Using PI System Data and

2 © Copyright 2011 OSIsoft, LLC.

Presented by

Using PI System Data and Events in your Enterprise and Line of Business Systems

Gopal GopalKrishnan & Ray Verhoeff, OSIsoft Sumanth Makunur, DTE Energy Raquel Goulart, Klabin & Flavio Maeda, Konitech Todd Mitchell, RockTenn


Yes, Business Processes Do Matter

HARVARD BUSINESS REVIEW ARTICLE


Production Maintenance Inventory Quality C

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http://videostar.osisoft.com/UC2010/presentations/PPT/UC2010_PT1893_Enterprise_Integration_Gopal_Verhoeff.pdf

http://videostar.osisoft.com/UC2010/presentations/PPT/UC2010_PT1893_Enterprise_Integration_Gopal_Verhoeff.pdf


ISA 95 Functional Model

PI System


PI Data Access

Analysis/Reporting Services

MII

PI System

PI Web Services

PI OLEDB Enterprise

PI JDBC PI OPC DA/HDA

Server OSIsoft SDKs PI Data Access family of products

http://www.sap.com/index.epx



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PI Notifications

PI OLEDB Enterprise

PI JDBC

PI Web Services

PI System


Use cases

• Maintenance (Asset Management)

– IBM Maximo – condition-based maintenance

• Quality

– SAP QM (Quality Management) via MII

• Costing

– EPS (Enterprise Performance Solutions)


About DTE Energy - Detroit Edison

DTE Energy Co.

• 10th largest electric utility & 11th largest gas utility

• $8.6 billion revenue

• 9,800 Employees

• Investing $1 billion in biomass, solar, wind and other renewable energy

Detroit Edison

• Michigan’s largest electric utility with 2.1 million customers

• Over 11,080 MW of power generation, primarily coal fired


Use Case – Maintenance

• Current business process – - Calendar based (90 days, 6 months …) PM (preventive maintenance) tasks – - Reactive maintenance, i.e. maintenance after equipment failure

• Revised business process

– Usage based instead of calendar – Condition-based instead of calendar or reactive

Sumanth is a maintenance manager and wants to: > Cut costs by eliminating unnecessary maintenance tasks > Improve equipment availability by doing maintenance before failure


EQUIPMENT

OPERATING PARAMETERS

Running or Idle

Pressure

Temperature

Rpm

Vibration

Oil level

PI System

Portal

(via Maximo Integration Framework)

PI Notification Triggers

WORK ORDER

Measurements

Process Analysis

Data

or

WorkOrder Trigger

Acknowledgment

OPTIONAL

GAUGE

CHARACTERISTIC CONTINUOUS

Condition Assessment Acknowledgment

OPTIONAL

CRON TASK

PI System to Maximo data flow

PI Notifications


XML Data Flow

OCS

EMAIL

XML XSL Transform

PI Notifications

Maximo

Office Communicator

XML Delivery Channel (PI Notifications toolkit – OSIsoft vCampus)


Usage based maintenance - Types • Run-hours

– Pulverizer (is Running if Amps > 10) – Coal feed conveyor – High pressure service water pumps

• Run-modes – number of starts (peaker combustion turbine (CT) blades) – number of trips

• Run-weight – tonnage processed (mining industry) – flow-rate (time-integral) converted to volume (Slurry Pumps)

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Maximo Meter integration via XML messaging


Condition-based maintenance • Failure or performance correlated to a slowly degrading metric

– Temperature (bearings, motor windings, gas circuit breaker etc.)

– Pressure or DeltaP (Heat-exchanger plugging, Filters, Nitrogen cylinder low pressure,

GCB low pressure

– Vibration, amplitude (need to interpret along with operations data in the PI System) – Level (Transformer oil tank level too low)

• Instrument drift

• Process control loop health


Boiler convection tubes plugging Rapid rate of change of Delta P over several days is a trigger for maintenance

Delta P (PI System expression calculation, ad hoc plot)

Rate of Change logic in PI Notification

(Current 24 hour AVG - 5 days ago 24 hour AVG) > 1


Benefits of using PI System data in Maintenance

• Save maintenance $$

• Reduce equipment downtime

– Catch equipment failures before they happen

• Improve reliability


Savings with usage based strategy - Pulverizer

Maintenance: 160 PM hours per pulverizer per year; 16 pulverizers per site, 6 sites

Actual run hours: 80% based on PI System data, implies a 20% savings

Projected savings: 480+ PM hours (approx. $25,000 at $50/hour) per year per site equals

$150,000 for 6 sites


Savings with usage based strategy - Conveyor

Maintenance: 60 PM hours per conveyor per year; 22 conveyors per site, 6 sites

Actual run-hours: 25% based on PI System data, implies a 75% savings

Projected savings: 900+ PM hours (approx. $45,000 at $50/hour) per year per site implies

$270,000 for 6 sites


Use cases



• Quality

– SAP QM (Quality Management) via MII

• Costing



About Klabin • Leading paper producer in Brazil

– Packing paper and board – Corrugated boxes – Industrial sacks

• 10,000+ employees • 2010 Sale - US$ 3.7 Billion • 17 manufacturing sites • 110+ years old company


Use Case – Quality Management

• Lab data already in the PI System – Send to SAP QM (Quality Management) via MII

• Lab sample template in SAP – Manual entry in SAP – results download to PI System

Raquel is a Quality Engineer and wants to: >Issue the Quality Certificate in SAP as soon as lab results are available >Eliminate error prone manual entries in SAP

PI System

PI System


Data Flow: PI System to SAP via MII

PI System

SAP MII

SRP

MS SQL DB

SAP

QM

Quality Certificate

PI Interface Acquidata

or Excel

Aquidata Lab

System

Lab results Air Permeation, Bursting strength, Thickness, Roughness, Tearing, Density …

PI RDBMS Event: Roll turn-up SAP RFC calls


SAP MII


SAP MII screen – Action blocks


Jumbo Roll Data in PI System

• PI BatchView

• PI ProcessBook


Jumbo Roll Production data in SAP MII

Monitoring screen in SAP MII showing the mapping between the PI System Product Code and the SAP Product Code with the Test Results for each batch (Jumbo Roll)


SAP QM – Test Results

Transaction QE51 : Validate the tests in QM for the lab data from the PI System. And, Certificate of Analysis (CoA) is created.


Benefits from integrating Quality data – PI System to SAP QM

Eliminated manual data entry into SAP

Eliminated the human errors associated with the same

Decreased decision-making time for disposition of rolls

Increased overall operational performance on PM #16

Increase overall paper laboratory efficiencies

Next step: Integration with SAP PM for condition-based maintenance


Use cases



• Quality

– SAP QM via MII

• Costing



About RockTenn • Headquartered in Norcross, GA, Sales $3 Billion, 10,000 + employees

• One of North America’s leading producers of ― Paperboard ― Containerboard ― Consumer and Corrugated Packaging ― Merchandising displays

• Production facilities concentrated in North America ― 11 Recycle Paperboard Mills ― 1 Recycle Container-board Mill ― 1 Bleached Board Mill ― 90+ Converting Plants

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Use Case – How much does it cost?

Problem - data is now in different systems and is not integrated. Where is it? • Production data, component flows, and production statistics - PI System • Production records - Majiq (paper roll tracking system) • Quality data not captured in PI System - Stand-alone relational database • Other cost data – JDE ERP (overhead, labor etc.), Material pricing

Todd is a Production Engineer and wants to: • Know which paper Grades and Calipers cost to manufacture • Have better insight into product pricing • Have all this information right away and calculated for me!

Solution - data is all in one place, consistently allocated, and available. • EPS (Enterprise Performance Systems) Cost Management Suite • PI System software to integrate PI System data, Majiq data, and other cost data


OSIsoft Products and Services Employed

• Enterprise Agreement in place since 2007

– No tag limits so we can capture everything

– Access to full suite of PI System software and expertise

• PI ACE

• PI Web Services

• PI Interfaces

• OSIsoft vCampus and CoE (Center of Excellence) for advice

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EPS Cost Management Suite • EPS is a software and consulting company – located in Atlanta, Georgia • Specialized in cost management systems • Focused on the pulp and paper industry

We consider this as Middleware

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EPS Basic System Integration Reporting is handled primarily outside of EPS. We are using PI Client tools and reporting over SQL data.


Costing Data Structure Based on Production Units

• Reels, Rolls, Pulp Bales • Utility Production – Steam Generation, Electricity • Pulp Production, ClO2 Production

Tied to Consumption of raw materials – by Recipes • ClO2 (chlorine dioxide) - Tag • NaClO3 (sodium chlorate) - Tag • H2SO4 (sulfuric acid) - Tag • Etc.


PI Server

EPS

MAJIQ

PI Web Services

PI ACE

Bleach Pulp Electricity Steam Etc.

Upload

Production Records (start/end time)

Reel, Bale, Process

PI RDBMS

Beta Site Demopolis, AL

Data Flow: Production Costing


Demo - integration w/EPS (costing) at RockTenn

http://vcampus.osisoft.com/live_2010/m/live2010/7826.aspx




Results and benefits (work in progress)

- Better Visibility ofcost data to control costs

- Data is available to PI System client software real time

- Operators use PI ProcessBook and PI DataLink

- Data is available through EPS and external reporting

- Allows the Mill and Finance to concentrate on grade margin to develop opportunities.

- Time spent on manual costing process now reallocated

- What if analysis is possible (e.g., chemical costs change)



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PI Notifications

PI OLEDB Enterprise

PI JDBC

PI Web Services

PI System


Conclusion and Questions • Use PI System infrastructure tools for Line-of-Business

integration tasks – PI Data Access, PI Notifications, and others – Start small – doesn’t have to be a big project

• Other resources - OSIsoft vCampus

• Talk to other PI System users already doing this

Thank you

© Copyright 2011 OSIsoft, LLC.


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Using PI System Data and