“nextgen” hmi/scada decision support for operations · decision support for operations the...

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Decision Support for Operations The future of HMI/SCADA

Dr. Bernard E. Cubizolles Global Product Marketing Manager – Automation Software

GE Digital

Milano - December 3, 2015

The Smart Operator

Prevent Operator Mistakes and Speed Response

Decision Support | November 2015 3

NE

ED

S •The right information for more informed

decisions at the right time

•Early problem detection & intelligent alerts

•Secure & easy deployment

GET OPTIMIZED

Maintenance Optimization

GET INSIGHTS Industrial Intelligence

GET CONNECTED

Machine & Asset Performance

•Full operating visibility for increased asset performance

• Increased Operator efficiency

•Reduced downtime

•A Secure Industrial Internet Platform!

OU

TC

OM

ES

From Sensor to the Cloud

4

Sensor Readings Alarms & Events Sensor Readings

Data collection & asset control

Alarms & Events

Cloud

Sensors

SCADA is the edge node of the industrial internet

Evolution of HMI/SCADA Systems

‘80’s ‘90’s ‘00’s ‘10’s

Apple iPad

Windows 1.0 2.0 3.0 3.1 95 Vista 98

NT 2000

XP

SVR 2008 SVR 2003

7 8 10

LIMITED CONNECTIVITY FULLY CONNECTED

Windows-based MMI -

HMI/SCADA for the masses I/O centric

Micro computers running UNIX or equivalent … • Proprietary • Islands of automation

• Expensive

Networked / connected

Equipment centric

IT W

OR

LD

AU

TO

MA

TIO

N W

OR

LD

Decision Support HMI/SCADA

“Industrial Internet” enabled User centric

YOU

AR

E HER

E

GE iFIX

1.0

iFIX

3.5

iFIX

5.8

iFIX

5.0

iFIX

4.0

iFIX

2.0

iFIX

2.1

iFIX

2.5

iFIX

2.6

iFIX

3.0

iFIX

4.5

iFIX

5.1

iFIX

5.5

iFIX

3.5

W

Dto

p

iFIX

2.2

Th

e F

IX

FIX

DM

AC

S1

.0

FIX

32

NT

FIX

32

FIX

7.0

FIX

6.1

5

FIX

6.1

FIX

6.0

FIX

5.0

FIX

3.0

FIX

4.5

FIX

3.2

FIX

DM

AC

S 3

.0

FIX

DM

AC

S 2

.0

TRIGGER SITUATION AWARENESS ACTION

(Manual) Action

Alarm Hear

See

Smell

Feel

Move from alarm to the right action, fast

TRIGGER SITUATION AWARENESS ACTION

Be

fore

Manual Action

Alarm

Aft

er

INCREASED

PERFORMANCE

Manual Action and/or Electronic Workflow

Alarm

Prevent mistakes from happening!

GE Workflow GE HMI/SCADA

It’s a 2-step process …

Communicate the right information clearly & in a timely manner

Guide operator actions right in their familiar environment (HMI, …)

2

Decision Support for Operations


Integrated Work Processes

Prevent Mistakes

Efficient HMI*

Identify Problems &

Causes

Information Anywhere, Anytime

On-Demand Support

Intelligent Warnings

Operational Analytics

DECISION SUPPORT

*HMI: Human Machine Interface

40% Faster Trouble-shooting

40% Reduced Waste

70% Increase in Productivity

33% Increase in

Operations Capacity

2x Efficiency

5X Increase in Problem Detection 37% Increase in Abnormal Situation Handling

Decision Support for Operations


Prevent Mistakes

Identify Problems &

Causes

On-Demand Support


DECISION SUPPORT


Prevent Mistakes

Efficient HMI*

Identify Problems &

Causes

On-Demand Support


DECISION SUPPORT

*HMI: Human Machine Interface

User Interface vs User Experience

12

UX UI

From Black & White to …

1980 Today

HMI Screen Design

is NOT about

fine art

14

Best HMI design practices Great design for a better User Experience

“Operators should be able to recognize which information

needs their attention and what it indicates …

at a glance”

GE HMI/SCADA Recommended design

Human centered design approach Research, design and validation with 100+ operators in 21 plants in 5 countries

The UX design process:

• Discovery

• Concept design, evaluation

• Design & Prototyping

• User validation & assessment

• Production evaluation with a plant simulator

17

What makes a good operator interface from an Operator perspective?


SIMPLE INTUITIVE

CONFIDENT SEAMLESS

Recognize and understand information with ease and speed

Anticipate and recognize issues quickly, and respond instantly

Have confidence in the control system

Complete their tasks and navigate seamlessly

Los Angeles Department of Water & Power The largest municipal utility in the US, servicing an area of over 465 square miles


GE iFIX helps to:

• Maintain more than 7200 miles of water

pipelines

• Monitor more than 100 Reservoirs and

Tanks, 400 Regulator Stations, 70 Pump

Stations and 30 Treatment Stations

• Deliver 513 million gallons of clean water

every day to more than 4 million people

Los Angeles Department of Water & Power


High Performance HMIs

• Help Operators visualize a process

• Quickly determine an abnormal situation

Topographical HMIs

• Help Operators visualize system areas

• Important when moving water across a large city

Schematic Process Style HMIs

• Help Operators find the root cause and isolate issues in the field

• Important when working with many different types of facilities

5X Increase in Problem Detection


Prevent Mistakes

Identify Problems &

Causes

Information Anywhere, Anytime

On-Demand Support


DECISION SUPPORT

Back in the old days … Fixed visualization - HMI/SCADA clients


Operator from the 1980s patiently acknowledging false alarms …

Today …

• “Casual” users

• Shifting skillsets & roles

• Need simplification & guidance

Title or Job Number | XX Month 201X 23

Empower remote users

IT

Executive Management

Management

Quality Manager

Maintenance Manager

Process Engineer

Operations Manager

Operator / Supervisor

GE Scorecard

KPIs GE Mobile

The right information delivered to the right person, anywhere any

time

HMI anywhere – GE Webspace

“While in my office,

I can perform a

detailed analysis

of the problem

before I decide to

send someone

over!”

Outcomes

• Speed troubleshooting by 40% *

• Faster responsiveness to issues and better decision making

• Better operations management through increased process visibility

* Cornell University


Integrated Work Processes

Prevent Mistakes

Identify Problems &

Causes

On-Demand Support


DECISION SUPPORT

Operators, Contractors, Engineers need structured Documents and a common Reference

• Work Instructions,

• Standard Operating Procedures,

• Policies

• PMs

… to ensure consistency, repeatability, conformance to standards & accountability on task completion.

Bridge the Operations & Maintenance Gap with electronic Workflows

Drive the right actions, every time, globally

KEY OUTCOMES

1. Reduce troubleshooting time and risk of making errors

2. Decrease downtime, maintenance and costs

3. Capture knowledge of your best operators & reduce training time

4. Record & track work processes for compliance

Consistency Repeatability

Conformance

to standards

Accountability on

task completion

Prevent Operator Mistakes | November 2015

Capture best practices before experts retire and facilitate transfer of knowledge

Drive the right actions, every time, globally with GE Workflow

KEY OUTCOMES

1. Reduce troubleshooting time and risk of making errors

2. Decrease downtime, maintenance and

costs

3. Capture knowledge of your best operators & reduce training time

4. Record & track work processes for compliance

Consistency Repeatability

Conformance

to standards

Accountability on

task completion


Prevent Mistakes

Identify Problems &

Causes

On-Demand Support


Operational Analytics

DECISION SUPPORT

Analytic Capabilities An operational game-changer….

“~75% of all alarms are NOISE”

Alarms filtering allows for a 60% reduction*!


* Customer interviews

F C

E

D

G

A

H

B

Drive the

right action!

• By Role • By Area • By Asset Type • By Severity

Solve multiple data streams

Flow

Pressure

Speed

Alarm Hi

Temp

Flow

Traditional technique: Single-sensor equipment protection

Early stages of damage

See alerts before

traditional alarms

Normal operation

Few false alarms

Real-time, multivariable analysis

Dynamic Bands

Alerts / Incidents

Alarm/Trip

Optimize & reduce risks using Analytics

Data Stream

Analytic Plug-in

NOT RUNNING

RUNNING

NOT OPTIMIZED

RUNNING

OPTIMIZED

- €

€

€€

Something important is likely to happen & why!

Something important is happening NOW & why!

What is going to

happen?

Available now GE Facilities Reasoners

• Chiller Reasoner

• Air Handler Units Reasoner

• Terminal Boxes / VAVs* Reasoner Analytic Plug-In

Powered by CSense

*VAV: Variable Air Volume

East

Zone

West

Zone

North

Zone

South

Zone

Fan

Control valve

Cooling coil Heating

coil

Airflow

Damper

• Chilled Water Coil • Cool Down • Cooling Coil Discharge Air

• Dual Temperature Coil

• Discharge Air • Dehumidification • Demand Control Ventilation

• Direct Expansion Cooling • Dual Temperature Coil

• Economizer • Electric Reheat

• Exhaust Air Damper

What you can’t See, we detect – 100s of Analytics and Checks!

• Gas Reheat • Heat Pipe • Heating

• Inlet Guide Valves • Supply / Return Fan • VFD

• Mixed Air and Damper • Morning Warm-Up • Night Purge and Setback

• Optimal Start and Stop • Outside Air and Damper

• Preheat Coil and Discharge • Reheat Coil and Discharge • Return and Supply Air/Fan

• Return Water • Steam • Zone Air

Air Handler Unit Analytics Advanced Detection Drives Superior Energy Savings and Reliable Comfort

• Face and Bypass Damper • Flow Switch • Filters

• Freeze Dump

SouthCoast Hospital Advanced Detection across Four Hospital Buildings

Continuous Commissioning Project – 100’s of Analytics on

almost 1000 Assets!

• Four Hospitals buildings with 160 000 M2

• Four major building/asset management systems – Carrier,

Siemens, Johnson and Honeywell – all on BACnet

• $4.4 MM per year electric bill, $1.5 MM gas bill

• 6 748 Employees

• Serves over 703 000 People in 33 Communities in South East

Massachusetts and Rhode Island

• Control Points Monitoring – 18000+ • Potential Energy Cost Savings Found – $1.7

MM+ • First Check Utility Incentives – $240000+ • Payback Period of ~1.5 Years

Corrective Action

Potential Causes

Fault Detection and Diagnosis

45 RtOI Webinar

12/3/2015

“Not only the system gives me information about an upcoming issue, but it tells me what to do to prevent it!”

Outcomes Decision Support for Operations …

• Less training

• Faster reaction

• Safer operations

• Increased productivity / efficiency

46

Our approach delivers

Strategic Business Outcomes

Next Generation HMI/SCADA What’s Coming?

FRESH

PERSPECTIVE

AHEAD

*iFIX & CIMPLICITY

Safe Harbor Statements

This document contains “forward-looking statements” within the meaning of the Private Securities Litigation Reform Act of 1995. Forward-looking statements may be identified by words such as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning and include, but are not limited to, statements about the expected future business and financial performance of GE. Forward-looking statements are based on management’s current expectations and assumptions, which are inherently subject to uncertainties, risks and changes in circumstances that are difficult to predict. Actual outcomes and results may differ materially from these expectations and assumptions due to changes in global political, economic, business, competitive, market, regulatory and other factors. We undertake no obligation to publicly update or review any forward-looking information, whether as a result of new information, future developments or otherwise.

The information presented is intended to be an outline of general product direction and it should not be relied on in making a purchasing decision. The information on the roadmap is for information purposes only, and may not be incorporated into any contract and is not a commitment, promise or legal obligation to deliver any material, code, or functionality. The development, release, and timing of any features or functionality described for our products remains at our sole discretion.

NextGen HMI Rel. 1.0 -> iFIX 5.8 R2 Key Features

• Efficient HMI to quickly identify issues and causes to increase Operator Productivity

• Information navigates with the user

• Presentation adapts the device you are viewing on

• Structured Asset Model mapped to the SCADA database

• Native Web HMI

• Adoption of HTML5 Technology - ability to integrate 3rd party HTML5 widgets

• Multi-touch support

• Seamless extensibility for existing iFIX 5.8 installs

49

Efficient Visualization A single technology for Fixed, Web, Mobile

• Model based Navigation

• Common Model Interface

50

HTML5

Main HMI Graphic: Process layout, Overview Displays, Machine Overviews

Exception Views Alarms, Events,

Alarm Summary Detailed event & alarm summary

Downtimes, SoE

KPI Views Asset data, Read/Write,

Runtime Assembly

Analytic Views Trends, Reports,

Grids

Summary of outcomes A new User Experience

• Efficient HMI Out-of-the-Box

• Fast development - Fast deployment

• Full featured HMI anywhere, any time

Lower TCO!

Decision Support | November 2015

FRESH PERSPECTIVE

AHEAD

Milestone #1* Unified Client HMI Widget - Real Time Data Visualization

1. Excel-based model definition of equipment types andinstances

2. WebHMI widget creation through iFIX Workspace

3. Binding widgets to model

4. Web-based HMI with real-time data from iFIX SCADA engine


* Q2 2016 – iFIX Version

General Electric Company reserves the right to make changes in specifications and features, or discontinue the product or ser vice described at any time, without notice or obligation. These materials do not constitute a representation, warranty or documentation regarding the product or service featured. Illustrations are provided for informational purposes, and your configuration may differ. This information does not constitute legal, financial, coding, or regulatory advice in connection with your use of the product or service. Please consult your professional advisors for any

such advice. No part of this document may be distributed, reproduced or posted without the express written permission of General Electric Company. GE, Predix and the GE Monogram are trademarks of General Electric Company. ©2015 General Electric Company – All rights reserved.

Thank you!