Asset Performance Management for Mining
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1 Asset Performance Management for Mining Digital Mine Webinar June, 2016 Imagination at work
2 Industrial Imperative: Redefine the Game Industrial productivity Meets the Digital Twin 4% % Physics + Analytics
3 GE: the digital industrial company GE FOR GE GE FOR CUSTOMERS GE FOR WORLD Supplier Customer PRODUCTIVITY Digital thread Predix + data Digital twin APPS GE s software business Inside-out strategy Outcomes for customers PLATFORM Predix Secure Cloud for industry $15B software business by
4 Implementing the Digital Thread E n g i n e e r i n g d e s i g n Design for productivity / cost M a n u f a c t u r e Optimized manufacturing S e r v i c e s Condition-based services O u r e x p e r i e n c e H Turbine 2X faster, lower launch cost 100 brilliant factories driving yield, cycle, downtime 30,000 field engineers sensor based, onboard algorithms, mobile GE: best example of the Industrial Internet at work 4
5 Outcome Assurance: Physical + Analytical Analytics Physics + Data Continuous & accessible + + Statistics Machine Learning Artificial Intelligence Unlock trends, segment Physics Apply domain expertise = Benefits Performance based business models Reliability & Availability Operations, Maintenance, Fuel Cost Repair & Overhaul Frequency & Cost 5
6 APM Powered By Predix Value Proposition Improve reliability and availability of GE and non-ge equipment, reduce Total Cost of Ownership, and reduce operational risks with APM Predix Machine and Equipment Health Get a complete, accurate, and centralized view of your assets, their current state, and health. Reliability Management Predict and diagnose equipment issues so you can Respond before assets fail. Maintenance Optimization* Balance reliability, performance, and costs to develop the best maintenance strategies. HOME
7 Gold producer optimizes control loops and increases recovery Actions from first on-site optimization Challenges Large variations in plant Sump overflows Equipment inefficiency Loops not reaching setpoint or unstable PID Tuning Actuator maintenance Sensor maintenance Control strategy Operational strategy System configuration Actions 20 Loops in Grinding and Flotation areas initially evaluated and optimized by Mine Performance team followed by continuous monitoring phase Recovery before Results 50% sump overflow reduction 20% less gold in tailings in flotation circuit 14% more gold in flotation circuit concentrate Equal to production increase of USD900k/year Contributed to 1.5% recovery increase Recovery after 7
8 High exhaust temps & low boost pressure Haul Truck Avoided damage to engine and loss of production Underlying cause? Air cleaner that had not been replaced as needed during a previous maintenance activity, causing the cleaner to be used long past its functional life. Value to the customer? Air cleaner was preventing proper airflow to the combustion cylinders, in turn causing excessive temperatures in the engine that could have led to a catastrophic failure.
9 Incorrect operation of a lube oil pump detected at a mining facility Avoided bearing damage and loss of production Underlying cause? Upon investigating higher than expected lube oil cooler flow and pressure, the customer found a starting lube oil pump had been left on. Value to the customer? If the customer had continued to run with two pumps, they could have flooding the bearings causing damage and a subsequent outage. 9
10 Industrial Performance & Reliability Center GE s IPRC in Lisle, IL Remote Monitoring and Diagnostics services for GE and Non-GE equipment Predictive analytics from the cloud (software as service) for 14+ years, with customers including: GE Service Objective: Decrease cost to serve, Increase analyst productivity, simplify IT, and accelerate innovation in service delivery GE Service Solution: GE s APM Powered by Predix to improve collaboration, streamline delivery of Remote Monitoring and Diagnostics, and more-easily expand services to new customers. Desired Outcome: Increase Customer Satisfaction Improved collaboration Knowledge & Case Management Improved user interface Ability to string together multiple analytics
11 Increased Asset Availability Training System Build Asset Configuration Deploy Assets Training of Analytics Asset Configuration Deploy Assets Training of Analytics + Staff Leveraging GE Services & GE Industrial Cloud Rapid Delivery Of Outcomes Through Services GE Services Model 1. Rapid Results: GE Services commence as soon as the data becomes available and the software has been trained. Monitoring 2. Flexibility: The customer has the flexibility to easily scale the solution based on requirements. 3. Risk Minimised: TCO (Total Cost of Ownership) is visible from outset. Software Only Model 1. Slower Delivery: A traditional SW only approach will incur significant training, resources and personnel. Key GE Service Model SW Only Model Monitoring Time 2. Increased Risk: This increases risks and extends the time to achieve ROI. 3. Scalability Challenges: As the customer wishes to scale the solution resourcing peaks are required to meet the implementation challenges. This can divert focus from existing assets and compromise the success of existing outcomes 1
12 Sustainability of results Leveraging GE Services & GE Industrial Cloud Services Delivers Long Term Sustainable Outcomes Delivering Sustainable Outcomes GE Services will provide high value outcomes over the long term due to: 1. Dedicated system and domain experts. 2. Focus on criticality & prioritization. 3. More effective deployment of skills 4. Remove the risks associated with conflicting work requirements. 5. Knowledge Sharing 6. Technical support available in house Monitoring A traditional site based SW only approach will often struggle to sustain returns longterm due to: 1. Difficulty retaining personnel 2. Diversion of staff due to conflicting priorities 3. Training requirements and variable skills sets 4. Lack of technical backup in the event of problems Key GE Service Model SW Only Model Time 1
13 Industrial Imperative: Redefine the Game Industrial productivity Meets the Digital Twin 4% % Physics + Analytics
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