Machine Learning and Predictive Analytics

Guidebook for Water Engineers

Leverage Domain Expertise to Drive Optimization – Without Needing a Data Scientist
Water utilities have no shortage
of data – real time and historical.
But, getting value out of that data Power (HP)
to ease compliance, reduce costs, 80% Discharge Pressure
Efficiency
and drive greater efficiency means Total head
using analytics as a foundation for
optimization.
Visual representation of efficiency optimization
Fortunately, the journey to success with machine learning Figure 1: Engineers can use analytics to optimize pump efficiency
and analytics doesn’t mean that process engineers need to be and gain new improvement insights in just hours.
data scientists. Proven processes and software technologies
make analytics do-able for every industrial organization.

Engineers Are the Process Experts To drive analytics and improve processes, process engineers can align domain expertise to five capabilities:

Process engineers have exceptional domain expertise to put 1. Analysis - automatic root cause identification accelerates continuous improvement
together process models – or Process Digital Twins – and
2. Monitoring – early warnings reduce downtime and waste
be able to interpret the models. This is the foundation for
improving competitive advantage and success with analytics. 3. Prediction – proactive actions improve quality, stability, and reliability

4. Simulation – what-if simulations accelerate accurate decisions at a lower cost

5. Optimization – optimal process setpoints improve throughput at acceptable quality by up to 10%

Advanced techniques like predictive analytics play to industrial
process engineer's strengths while taking advantage of their
domain expertise. With tools like Proficy CSense, process
engineers can identify risks, opportunities, and future outcomes
to better scale their operations.
Additionally, while today’s software features enhanced ease of use and no-code implementation extensible
with Python, process engineers can still lean on product experts in combination with their own domain
expertise to mine data and leverage analytics to improve operations.

Success with Predictive Analytics

As an example, GE Digital helped a mid-sized water utility predict pump failure up to 16 days in advance,
using Proficy CSense. This was achieved without writing a single line of code and using historian data that was
readily available.

The component identified as causing the pump failure was a critical bolt prone to corrosion - however it was
Figure 2: A mid-sized water utility was able to predict pump failure up to 16 days
challenging to visually inspect based on its location. When the bolt eroded, its threads would loosen and lose
in advance, using Proficy CSense.
contact, allowing the impeller to wobble. The extra vibrations created by this movement would result in more
damage to the motor and its coupling. Eventually, the bolt head would separate, resulting in the impeller
dropping out of the housing and causing a catastrophic failure. The outcome is this cheap bolt takes this very
expensive pump out of commission for weeks.

Using Proficy CSense and a trained data model, patterns and changes to vibration signals are now being
monitored, and future failure can be detected. The outcome is the water utility has two weeks to schedule
preventative maintenance versus wasting resources on unplanned downtime, resulting in only a one-day
disruption versus weeks.
Analytics and Control Loop Optimization
As a use case example, process optimization is key to water utilities,
and control loops are the critical components. “Out of tune” loops can
affect whether water meets specification, chemical usage, and energy
consumption, and ultimately increase the risk of not being compliant.
AI and machine learning can be used to improve and optimize control
loops to generate big savings and reduce risks.

What is a control loop?

A simple form of a process controller is the thermostat which maintains

the temperature of a room according to a given setpoint. It operates as
a closed loop control device, trying to minimize the difference between
the room temperature and the desired one.
Figure 3: AI and machine learning can be used to analyze and improve control
The industrial version is the PID (Proportional-Integral-Derivative) loops to optimize performance KPIs, generate big savings and reduce risks.
control loop - an essential part of every process applications. PID loops
have been around for a very long time. The first pneumatic instruments
featuring a proportional controller were developed by Taylor Instrument
Companies at the beginning of the 20th century,

Nowadays, loop controllers are available as standalone devices called

single loop controllers, but the most common version is a piece of
code that resides in a PLC (Programmable Logic Controller) or a DCS
Learn about PID control
(Distributed Control System). It makes it easier to combine them loop optimization
to create advanced control diagrams like cascade or feed-forward
control, or split range required for complex control.
Learn how GE Digital's latest version of Proficy CSense provides new tools for
optimizing unhealthy control loops and creating simulations – in just minutes.

Unhealthy PID loops cause Process Variation – which leads to:

• Equipment breaks
• Downtime
• Lower quality, throughput and OEE See How
Control Loops: Small Tweaks, Big Impacts
A lot of literature exists that describe the behavior of PID loops and how to tune them. However, it still One example is dissolved oxygen control in the aeration section of activated
represents a challenge for many as all the processes are different. An advanced analytics system such as sludge treatment plants that have a central impact on effluent water quality,
GE Digital’s Proficy CSense can help by looking at historical data to create a model of the actual profile and efficiency of treatment and energy usage, and ultimately the lifetime & wear on
recommend new settings accordingly. The model will take into account the change of parameters that equipment such as blowers.
affect reliability.
Analytics can be used monitor and optimize the performance and tuning of
For example, the use of PID process control loops in wastewater treatment plants are common. However, PID control loops in the waste water process (for example dissolved oxygen
unhealthy, suboptimal or underperforming control loops cause process variations, resulting in: control) to reduce process variation, compensate for disturbances and ensure
the process operate close to optimal states. This can result in significant
• Increased equipment wear and shortened equipment lifespans
improvements in equipment life, effluent water quality and treatment efficiency
• Bad quality or variations in effluent water quality and energy usage with significant margins.
• Increased and inefficient energy usage
For process optimization, analytics solutions need to provide multiple
capabilities: process modelling and troubleshooting as well as online
deployment and real time monitoring. Data is prepared, visualized, and rules-
Metering based, data driven process models can be constructed. Using these models, root
causes of process deviations are identified, so processes can be optimized.

Environmental Quality
Conditions

DATA
Plant Manual
Management Procedures

Resource
Utilization

Figure 4: An advanced analytics system can solve problems by looking at historical data – including from Figure 5: Analytics solutions need to provide multiple capabilities: process modelling and
multiple sources – to create a model of the actual profile and recommend new settings accordingly. troubleshooting as well as online deployment and real time monitoring.
Predictive Analytics and Bad sensor data can mean chemical dosing issues, asset downtime, compliance issues, and safety risks as well as a dirty data
foundation for continuous improvement programs. Water utilities need to have good data that can be leveraged for operations,

Sensor Health ad hoc analysis, and higher level analytics.

Over time, sensors tend to deviate, impacting processes and operations. But, it’s time consuming to manually determine if and
Applications for predictive analytics are why sensors are working or failing ahead of increasing risk.
endless, but a possible first step: engineers
Predictive Analytics and Sensors
can use analytics to monitor sensor health.
Engineers can employ a predictive analytics app such as Proficy Sensor Health to continuously monitor and analyze sensor
data. Users can target anomalies and minimize their potential impact. The analytics app provides an easy way to automate the
detection of bad sensors, where data is deviating from normal conditions.

When an anomaly is detected, the app can generate alarms to speed repairs, replacements, and recalibrations.

By using predictive analytics to monitor sensor health, engineers can:

• Reduce downtime: Sensors are often used to provide indications that equipment
is running correctly. Incorrect readings can lead to equipment failure or damage.
Early detection of a sensor that is no longer giving accurate or consistent results can
provide advance warning that enables maintenance to replace or recalibrate the
sensor before the worst happens.

• Improve compliance: Sensors are often used for measuring the ambient
surroundings of a process are within specification. If the sensors used are not
accurate or functioning correctly, it can lead to a process being out of specification,
and therefore a risk of non-compliance.

• Ensure sensor data quality: Ensuring data quality in downstream analytics is part
of IoT-fueled improvements. If the intent is more advanced use of analytics for a
process, the need for ensuring data quality is critical.

Figure 6: Follow these strategy steps to good sensor health, leveraging predictive analytics
and machine learning.
How to Select the Guidance for engineers
Right Predictive 1 Make sure that “predictive analytics” isn’t buzz hiding risky, unproven software and

Analytics Solution
newbie “experts.”

For example, GE Digital has offered and implemented analytics solutions for more
than 15 years, serving industrial organizations around the world across a diverse set of
Water utilities recognize that it’s imperative to move industries.
forward with predictive analytics to accelerate
innovation. Consequently, new analytics startups and Work with a partner that you can trust and know will support you for the long term.

consulting companies are showing up every week.

2 Select industrial advanced analytics with a troubleshooting component that enables
How does an engineer select the right predictive engineers to rapidly troubleshoot continuous, discrete, or batch manufacturing process
analytics solution? performance by mining insight from available sensor and production data.

Seamless connectivity, rich visualization, and predictive analytics enable engineers to

analyze operating scenarios, quantifying the impact that operational changes will have
on key performance metrics and identifying causes for performance variation.

Additionally, to support the full IoT value journey, look for capabilities from simple
calculations to predictive machine-learning models to real-time optimization and
advanced-control algorithms.

Be sure that the analytics package enables engineers to rapidly develop analytic
3
solutions – supporting improvements in production throughput, yield, quality, and
efficiency with significant margins.

A comprehensive analytic solution-development environment provides visual analytic

building blocks to build and test calculations, predictive analytics, and real-time
optimization and control solutions with connectivity to real-time and historical data
sources and drag-and-drop access to rich functional libraries.

Figure 7: To support the full IoT value journey, look for capabilities Plug-and-play connectivity to historical and real-time data sources and automation
from simple calculations to predictive machine-learning models to systems make for faster configuration. Built-in support for data quality makes real-time
real-time optimization and advanced-control algorithms. data cleaning and validation easy.
4 Confirm that the analytics package can speed deployment with templates for
greater efficiency.

Engineers should be able to save analytics solutions as reusable templates

for easy deployment to similar assets or process units. Additionally, while
the analytics troubleshooting component should enable engineers to find
answers faster with analytics-guided data mining and process-performance
troubleshooting, the development/configuration capabilities should allow them
to more easily capture expert knowledge and best practices into high-value
analytic templates for rapid enterprise-wide deployment.

5 Focus on analytics solutions developed with engineers – not just data scientists
– in mind.

With an analytics package that is accessible to engineers, teams can create

a Process Digital Twin for smarter operations. Visual drag-and-drop analytics
accelerate time to value and reduce dependence on data scientists and
programmers. Online demos enable rapid mastery of the software with easy-to- From Small Projects to
Multi-Plant Optimization
follow demonstrations and guided simulations.

As previously mentioned, a rapid development environment is critical. The best

solutions provide rapid wizard-driven data mining for engineers for fast time-to-
All automation and process engineers can and need to develop capabilities in
insight, an easy visual drag-and-drop environment for subject matter experts
analytics and machine learning to remain competitive – both at an individual
and engineers, and analytic solution templates without programming for simple
professional level as well as to help their industrial organization – in our world of
calculations, data cleaning, maths, statistics, machine-learning models, real-
digital transformation.
time optimization, and advanced process control.
Over time, engineers can go from small projects to pilots to plant wide optimization
with deep application of analytics. Engineers’ deep domain expertise provides a
foundation for modelling processes and developing the analytics that are game
changers in very specific applications. The combination of applied analytics
technology with those Process Twin models uncovers hidden opportunities for
improvement over-and-over again.
Start your Analytics Journey Additional Resources
If you’re ready to optimize with analytics, GE Digital’s Proficy CSense turns
raw data into real-time value with a Process Digital Twin. The software uses Access more information on
AI and machine learning to enable process engineers to combine data across Proficy CSense
industrial data sources and rapidly identify problems, discover
root causes, and automate actions Product Info
to continuously improve quality,
utilization, productivity, and
operations.
Predicting Asset Failure and Process
Changes with Self-Serve Analytics
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and solutions that are connected, responsive and predictive. GE is organized around a global exchange of
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Specifications are subject to change without notice. 03 2022