© 2008 osisoft, inc. | company confidential oceania technology seminar 2008 © 2008 osisoft, inc. |...
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© 2008 OSIsoft, Inc. | Company ConfidentialOCEANIA TECHNOLOGY SEMINAR 2008OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
© 2008 OSIsoft, Inc. | Company ConfidentialOCEANIA TECHNOLOGY SEMINAR 2008
PI at Pan Pac PulpmillPI at Pan Pac Pulpmill
James Bell and Roger JonesJames Bell and Roger Jones
2OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
INTRODUCTIONINTRODUCTION• Introduction to Pan Pac Pulpmill
• Describe use of PI at Pac Pac
• Electricity Market Interfacing
• Future values in PI
• Other Interfaces
• Redundancy – PI Server– Interfaces
3OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Pan Pac PulpmillPan Pac Pulpmill• Forest Owner and Forest Product Manufacturer• Operational since 1973• 100% Japanese owned• All pulp sold to Shareholder, Oji• Pulp Capacity 260,000T• Revenue > 250m
• Thermo-mechanical process– 80MW peak load. Annual usage ~2% NZ power
4OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
PI BackgroundPI Background• 5000 tag system operational since November 2001
• Upgraded to 10,000 tags in 2004
• Upgraded to 15,000 tags in 2007
• Operating PI Professional Server (HA) with PI-ACE
• Interfaces– OPC– RDBMS– HTML– PerfMon– SNMP
5OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
PI BackgroundPI Background
Standardising Control Systems
– Started with many
• ABB AC800• ABB AC410• Allen Bradley PLC network• Rosemount RS3 (RNI interface)• Bailey
– Changing major control systems to DeltaV
6OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
PI BackgroundPI Background
Standardising Control Systems
– Now we have:• ABB AC800• ABB AC410• Allen Bradley PLC network• Rosemount RS3 (RNI interface)• Bailey (interface via DeltaV)• DeltaV
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System overviewSystem overview
PIServer1(Primary)
PIServer2(Secondary)
Internet
PIControl1 PIControl2
PI ACE
Firewall
Corporate LAN
Control LAN
Firewall
PIRefining
DeltaV LAN
DeltaV OPC Server1DeltaV OPC Server2
ABB OPC ServerPLC Network
GE Multilins
Cooling TowerControl System
Perfmon
HTML
COMIT
Web Services
SNMP
ACE
Weather Station PC
RDBMS
ParticulateMonitor
8OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
PI at Pan Pac - ElectricityPI at Pan Pac - Electricity
Electricity is significant to our business
– Electricity makes up ~40% of product cost– Annual Power bill $30M to $40M
• Electricity Data Interfacing
– HTML interface– Web services– Comit interface built for Pan Pac
9OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
HTML interfaceHTML interface• New electricity market load charge system in July 2007
– Regional coincident peak demand (RCPD)
– Highest 100 ½ hour peaks for lower North Island
– Occur in winter, June to August
– Cost >$60,000/MW.pa. Potential cost >$4.5M pa
• Reduce load in the “100 peaks”, significant savings possible
• Problem:
– Forced on industry with little warning (applied retrospectively)
– Web based RCPD load data not available until 24 June 2007
• Discovered free website
– Possible to estimate RCPD
– 5 minute update (better than official information)
10OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
HTML interfaceHTML interface• Solution - HTML interface (Web scraper)• Strips text off web • Issues
– No control of websites– Only HTML
• Shut plant at right time• Saving >$2M in 2007/08
11OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Web ServicesWeb Services• Web Services
• ACE gets Web Service Data
• Web Service supplied by EM6– Scada– RCPD on trial– One minute updates
Web Service
PI ACE
12OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Comit InterfaceComit Interface
• COMIT– A custom interface by OSIsoft NZ– Two step process
• WebFetch queries website and returns csv file• COMIT interface processes csv and sends data to PI
COMIT Interface PIWebFetch
13OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Future DataFuture Data
• Electricity Market– Provides forward prices (up to 4h in future)
• Used for decisions on plant operation– Need to see future data
• Workaround 1– ProcessBook VBA
14OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Future DataFuture Data
• Workaround 2– Writing week-ahead interruptible load market offers
• We send data to PI with timestamps –365d!• Custom PB display for operators
M:IR.BID.Future.30m.MWh
MW
Future SIR Bids - (ignore year)
12-Apr-07 10:21:21.17 19-Apr-07 10:21:21.177.00 days
10
20
30
40
50
60
0
7020.00
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Interface to Proprietary DeviceInterface to Proprietary Device
• Particulate Monitor (Air Quality) – proprietary device
• Problem: no comms to device, manual download required
• Solution! Serial to wireless Ethernet + PI ACE
• Using VB.NET, send command, return data
• Now we can alarm on breach, and monitor with ease
Air Quality
30
80
-20
160
16OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
More options…More options…Cooling Tower Control System
– Required Modbus TCP/IP interface, for 9 points!
• Workaround – Use third party Modbus TCP/IP to OPC Server (cheap!)– Use existing OPC Interface Node to get data into PI
• Support OSIsoft!
17OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
RedundancyRedundancy• We heavily rely on PI
• PI critical to operations-$1000 decisions often every ½ hour• 3 Points of Failure PI Server, PI Interface, OPC Server
• Interface level failover– OPC Interface level failover to DeltaV OPC Server
– It works! We never lose data from DeltaV due to Interface shutdown
• OPC server level failover– Single DeltaV OPC server was largest risk for data loss
– Now dual OPC servers are used, failover is in place and has already prevented data loss from OPC server failure
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Redundancy - HARedundancy - HA
• High Availability– Installed PI Server PR1 (HA)– Primary and Secondary PI Servers
• Good Stuff– Server Maintenance– Seamless failover
19OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Recalculation-can’t overwrite an existing value
• We use preliminary results before recalc on final values
• Delivery of fix Oct 2007, we could have used different method but decided to wait for fix …..but still no patch release.
Issues with HA’s Buffer sub-systemIssues with HA’s Buffer sub-system
20OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Issues with HA’s Buffer sub-systemIssues with HA’s Buffer sub-system
• Our custom interfaces don’t use Buffer SS = no data to Secondary Server
• Manual data entry = no data to Secondary Server
• Fallback to Primary PI Server– HA clients (PB, DL) don’t ‘fallback’ to Primary when it
becomes available– With the above missing data this can mean users don’t
see all data until reconnection to Primary
21OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential
Looking to the FutureLooking to the Future
• PR2 looks like it will resolve most of the issues we have.
• Future data in PI will be great!