large pi deployment a.b.i.’s experience by jacques lehouillier it coordinator - it architecture...
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Large PI Deployment
A.B.I.’s Experience
By Jacques LehouillierIT Coordinator - IT Architecture
Aluminerie de Bécancour [email protected]
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Who’s A.B.I.
Why We Needed PI
The Deployment
Where We Intend To Go
Large PI Deployment
A.B.I.’s Experience
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Index
Who’s A.B.I.• Aluminerie de Bécancour Inc.
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Index
Who’s A.B.I.– An aluminum smelter.– In the town of Bécancour, on the South shore
of the St-Lawrence river, half way between Montréal & Québec City
Montréal
Québec
Bécancour
– Covering a 1.5 km (1 mile) by 1 km (0.6 mile) area
– 5 plants in 1
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Who’s A.B.I.– Two potlines built in 1986 to produce 240 000
mt of aluminum– Addition of a third potline in 1990 to increase
production to a total of 360 000 mt– We are currently producing 376 000 mt– We have three owners
• Reynolds Metals Corporation (U.S.)• Alumax (U.S.)• Pechiney (France)
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Who’s A.B.I.– We transform alumina (Al203) into molten
aluminum which is cast into three types of products :
• Slabs : flat rolling - foil, beverage cans, ...• Tee ingots : remelting - car wheels, ...• Extrusion billets : extruding - tubing, window frames, …
– Targeted markets :• Car industry• Consumer products• Construction industry• air tanks for scuba diving
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Why We Needed PI• The current situation
– Our old architecture• 18 PDP11 used as HMI’s and SCADA
– Our major weakness: PDP11• Small amount of aggregated data available to
the production staff through our MIS– Relic of the RS-232 era – Inability of the PDP11 to process large
amounts of data
• They don’t pass Y2K as is
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Why We Needed PI• The Potline Project
– Fast access to pot information• 240 pots per potline• With PDP11 : 1.5 min / pot
– 240 pots * 1.5 min/pot = 6 hours– our operators work 12 hour shifts
• Data from 17 tags per pot at an average rate of 30 sec for 72 hours
• Desired access time : 10 sec
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Why We Needed PI• The Potline Project
– Graphical interface• With PDP11 : ???• Interface desired by user : Windows style• The users had examples of an application
from Tomago, an aluminum smelter in Australia
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Why We Needed PI• We want to make PI an important
part of our production process reengineering– A production data archive– Batch management
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Index
The Deployment• Prerequisites
– Have your users determine what data are important to them
– Present the available tools from OSI• ProcessBook• PI DataLink
– Have them outline the desired views of their information
• Graphics• Reports• Synoptics
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The Deployment• Prerequisites
– Underline the difference between data & information
Datavariation
Information
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Index
The Deployment• Prerequisites
– Underline the difference between data & information
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The Deployment• First Step
– Alpha 2000 with OpenVMS– Potline #2– 30k tags
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The Deployment• The Potline Project
– Solution• PI as the data archive• Delphi 2.0 to develop the user interface &
the application– Result
• Access time : 5 sec
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The Deployment• First Step
– Problems• lack of tags
– 240 pots * 100 tags– Calculated tags– group tags– potline tags– Sum > 30k tags
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The Deployment• Second Step
– Alpha 2000 with OpenVMS– Casthouse– 35k tags
• Third Step– Alpha 800 with OpenVMS– Potlines #1 & #3– 40k tags– Potline #2 : additional 10k tags
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The Deployment• Next Step
– Alpha 800 with Windows NT– Anode making – 30k tags
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The Deployment• Warning:
– Standardizing to Windows NT• Migration problems
– Alpha 2000 OpenVMS to Alpha 800 NT– Migration tools not available
• Command Line Management tools • Waiting for version 3.2 on NT
– Carefully evaluate your tag needs• More can be cheaper then less
– Don’t limit the number of tags• Our users are archiving everything
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Where We Intend To Go• Event driven publishing
– SQC driven (SQC server)– Event Subscribe & Publish
• Plantwide product tracking (genealogy)– via Intranet & Windows stations
Agora’s draft Genealogy