Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Using PI for Reporting

Regional Seminar Series

Skye Blair and Alan PolkProcess Automation EngineersBASF

August 11, 2009

© Copyright 2009, OSIsoft Inc.  All rights Reserved.  2 Empowering Business in Real Time.

Environmental Applications

3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

BASF – McIntosh Site

• Washington County, Alabama• Specialty Chemical Manufacturing• 800 Employees• 1,553 Acres

4 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

OSI PI Installation Base

• 1 Enterprise PI Server

• 1 SQL Server

• 12 Collection Nodes– 7 Novatech D3 (VMS)– 3 Emerson DeltaV (Windows)– 1 Schneider Modicon (Windows)– 1 GE iFix (Windows)

• 39,000 PI Tags

5 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Mon/Mact Compliance

• What is MON/MACT?

– MON/MACT requires facilities that utilize Miscellaneous Organic NESHAPs (MON, typically solvents) to provide proof that permissible emission limits have not been exceeded utilizing Maximum Achievable Control Technology (MACT)

– The burden of proof lies with the facility to prove that emission limits were not exceeded, not on the government.• Violations up to $27,500/day

– Went into effect May 2008

6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Solution Overview

• Collect data on applicable sampling points in PI

• Condition data for Compliance Software

• Communicate conditioned data to Compliance Software

• Compliance Software handles alarming and reporting.

7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Collect Data

• Data is collected via PI Collection node for any point pertaining to MON/MACT Compliance– Temperature of Emission Burning Stacks– Flows of Solvent Containing Streams– Analyzer content of analyzed streams– State of Relief Valve

• Where PI Collection is not redundant, a stand-alone chart recorder is attached to the sampling point for backup data collection

8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Conditioning Data

• Mon/Mact Reporting is based on One Hour Averages– Minimum 4 Points/Hour for compliance– Data Integrity must be ensured.

• Data Integrity– A Minutes Past the Hour tag was created in all DCS/PCL

applications and trended in PI– When data is collected over a 1 hour period, the minutes past the

hour tag must be collecting over that period, if the tag is not, then communication with the control device has failed, and PI data is not reliable.

9 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Conditioning Data

• A PI Performance Equation is used to calculate the Rolling 1 Hour Average

– If data is uncertain, then a 99999 is trended, otherwise, the average is trended.

– E.g.• if tagval('node-u_minutesph','*') = tagval('node-

u_minutesph','*-10m') then 99999 else TAGAVG('FT19233A','-1h','*',90)

10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Compliance Software

• Stand alone Compliance Software Server located off-site at vendor provided location

• OPC connection from Enterprise PI Server to Compliance Software Server

• For all collected points, emission limits are configured in compliance software– If limits are exceeded, email notifications are provided

• Quarterly Reports generated for all excursions.

© Copyright 2009, OSIsoft Inc.  All rights Reserved.  11 Empowering Business in Real Time.

Utility Applications

12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Utilities Reporting Plant Structure

• 7 Production Units

• Stand alone utilities

• Stand alone waste water treatment

• The utilities and waste water treatment are metered to individual production units for transparent cost analysis.

13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Gathering Data

• Utility flow data collected by dedicated PLCs in each production unit

• Data totalized daily in PLC

• Daily totalized values trended in PI separately from current flow value

14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Calculation Process

• Daily totals are imported into Microsoft SQL

• Totals are run through a set of iterative calculations in SQL to determine where all utilities were consumed during the previous 24 hours

SteamTOT = ΣSteamUnit + SteamLoss

SteamUnit = SteamUsed + (SteamUsed/ SteamTOT)*(SteamTOT - ΣSteamUnit)

Loop until Steam Loss is essentially zero.

• Results are placed back into SQL and then transferred back to PI

15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Reporting Process

• From SQL database, daily utility usage reports are generated which are automatically FTP to ERP systems and imported.

• Utility Reporting used for billing of cost of production.

• Utility Reporting can also drive process changes.

• Waste water usage is transferred to environmental reporting suite.

16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Future Plans

• FTP of comma delimited reports is unreliable– Dedicated PI-ERP interface for automatic data transfer is

planned.

• SQL database is complex and requires an extra server– SQL calculations to be re-written as PI Performance

Equations?• Performance Equations have limitations• Looking into using PI ACE

17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Questions?

Thank youThank you

© Copyright 2009 OSIsoft, Inc.

 777 Davis St., Suite 250 San Leandro, CA 94577