Milano - December 3, 2015 Decision Support for Operations The future of HMI/SCADA Dr. Bernard E. Cubizolles Global Product Marketing Manager Automation Software GE Digital Imagination at work
The Smart Operator Prevent Operator Mistakes and Speed Response
OUTCOMES NEEDS GET CONNECTED Machine & Asset Performance GET INSIGHTS Industrial Intelligence GET OPTIMIZED Maintenance Optimization The right information for more informed decisions at the right time Early problem detection & intelligent alerts Secure & easy deployment Full operating visibility for increased asset performance Increased Operator efficiency Reduced downtime A Secure Industrial Internet Platform! Decision Support November 2015 3
From Sensor to the Cloud SCADA is the edge node of the industrial internet Cloud Data collection & asset control Sensor Readings Alarms & Events 4 Sensor Readings Alarms & Events Sensors
IT WORLD AUTOMATION WORLD The FIX FIX 3.0 FIX 3.2 FIX 4.5 FIX 5.0 FIX 6.0 FIX 6.1 FIX 6.15 FIX 7.0 FIX 32 NT FIX32 ifix 1.0 ifix 2.0 ifix 2.1 ifix 2.2 ifix 2.5 ifix 2.6 ifix 3.0 ifix 3.5 ifix 3.5 W Dtop ifix 4.0 ifix 4.5 ifix 5.0 ifix 5.1 ifix 5.5 ifix 5.8 Evolution of HMI/SCADA Systems 80 s 90 s 00 s 10 s Decision Support HMI/SCADA YOU ARE HERE Micro computers running UNIX or equivalent Proprietary Islands of automation Expensive Windows-based MMI - HMI/SCADA for the masses I/O centric Networked / connected Equipment centric Industrial Internet enabled User centric GE FIX DMACS1.0 FIX DMACS 2.0 FIX DMACS 3.0 LIMITED CONNECTIVITY FULLY CONNECTED Windows 1.0 2.0 3.0 3.1 95 98 XP Vista 7 8 10 NT 2000 SVR 2003 SVR 2008 Apple ipad
TRIGGER SITUATION AWARENESS ACTION See Hear Smell Feel Alarm (Manual) Action
After Before Move from alarm to the right action, fast TRIGGER SITUATION AWARENESS ACTION Manual Action Alarm Alarm Manual Action and/or Electronic Workflow INCREASED PERFORMANCE GE HMI/SCADA GE Workflow Prevent mistakes from happening!
It s a 2-step process Communicate the right information clearly & in a timely manner Guide operator actions right in their familiar environment (HMI, )
Decision Support for Operations Efficient HMI* Information Anywhere, Anytime Identify Problems & Causes DECISION SUPPORT On-Demand Support Prevent Mistakes Intelligent Warnings Integrated Work Processes *HMI: Human Machine Interface Operational Analytics Decision Support November 2015 9
Decision Support for Operations 40% Faster Trouble-shooting 5X Increase in Problem Detection 37% Increase in Abnormal Situation Handling Identify Problems & Causes Prevent Mistakes DECISION SUPPORT On-Demand Support Intelligent Warnings 40% Reduced Waste 70% Increase in Productivity 33% Increase in Operations Capacity 2x Efficiency Decision Support November 2015 10
Efficient HMI* Identify Problems & Causes DECISION SUPPORT On-Demand Support Prevent Mistakes Intelligent Warnings *HMI: Human Machine Interface Decision Support November 2015 11
User Interface vs User Experience UI UX 12
From Black & White to 1980 Today
14 HMI Screen Design is NOT about fine art
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? Recognize and understand information with ease and speed SIMPLE INTUITIVE Anticipate and recognize issues quickly, and respond instantly Have confidence in the control system CONFIDENT SEAMLESS Complete their tasks and navigate seamlessly Decision Support November 2015 18
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 Decision Support November 2015 19
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 Decision Support November 2015 20
Information Anywhere, Anytime Identify Problems & Causes DECISION SUPPORT On-Demand Support Prevent Mistakes Intelligent Warnings Decision Support November 2015 21
Back in the old days Fixed visualization - HMI/SCADA clients Operator from the 1980s patiently acknowledging false alarms Decision Support November 2015 22
Today Casual users Shifting skillsets & roles Need simplification & guidance Title or Job Number XX Month 201X 23
Empower remote users The right information delivered to the right person, anywhere any time Executive Management GE Scorecard Management IT Operations Manager Quality Manager Maintenance Manager Process Engineer Operator / Supervisor KPIs GE Mobile 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
Identify Problems & Causes DECISION SUPPORT On-Demand Support Prevent Mistakes Intelligent Warnings Integrated Work Processes Decision Support November 2015 27
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 Conformance to standards Repeatability Accountability on task completion
Capture best practices before experts retire and facilitate transfer of knowledge Prevent Operator Mistakes November 2015
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 Conformance to standards Repeatability Accountability on task completion
Identify Problems & Causes DECISION SUPPORT On-Demand Support Prevent Mistakes Intelligent Warnings Operational Analytics Decision Support November 2015 33
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Analytic Capabilities An operational game-changer. ~75% of all alarms are NOISE
Alarms filtering allows for a 60% reduction*! D C E F By Role By Area By Asset Type By Severity H G A B Drive the right action! * Customer interviews Decision Support November 2015 37
Solve multiple data streams Traditional technique: Single-sensor equipment protection Alarm/Trip Flow Real-time, multivariable analysis Flow Alarm Hi Dynamic Bands Alerts / Incidents Pressure Speed Temp Normal operation Few false alarms Early stages of damage See alerts before traditional alarms
Optimize & reduce risks using Analytics Analytic Plug-in What is going to happen? RUNNING OPTIMIZED Something important is likely to happen & why! RUNNING NOT OPTIMIZED Data Stream Something important is happening NOW & why! - NOT RUNNING
Available now GE Facilities Reasoners Chiller Reasoner Air Handler Units Reasoner Terminal Boxes / VAVs* Reasoner *VAV: Variable Air Volume Analytic Plug-In Powered by CSense Airflow Damper Fan East Zone West Zone North Zone South Zone Heating coil Cooling coil Control valve
Air Handler Unit Analytics Advanced Detection Drives Superior Energy Savings and Reliable Comfort Chilled Water Coil Cool Down Cooling Coil Discharge Air Dual Temperature Coil Discharge Air Dehumidification Demand Control Ventilation Direct Expansion Cooling Dual Temperature Coil Face and Bypass Damper Flow Switch Filters Freeze Dump Mixed Air and Damper Morning Warm-Up Night Purge and Setback Optimal Start and Stop Outside Air and Damper Gas Reheat Heat Pipe Heating Inlet Guide Valves Supply / Return Fan VFD Economizer Electric Reheat Exhaust Air Damper Preheat Coil and Discharge Reheat Coil and Discharge Return and Supply Air/Fan Return Water Steam Zone Air What you can t See, we detect 100s of Analytics and Checks!
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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 Fault Detection and Diagnosis Potential Causes Corrective Action Control Points Monitoring 18000+ Potential Energy Cost Savings Found $1.7 MM+ First Check Utility Incentives $240000+ Payback Period of ~1.5 Years
Not only the system gives me information about an upcoming issue, but it tells me what to do to prevent it! 45 RtOI Webinar 12/3/2015
Outcomes Decision Support for Operations Less training Faster reaction Safer operations Increased productivity / efficiency Our approach delivers Strategic Business Outcomes 46
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 3 rd 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 HTML5 50
Main HMI Graphic: Process layout, Overview Displays, Machine Overviews Exception Views Alarms, Events, Analytic Views Trends, Reports, Grids Alarm Summary Detailed event & alarm summary Downtimes, SoE KPI Views Asset data, Read/Write, Runtime Assembly
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! FRESH PERSPECTIVE AHEAD Decision Support November 2015
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 Decision Support November 2015 53
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