor bleed valves

• Malfunctioning evaporative cooler water distribution system

• Compressor damage from surge event

• Live technical trip and runback support in more than 200 languages


PGS M&D

MONITORING + DIAGNOSTICS + PROGNOSTICS24 x 7 Global operations | 500+ power plants in 60+ countries

1,440+ gas turbines | 280+ steam | 100+ million hours operational data


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Event Background

The M&D bearing metal temperature (BMT) analytic triggered an alert to the M&D Center for elevated temperatures on a 7FH2 generator bearing. The M&D Tier I specialist reviewed the data and determined that the #2 generator bearing (collector end) temperatures were exceeding the M&D warning limit of 250 deg F. The Tier I specialist escalated a case to Tier II for further review.

Recommendations & Actions

The M&D Tier II expert reviewed the BMT trends for the past month and noted that that collector end bearing temperatures had gradually increased over the past 2 weeks, while the turbine end bearing temperatures had gradually decreased. This indicated a possible shift in alignment. The M&D Tier II expert advised the customer to inspect the bearing and check alignment during the upcoming planned outage (a few weeks away). The M&D expert also recommended that site continue to monitor the collector end BMTs to ensure they do not exceed 265 deg F. If the BMTs continued to trend upwards, M&D recommended that the site temporarily lower lube oil temperature to 120 deg F until the issue could be resolved.

Investigation during the planned outage revealed collector end bearing damage due to misalignment. The bearing was replaced and the generator/turbine re-aligned.

Customer Impact

M&D analytics alerted the M&D Center to elevated generator BMTs.

M&D promptly provided accurate recommendations, including short term actions to take if the BMTs should continue to increase.

M&D Customer Impact – Bearing Metal Temps


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Detected Catches• Broken valve diaphragm found on an integral compressor at an

air separation

• Faulty fuel valve found on a CNG engine at a natural gas compression facility

• Faulty lube oil filter on an engine discovered at a natural gas compression facility

• Broken bolt on a waste gate valve found on CNG engine at a natural gas compression facility

• Low lube oil level detected on a CNG engine at an oil and gas facility

• Faulty spark plug detected on an engine at an oil and gas facility

• Bad ignition coil detected on a combustion engine cylinder at a pipeline facility

• Loose combustion coil connection on a reciprocating engine at a mid-stream gas pipeline

• Broken valve bolt found on a reciprocating compressor at an oil and gas facility


Oil & Gas APM Experience


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Problem Detected:

What did GE’s analytics software find?

In late April, the GE SmartSignal solution detected a step change up on the lube oil header temperature and thrust bearing temperatures on a compressor at an oil and gas facility. Given the speed and load on the machine, the lube oil header temperature was expected to remain at approximately 133°F (56°C). However, the actual temperature had increased to approximately 146°F (63°C). GE’s Industrial Performance & Reliability Center (Industrial PRC) sent a high priority email notification to the customer and began tracking the issue on the weekly calls.

What was the underlying cause?

Upon investigation, the customer discovered that the step change in lube oil header temperature was caused by a cooling fan, which was inoperable due to a defective bearing on the fan motor. The customer subsequently replaced the defective bearing and placed the cooling fan back in service. The lube oil header temperature returned to model prediction.

What is the value to the client?

Early notification from the GE SmartSignal software and the Industrial PRC provided the customer an opportunity to ensure replacement parts were on site and proactively replace the defective bearing. If the cooling fan had not been repaired, the prolonged elevated lube oil temperature and associated lower lube oil pressure would have resulted in accelerated bearing wear on the compressor. The Industrial PRC was able to help the customer verify that its maintenance action was successful by showing that actual values returned to expected values.

Defective bearing detected on a lube oil cooling fan motor at an oil and gas facility in Angola, Africa


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asset performance management...human productivity. today, the technology of our time is digital....

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