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Transformation Story-1

Remote Fracking Digital Diagnostics powering new business models

Transformation Story-8

Cerebra is powering next generation industry 4.0 model for one of the largest adhesive manufacturer in the world across 133 plants.

Transformation Story-3

Reducing cryogenic risks in LNG shipments by mining of patterns across 260 million sensor events

Transformation Story-1

Remote Fracking Digital Diagnostics powering new business models

The Problem
  • Critical equipment failure causes daily loss of Million dollars at Shale fields
  • Failure-prone complex mechanical assets as Fracturing Pumps, Acidizing unit.
  • High fuel expenditure occurs from the non-optimized utilization of assets
  • Complications involved in managing assets at massive scale
How Cerebra Solve it?
  • Cerebra IOT Prognostics/Diagnostics platform ingested signals from a variety of frontline industrial assets in real time like - Acidizing units, Fracking pumps, chemical additive units, blenders, large generators.
  • The specific signals analyzed include Pressure signals, Oil temperature signals, horsepower signals, rpm signals, discharge pressure signals.
  • Find Anomalies to Potential Fault Modes.
  • Predict Failures & Maintenance Requirement.
  • Forecast Spares requirement, and Optimize Asset Performance & Utilization.
The impact on outcome

Cerebra, Flutura's Machine Intelligence Platform, created a new revenue stream for our customer by enabling them to provide digital offerings to their customers with:

  • Reduced Downtime, Scheduled and Breakdown Maintenance Cost from improved predictive maintenance
  • Increased Asset Performance & Utilization with Asset Performance Monitoring & Benchmarking
  • Timely Spare Refurbishment leading to Increased Cross-selling & Upselling Opportunities
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Transformation Story-8

Cerebra is powering next generation industry 4.0 model for one of the largest adhesive manufacturer in the world across 133 plants.

The problem

The customer is one of the Largest adhesive manufacturer in world with 133 plants globally Adhesives used in aviation, automotive and electronic industries. The problem they faced was to increase the quality and yield of the factory lines by controlling 2 levers - viscosity and softening points.

How Cerebra Solved it

Cerebra IOT signal intelligence platform was ingested 3 years of sensor data regarding plant operations from temperature sensors, rpm sensors, torque sensors and pressure sensors which were strapped on to industrial mixers Cerebras ensemble models used to filter signal from noise and specifically identify the contributors to quality. This process was Scaled to 33 plants, 1400 manufacturing lines and 16 event types cumulatively streamed in 20 million sensor events analysed.

Impact on outcome

More than 140 million dollars of savings from defective products across 3 years.

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Transformation Story-3

Reducing cryogenic risks in LNG shipments by mining of patterns across 260 million sensor events

The Problem
  • Emergency Assistance & Response system was manual, expensive and time-consuming.
  • False alarms add to the cost and effort.
  • Delay in action causes avoidable loss of million dollars.
How Cerebra Solve it?
  • Cerebra digital solutions focus on monitoring and diagnostic tools to improve reliability and increase the quality of the customer service.
  • The data from LNG Platform collects on Cerebra Edge Server. Around 145 Parameter captured at a sampling frequency of 5 seconds.
  • The Cerebra Edge platform configured and commissioned with Heuristic's Rule and Physics Diagnostic Engine to identify any potential threats Scenarios.
  • On any threat scenario going ON, The Emergency Team intimated through Notification either over SMS, Email, and Real Time Application.
  • The duty Office leverages Cerebra Platform to analyze the scenario and relevant Sensor Signal to recommend corrective action to the Onshore Team.
  • Cerebra Central Application deployed on the Central Cloud Server where the historical data stored for further analysis.
The impact on outcome
  • Leveraged a quick response system to address the operational failure/ threat scenarios.
  • Provide Overall LNG Health Reports on Periodic basis to their customers
  • Enables the client Design team to improvise design based on data pattern observed under various scenarios
  • Asset Health monitoring benefited in arresting revenue loss of Millions incurs through unplanned downtime.
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Transformation Story-4

Optimizing catalyst yield using Cerebra's deep learning algorithms

Transformation Story-5

Reducing valve & reactor downtime in Chemical processing plants by integrating Physics and Statistics.

Transformation Story-6

Cerebra IOT Signal Intelligence platform powering Prognostic and Diagnostic processes for large Houston based Oil and Gas OEM

Transformation Story-4

Optimizing catalyst yield using Cerebra's deep learning algorithms

The Problem
  • The process data collected and stored over the years were idle.
  • Other than quality checks at each level of the process, the customer adopted no measures to control the process to achieve desired output.
  • When the quality of final output differs from the required level, they will reject the batch which causes loss of million dollars, time and effort.
  • The quality of the final output differs from the expected level when the R&D laboratory formulas apply to the bulk manufacturing process.
  • The customer has no option to monitor and control the process in real time
How Cerebra Solve it?
  • Cerebra IOT signal intelligence platform ingested years of data collected from dropping, forming, aging, washing, and calcination stages of catalyst manufacturing.
  • Benchmarking the process and quality (Quality Scoring), understanding the casualty and correlation (Diagnostics) and predicting the quality of end product in real time (Prognostics).
  • Continuously improves the quality of catalyst produced in the manufacturing plant (Dynamic Process Environment).
  • Cerebra predict potential quality failures allowing the operations team to take real-time actions to control process deviations.
The impact on outcome
  • Optimized Catalyst Quality and the operations to a large extent.
  • Arrested revenue loss of million dollars incurs by rejecting the poor quality final output.
  • Prognostics enabled proactive actions on the manufacturing process to control quality variations of the final output in real time.
  • Extended scope for bringing right quality product at the first time which will save a lot of cost, effort and time.
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Transformation Story-5

Reducing valve & reactor downtime in Chemical processing plants by integrating Physics and Statistics.

The Problem
  • Highly interdependent Chemical Processing industry assets impacts a malfunctioning/failure of one asset /component in bringing down the entire process.
  • Incorrect controller configurations causing the process downtime leads to a loss of $200,000 per process line per day.
  • The process downtime results in the quality deterioration of the additives and also higher operators and utility costs.
How Cerebra Solve it?
  • Cerebra platform was ingested with Chemical Reactor Valve Sensor Data which included Pressure, Valve opening % and temperature, Controller Configuration Information ( Set point, P-I-D, etc.)
  • The Cerebra Valve Diagnostics Module evaluated the Valve functioning using a variety of diagnostics tests for Flow Characteristics, Hysteresis, Dead Time, Stiction etc.
  • Cerebra solution provided an indication of the malfunctioning of the valve and accurate visibility to the extent of variation which helps the operators to prioritize and minimize the downtime through exhaustive prognostic models.
The impact on outcome

Timely detection of the valve malfunction and controller re-calibration brought down operational costs.

  • Reduce the unplanned process downtime by earlier detection of faulty assets and incorrect configurations and can result in up to $7 million savings for every reactor in a year through reduced reactor down time
  • Radically improve catalyst life which is the most expensive ingredient of the entire process
  • Enhancing the quality of output by maintaining the operating conditions (pressure, temperature are as per controller output) in acceptable range.
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Transformation Story-6

Cerebra IOT Signal Intelligence platform powering Prognostic and Diagnostic processes for large Houston based Oil and Gas OEM

The problem

One of the World's largest manufacturers of Shale field equipment and natural gas/diesel engines based in Houston is heavily dependent on OEMs to minimize asset failures and downtime: There were 2 specific problems they wanted to solve.

Create new business models for Prognostics and diagnostics as a service How to proactively auto generate spare part requests triggered by sensor events and thereby reduce inefficiencies

How Cerebra Solved it

Cerebra IOT Prognostics/Diagnostics platform ingested signals from a variety of frontline industrial assets in real time like - Acidizing units, Fracking pumps, chemical additive units, blenders, large generators,. The specific signals analyzed include Pressure signals , Oil temperature signals, horse power signals, rpm signals, discharge pressure signals to: find Anomalies to Potential Fault Modes, predict Failures & Maintenance Requirement and Forecast Spares requirement.

Impact on outcome

Machine data becomes a new source of revenue using Cerebra IOT Prognostics/Diagnostics platform with a revenue generation of 120 million+ across first 3 years.

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Transformation Story-7

Cerebra triangulates signals from millions of machine events, thereby increasing the longevity of deep water assets by 40%.

Transformation Story-2

Anomaly forensics on SCADA streams to impact refinery operational outcomes

Transformation Story-9

Cerebra IoT Signal Intelligence platform helped maximize Plant Load Factor of a Hydroelectric plant by plugging process bottlenecks and reducing operational downtime by analyzing 120 signals.

Transformation Story-7

Cerebra triangulates signals from millions of machine events, thereby increasing the longevity of deep water assets by 40%.

The problem

Safety is one of the most complex subjects in the Oil & Gas industry. Traditional approaches to safety such as Process Safety and Occupational safety tend break down the subject into multiple silos and track lagging indicators of safety rather and leading indicators. As such, last mile real-time visibility into safety risk exposure is extremely limited, and one of the largest hydrocarbon producers in the world was facing this very problem.

How Cerebra Solved it

Safety Incidents happen as a result of man-machine interactions and the processes that govern these interactions. Cerebra ingested millions of machine signals from offshore assets, along with process, and people related signals and quantified safety risk exposure related to Assets, Processes, and People through sophisticated risk modeling algorithms. Signals ingested include machine events such as leakages, pressure changes and flow count, process related data such as audits and maintenance, and people related data such as operator expertise.

Impact on outcome

The offshore operations team has visibility into safety risk exposure across their rigs, and were able to ensure that they had the right information at hand that would be necessary to take proactive action to avert potential safety incidents due to machine failures.

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Transformation Story-2

Anomaly forensics on SCADA streams to impact refinery operational outcomes

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Transformation Story-9

Cerebra IoT Signal Intelligence platform helped maximize Plant Load Factor of a Hydroelectric plant by plugging process bottlenecks and reducing operational downtime by analyzing 120 signals.

The problem

One of the key problems hydroelectric plants face is that of limited PLF. Moreover, they have generation commitments with Regulatory bodies that they have to uphold to help manage peak loads, as well as fulfil general overall power demand.

How Cerebra Solved it

Cerebra IOT signal intelligence platform ingested electro mechanical signals from Small Hydroelectric plants, and detected signals to:

Predict Failure events Reduce Downtime and Maximize Uptime Predict Maintenance Requirement Forecast Spares requirement Optimize Generation

Impact on outcome

Overall the Hydro plants were able to Increase PLF , Optimized generation capacity and Minimize Regulatory Penalties.

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Transformation Story-10

Cerebra IOT signal intelligence platform discovered voyage/asset signals for a large shipping company

Transformation Story-11

Solar OEM is using Cerebra to power energy as a service business model by mining signals from 1.2 billion panel events

Transformation Story-10

Cerebra IOT signal intelligence platform discovered voyage/asset signals for a large shipping company

The Business Problem

The largest North American Vessel Classification Society, that has classified more than 13,000 vessels is embarking on a new journey to help the vessels capture instantaneous parameters. The company then wanted to understand the parameters affecting fuel consumption, and hence predict the fuel consumption as a function of these parameters thus leading to an improved performance of the vessel.

How Cerebra Solved it

Cerebra IOT Diagnostics/Prognostics platform was connected to monitor the 70+ instantaneous parameters streaming in from various vessels every 10 seconds. Cerebra picked up those predictors that had a significant influence on the fuel consumption, so as to build a predictive model to predict the fuel consumption under given set of conditions. The model learns and improves by itself based on the new data that gets streamed. The model was also able to pick up data anomalies that led to the conclusion that certain sensors on the vessels weren’t performing as per their specifications.

With the large amount of vessel performance data collected from various vessels across different vessel categories, the Cerebra platform was further able to provide benchmarks w.r.t. Fuel consumption for similar class of vessels. These benchmarks could further be utilized while designing & building new vessels, or to identify if any retrofits could be added to improve the performance of existing vessels based on benchmarking results.

The impact on outcome

Optimizing vessel speed to minimize Total Fuel Consumption (Propulsion Fuel Consumption + Electrical Generation Consumption) and thus improve the performance of the vessel resulted in savings upto $300,000/year for large vessels.

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Transformation Story-11

Solar OEM is using Cerebra to power energy as a service business model by mining signals from 1.2 billion panel events

The Context

Global Fortune 100 company innovating with off grid solar solutions.

The biz problem

Offer a new revenue stream where solar energy as a service.

Solution highlights

Cerebra was connected Photovoltaic cells, Inverters, Batteries, GRID, DC Loads.

Scale

100+ sites spread across two continents 100,000 events per site per year

Impact on outcome

Projected saving of a million dollars over 5 years by replacement of diesel generators and accurate sizing of solar panels.

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