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Overview

Knowledge3 (Kn3)
Knowledge Cubed (Kn3)
Overview

Modeling, optimization, and controls software platform


Uses unique technology including predictors (neural
nets), physics (rules), optimization (genetic algorithms),
and control (multi-variable control)
Can be applied off-line or on-line, open or closed loop
Capable of acquiring data from a variety of sources
Designed to be flexible for any application and
configurable for ease of use and customization
Platform for other products to be added to provide even
more benefits to the customer

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Kn3
Schematic

Raw Data Management and Rules


Inputs
Distributed
Validated Inputs Ys
Control
System (DCS) Neural Objective
Network Ys &
Multi- Models Constraints
Variable
Controller Test Xs
(MVC)
Setpoints
Multi-
Objective
Optimal Xs Optimizer

What-if Tool & Supervisory Optimizer


Control Modeling & Optimization

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Kn3
Modules

Data Management
Has detailed data management routines that use configurable
rules to process, validate, and replace data
Modeling
Uses predictive models that accurately predict complex
processes based on measured data adapts and learns
Optimization
Uses a powerful and efficient optimizer that determines optimal
control setpoints that do not violate any constraints
Controls
Uses mature technology designed to work with the DCS to
dynamically control multiple setpoints smoothly and safely
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Models
Overview

Models generate the expected value of


an output given one or more inputs that
impact the output
Kn3 supports two modeling technologies:
Rules Deterministic-based models
Neural Networks Empirical-based models
Any combination of these techniques can
be used making Kn3 uniquely powerful
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Rules
Overview

Deterministic rule writing and processing technology


a modeling technology using RuleDesk
Manages data by performing validation and
replacement rules
Outputs can be used as inputs into neural models and
optimizers
Neural model and optimizer outputs can be used as
inputs

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Predictors
Overview

Predictive modeling uses neural network technology


X1
X2

Inputs Outputs

Xn

Neural models mimic human nervous system behavior


Neural models are trained using data complete set is required
Data selection, validation, reconciliation, and replacement are essential
Inputs are any setpoints that impact the output
Model are retrained on-line to adapt to conditions in the field

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Neural Networks
Examples

Predicting net load to


assess whether control
setpoints will cause a
derate model is 99.9%
accurate
Predicting main steam
temperature to assess
whether inputs will cause
spraying model is 99.5%
accurate
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Neural Networks
Benefits

Neural networks are extremely accurate at predicting


even complex processes less operational risks
More accurate than statistical techniques and easier to
configure than physical models reduces errors and
time to configure
If the model is deemed inaccurate (because conditions
change), an automatic retraining of the model is
performed always up-to-date and learning
Kn3s neural networks have unprecedented speed and
can accept over 100 inputs can handle virtually any
problem and give an answer fast
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What-If Modeling
Using Neural Network Predictors

On-line what-if modeling gives real-time predictions


for key outputs related to any process on measured
data
What-if modeling allows user to enter inputs that
impact the process to predict how the unit will
respond
Platform collects data continuously and checks
model accuracies with current conditions; models are
updated if needed
Accuracy is generally greater than 98% for all models

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Optimization
Overview

Goal of the optimization is to find optimal


control setpoints that do not violate any
operational, safety, or environmental
constraints
Constraints prevent optimizer from operating
the plant in an unwanted regime
Optimization satisfies the following criteria:
Reliably and consistently finds the optimal solution
Fast enough to work in real time
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Genetic Algorithms
Optimization Technology

Kn3 generates optimal solutions using genetic


algorithms
Uses a mathematical model that emulates natural
selection only the strongest solution survives
Known for being reliable and consistent
Can optimize multiple goals (up to 6) at same time
Typically optimization takes only seconds to
complete

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Pareto Frontier
Overview

Pareto Frontier displays trade-off between optimization


objectives

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Controls
Overview

Multi-variable control (MVC) is GE Energys advanced


process control solution for multi setpoint problems
Works with the DCS to smoothly and safely adjust
setpoints based on optimization
Reduces the span of process variability
Results in a process with higher efficiency, lower
cost, and higher productivity
Mature technology that has been applied to several
industries including power generation

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Potential Applications
Can Be Applied to Virtually Any Process

Energy Optimization
Power generation, pipelines, water treatment
Improved Production Quality
Oil, steel, drugs
Pattern Recognition
Bomb detection, oil drilling, face recognition
Diagnosis
Health problems, fault detection, structural integrity

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Coal Boiler Optimizer
Overview

First application of Kn3 technology


On-line, open or closed loop, optimization
software for coal-fired units
Capable of improving efficiency,
availability, and reducing emissions
Can also be applied to other coal plant
systems: scrubbers, SCRs, water
treatment, sootblowing
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Birchwood Case Study
Overview

Technology is currently being used at


the Birchwood coal-fired plant in
Eastern US
240-MW t-fired CE boiler with SCR and
scrubber on backend
Goal is to reduce NOx emissions while
improving heat rate, with constraints
on CO, net load, and steam temps
Tests showed NOx reductions of 10% while improving
boiler efficiency simultaneously by 0.5%
Up to 20% NOx reduction and 1% boiler efficiency
potential improvement when done separately
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GUI Screen Shots
Predicting Net Load

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Birchwood Case Study
Savings for a 240-MW Unit

Improvements:
Heat Rate: 0.5% (fuel savings)
NOx: 10%

Fuel Savings Information:


90% capacity factor and 8,000 annual operating hours

NOx Savings Information:


US ozone season is 5 months long with NOx credit trading

Annual Savings:
Heat Rate: $US 200,000
NOx: $US 100,000
Total Savings: $US 300,000 (will scale with MW size of unit)

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Kn3
Differentiators

Flexiblebuilt to be generic Can be what-if calculator or optimizer, open or


closed loop, can be used on multiple problems at a plant
Configurablesimple configuration engine Shorter installation and reduced
costs
Unique optimizerpatented Multi-Objective Optimization More reliable, more
accurate, and can handle unlimited number of simultaneous goals
Fastnew technology provides superior speed Faster optimization leads to
better control under changing operating conditions
Unique technologyshows all optimal solutions for any range of weights on
objectives Provides full range of solutions and better info on how product got
there
Rules-based technologydetailed rules under the hood Better and more
powerful data management, heuristics combined with physics
Seamlessfully integrated into any existing software or DCS One solution for
the customer
Platformeasy to add to Can provide a more comprehensive solution by
adding other products (GE or third party)

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Installation Overview
Overview

Fully customized to fit customers unique needs


easy to configure
Turnkey installation requires ~ 1 month for modeling,
2-3 months for modeling + open loop optimization, and
4-6 months for full closed loop product easy to
install
Requires no outage no lost money
Customer involvement is important and well described
no surprises
Estimated plant time required: 4-6 man-weeks
installation process designed to minimize customer time

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Commercial
Overview

Fully customized to fit customers unique


setup
Several commercial options are available
including:
Milestone-based
Pay-for-performance
Financing
Paybacks of less than two years
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Support
Overview

Proactive Support
Daily system checks to assess health of system
Routine server maintenance
Model performance reports (accuracy and availability)

Reactive Support
24/7 on-call/email customer support to fix problems and
answer questions
Response time within 24 hours

Training
Hands-on, on-site training at plant once a year
Remote training on request 23 /
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Summary
Overview

GE has developed a modeling,


optimization, and controls platform
GE has proven the technical feasibility
for the technology and has
demonstrated it in the field
Will submit a proposal for review upon
request

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