© copyright 2011 osisoft,...

Presented by


Using the PI System in

Manufacturing

Pasha Ahmad

Amman Regional Seminar

October 31, 2011


3

Agenda

• Information Transformed into Asset for Survival

• PI System Infrastructure Summary

• Putting the Infrastructure to Use

• Using PI System in Different Industries

• Examples, Case Studies, and Discussion


4

Data, Information, and Intelligence

• Data

• Information

• Intelligence

• Information and Intelligence Converted into Assets


PI System Infrastructure + Applications Transforms

Information into Asset

Present

View data, identify

problems, and take

corrective action

with familiar, easy-

to-use graphical

tools.

Analyze

Access real-time or

historical role-

based data for the

entire enterprise at

any time.

Connect

Collect data from

hundreds of

sources.

Manage

Gather and archive

large volumes of

data. Scale to meet

your growing

business needs.

BUSINESS

Interfaces Servers Analytics Visuals

Facilities


The Real Value is Manufacturing Intelligence

“Manufacturing Intelligence (MI), also known as Enterprise Manufacturing Intelligence (EMI), software delivers real-time information about manufacturing processes to help businesses optimize the performance of these processes as well as manufacturing yields. MI software gathers and analyzes production data, provides role-based visualization, and helps manufacturers reduce waste. The software also enables the improvement of manufacturing processes, identification of best practices, and the ability to respond to exceptions and events.”

Manufacturing Intelligence:

• Delivers real-time information about manufacturing processes

• Gathers and analyzes production data

• Provides role-based visualization

Delivered Value:

• Optimize process performance and manufacturing yields

• Reduce waste

• Improve manufacturing processes

• Identification of best practices

• Respond to exceptions and events


Overcoming Logistical Challenges with

Collaborative Technologies

• Traditionally, computerized systems have been focused on automating calculations,

operations, and work flow processes.

• Automation is an effort to minimize the use of existing human resources.

• Emerging computer technologies are focused on ubiquitous access to integrated

information. Technologies like web-based portals, virtual presence, and business

intelligence tools enable collaboration, allowing organizations to address challenges in

new ways.

• Collaboration is an effort to maximize the use of existing human resources.

• Real-time information is essential to fuel the collaborative engine by enabling awareness

and supporting continuous improvement efforts.


Overview

• Enabling Awareness: The Value of Real–Time

• Delivering Opportunity: The Need for Infrastructure

• Overcoming the Challenge: Performance Intelligence

• Collaborating to Improve: The Real-Time Infrastructure in Action


Enabling Awareness

The Value of Real-Time


Assessment of Condition

Electrocardiogram

• Statement of “goodness”

• Actionable

• Critical

The Value of Real Time

Forecast

World Cup

Scores


Fuel flow spikes discovered costing $93,000 / year.

Wasted Fuel Gas


Fundamental Principle


TARGET FUEL

FLOW

Another Opportunity – Continuous Improvement



Capturing opportunities requires the right people.

The Challenge of Real Time


Delivering Opportunity

The Need for Infrastructure


Accessible by Expected Standards

• Interfacing with over 400 different automation sources

• Compliance with Industry Standards – OPC UA, PRODML, XML

• Query-based Access, OLEDB

• Integration with Microsoft Office Tools – Excel, VBA

• Integration with Microsoft and SAP Web Prortals

• Supports Application Development- OSIsoft vCampus


Relational Data Real Time Data

Formulas User Defined

Asset elements derived from a common

template for each equipment type

Contextual for Information Integration


Contextual for Users and Applications


Overcoming the Challenge

Performance Intelligence


Benchmarking

Performance

Against

Objectives

Articulation of

Performance

Rules

Accountability of

Manufacturing

Objectives

Collaboration Driven by Transparent Accountability


Organizational Presentation of Real-time Opportunities

PI WebParts 2010 for Microsoft SharePoint 2007 or SAP Enterprise Portal


Email with

links

relevant

information

Integration with

Virtual

Prescience

Technology

Event-based Notification of Real-time Opportunities

PI Notifications (PI System 2010)


Democratized Business Intelligence

Delivered through a familiar environment

Integrated into business productivity infrastructure

Built on a trusted and extensible platform

Improving organizations by

providing business insights to

all employees leading to better,

faster, and more

relevant decisions

Microsoft BI Vision and Strategy


Collaborating to Improve

The Real-Time Infrastructure in Action


Enterprise Integration of

Operational Data from

Wind Farms John Mostek, O&M Engineer

John Deere Renewables

OSIsoft 2010 Users Conference


Operating Commissioning Construction Operations Center

Project Locations


Enterprise Management System

PI System is the foundation on which our EMS

is built, and is the basis for dashboards

monitored in our Operations Center


Aggregation controls

(AF / MDB hierarchy)

Time controls

Dashboards

SharePoint portal environment on intranet, using PI WebParts


Real-time Status Displays

PI ProcessBook rich client application


Geospatial Context Customized code to overlay real-time PI System data in the Google Earth environment


Production Forecasting

Web services with PI System data queries, served up in Business Objects using Flash


Alarms and Notifications


Benefits

• 77% improvement across our fleet in Energy Capture performance metric within first 6 months of PI System roll-out

• Top-line impact of Operational Awareness

• Data fit within a consistent Enterprise platform

• Use of templates / PI AF hierarchy structure = rapid integration of new project sites

• Leverages existing sources of Metadata

• Extensive library of off-the-shelf interfaces available from OSIsoft

• Future data sources become an easy fit


• Integrated Water Management

Municipal, Industrial, Agricultural

Consumption

Smart

Meters


Integrated Water Management

• Similar concept as power, but in water.

• AMI and Smart Water Meters in homes.

• Domestic Water management.

• 32 million meters by 2016.

• $16B industry by 2020.

• Trial Palm Desert, 17% lower consumption.

• City of Toronto, cut meter readers saves $33M.

• California cut 20% water use by 2020.


Future Earth 2025 Documentary:

– Dust storms: Las Vegas $120M removing turf

– Water Wars (Indus, Nile, Jordan River)

– Wild Fires: Victoria, OZ in 2009. In last 5 years, rainfall in California

dropped 48%

– Lake Mead dry by 2021, no water for Las Vegas, no power for LA

– Collaboration, Conservation and efficiency is imperative.

• Water Scarcity Consequences


~30% Operating costs attributed to energy

3% USA National Energy Consumption

2 Gallons of Water / KWh consumed

Is This Sustainable?

Water / Energy Nexus


1. Moulton Niguel

Business Issues:

Increasing Power Costs

Tightening Budgets

Critical Peak Pricing

>200 kW dynamic demand response pricing coming

Business Value:

Real-time power management

$$$ savings in reduced power costs

Participate in more demand response programs


• Safe, Reliable, Efficient Ops

• Increase Pumping Efficiency

• Reduce Rates Beyond Time of Use (TOU)

• Minimize Demand Costs

• Optimize Rate Schedules

• Make Operators “Energy” Knowledgeable

• Maintain a “Continuous Improvement” Environment

• Make Energy Management a Business Process

Moulton Niguel Water – Energy Costs


Real-time Energy Management 15% or $200,000+ Annual Energy Savings


2. Halifax Water

Business Issues: Water loss management

ILI = 9.0

$$$ lost due to water leakage

Reduce Capex and water consumption

Business Value:

Automatic real-time leakage detection

$$$ savings in reduced water loss

Integrated view of entire water system

Sustainability

325,000 residents served


Halifax’s Success Water service to 325,000 people.

$650,000 / yr savings by reducing water

leakage (DMA Night Flows).

2 million gallons / day saved

Quickly account for non-revenue water

Reduced ILI to 3.0

Data to validate back-charge to

contractors.


“Sustainability, both sides of the meter.” Carl Yates, GM of HRWC

Real time water consumption dashboards for largest consumers

Halifax’s Success


43

Center of Excellence for Enterprise Operations Advanced Water Management: SMART and Sustainable

Kinetic Energy Recovery Close Supplier Relations Ultra Pure Water

Treatment Efficiency

Heat Energy Recovery

Manufacturing Use Efficiency

Stewards of the Resource Waste Water Treatment

Lake Champlain

Vermont’s

Greatest

Water

Resource

Smarter water for

a smarter planet

Instrumented – Obtain and

collect real time data

Interconnected – Data analysis

and visualization

Intelligent – Analysis becomes

action, transform how we operate


44

Center of Excellence for Enterprise Operations

SMART Waste Water Results

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Phosphorous

2005-6 Avg

2007-current avg

NPDES Discharges

Waste Water Sludge

Manufacturing Capability Up 30% since 2000

(excluding 2009)

Phosphorus: - 48%

Fluoride: - 44%

TDS: - 54%

Water & Waste Water Chemical Usage

Disposal Cost: - $49K/yr

Generation: - 600K lbs/yr

Annual Costs: -$401K/yr

Reduction: - 2,162K lb/yr

Burlington Waste Water Management Goals

- Quality: Meet or exceed regulatory requirements

- Reliability: Zero manufacturing down time

- Cost: $450K/year reduction in annual cost

Units mg/l NPDES limit 1.2 mg/l

Phosphorus Discharge


Philosophy for OSIsoft PI System in J&J Pharma

• Get away from counting “tags”

• Collect all data (GMP & non-GMP)

– Process, Alarm & Events, Batch Events

• Deliver a consistent infrastructure globally

– no differentiation from Commercial to R&D

• Provide common visualisation (thick & thin clients)

– Consolidated data visualization for improved process monitoring and historical batch analysis

– Consolidated alarm reporting for building management, process control, laboratory equipment, utility systems, warehouse equipment…

• Targeted compliant reporting (RtReports)

– Autoclaves, washers (non-MES related!)


Enterprise Agreement – Current Scope

Malvern, PA

Radnor, PA

Springhouse, PA

Cork, IR

Leiden, NL

Gurabo, PR

Manati, PR

Beerse, BE

Geel, BE

Schaffhausen, CH

Latina, IT

Higi, India


Enterprise Agreement - Delivering Value

• Get the data in the hands of the users



• Logistics – bulk solvent monitoring



• Utilities – AHU Airflows



• Alarm Monitoring & Paging



• Monitor Home Control Network (MCN)



• Compliant Reporting


53

Process Overview of Cement Operations


A single data format for all plant data management, analysis and archival

Crusher

Preblending

Additives

Raw Mill

Blending Silos

Precalciner

Kiln Cooler

Additives Cement

Mill

Clinker

Silo

Cement

Silo

Quarry

Quarry Data Raw Mill Data Kiln/Cooler Data Cement Mill Data Raw Mix Data

Enterprise Data Lab Data

PI will give you value by

real-time improvements in

• Energy savings

• Emissions monitoring

• Process data

• Product quality data

• Maintenance scheduling

• KPI measurements

PI can connect all your

islands of information

• Process controls systems

• Lab analysis devices

• Motor control centers

• Vibration analysis devices

• Gas analysis systems

• Infrared camera systems


Monitoring and Transforming into Intelligence

• Quarry Operations

• Crushing Operations

• Blending and Raw Material Grinding

• Preheat,

• Kilns

• Clinker Storage and Finish Grinding


Key Performance Indicators

1. Inventory Utilization

2. Energy Consumption

3. Capacity

4. Quality Indicators

5. Fuel Consumption

6. Asset Utilization


Dashboard of KPI’s for Each Plant Area

Operational Data Protected

“Cement producers need to develop their KPI operational and maintenance data, but be able to

share it with key support groups, this provides an important business benefits. Without the use of

the PI System, it would have taken them several months to gather and analyze the information.”

Customer Business Challenge Solution Customer Results / Benefits

• Providing key process indicators for

increased quality and production

• Closer monitoring of electrical and

fuel usage

• Developing long term historical

data for improved maintenance

• Implemented PI system to provide

connections to plant wide systems

• Provided focused view and data

analysis of MTC’s and emission

controls.

• Provides monitoring and analysis of

all equipment history

• Strong positive real-time composite

audit for all major plant areas

• Reduced energy costs and real-time

indicators for energy management

• Focused maintenance data to aid in

seeing problem areas before failures

occur

Process Monitoring

Real-time Web Access

Plan Execution \ Inventory Report

Equipment Health and Maintenance - Pemex

Control System Effectiveness

Multivariable Control Collaboration

Control System Effectiveness

Constraint Analysis

Data Reconciliation

Any Questions?

• Questions

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