pi system case studies in the cement industry -...
TRANSCRIPT
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Presented by
PI System Case Studies in the Cement Industry
Don Harroll OSIsoft Cement Industry Business Development
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ENERGY Solution Architecture Diagram
ION Enterprise Server
PIMS Server
OPC OSIso)
Interfaces PI
OPC Server ION
ACE
PI ACE Server
PI MD
OPC Server PCS HMI Plant Control
System
ION meters
PLCs
Electrical RTU network Plant Control Network
PI ProcessBook PI DataLink
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ENERGY PB Displays Examples
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ENERGY
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Emissions As part of the company’s cost reduction strategy, it decided to replace the current Emissions Monitoring System with the actual Plant Information Management System (PIMS) to reduce the TCO. PIMS is based in PI Server, PI AF (PI Asset Framework), PI WebParts, PI DataLink and PI SDK. The company has decided to decommission the usage of an existing environmental reporting system for keeping in compliance with Federal and Local environmental agencies. The company needed to pay an annual fee for being able to use the current environmental reporting system, this annual fee is paid by each cement plant that uses this reporting system.
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Emissions
Plant Server
OPC OSIso)
Interfaces PI
Rela:onal Database
DAHS
PI AF
Central Servers
OPC Server PCS HMI Plant Control
System
CEMS PLCs
Plant DAHS system
Plant Control Network
PI ProcessBook PI DataLink
SharePoint
Users machines
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Emissions Results • Data is available from a common and easy to use platform, and
most importantly the data is hosted inside the company’s network. • All needed information for environmental reporting is consolidated
on the PI Server, and this helps the integration and easy access to data in only one place.
• All environmental information is scalable to different levels at the organization from Excel reports using PI DataLink to internal websites using PI WebParts.
• We have more reliable ways to present just one version of the truth by using the different tools from the PI System platform.
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Emissions Tangible benefits • CEMEX will be saving 20K USD on annual fees, per each
location where the former environmental reporting system is being used, that means around 220K USD in total savings (per year) for the 11 cement plants in the USA.
• Therefore, we can reduce the TCO in the Environmental department for having/maintaining an in-house reporting system.
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Emissions Intangible benefits • We are extending the usage of our PI System platform to other
departments, other than Cement Operations, by stimulating the usage of the PI System platform in the company, and taking advantage from our EA with OSIsoft.
• We have started a way to standardize the development of reports needed at our cement plants.
• End users are discovering different ways where the PI System can help to add value in different areas of the company.
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QUALITY
Replacing these functionalities allows CEMEX to reduce TCO costs, by eliminating actual Quality Systems expenses like:
ü Application Support ü Hardware Maintenance ü Software Upgrades
Integrate Quality Lab Equipment to PIMS and develop new functionality in order to replace actual Institutional Quality Systems.
• Analyze and evaluate alternatives to integrate Quality information on a single infrastructure and replacing Quality Legacy applications functionalities such as:
ü Data extraction (interface) ü Manual Input ü Plant Configuration ü Reports ü Quality Assurance Margin indicator ü Interfaces to another systems
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QUALITY Quality
Solution Architecture
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QUALITY Quality
Solution Architecture
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QUALITY Quality
Lab Equipment Interface Configuration
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QUALITY Quality
Data Acquisition Report
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QUALITY Results using PI System features
• Single-platform for quality and production data
• Standardization
• Real-time quality KPI’s
• Faster data gathering process
• Enhanced data security
• Easy corporate consolidation
• Cross business visibility
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QUALITY Results using PI System features
Intangible Benefits
• Keep quality practices standardized
• Business unit benchmarking
• Production and quality data correlation
• Integrate X-ray equipment from different vendors
• Eliminate risk of technology obsolescence
• Easy integration with company ERP (SAP)
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QUALITY Results Phase 1 - Deployment (14 plants in Mexico)
Tangible Benefits
• Reduce TCO of previous in-house system by USD $ 800 k/year approx.
• Calculated ROI is 6 months • No extra cost for OSIsoft licenses, all are included in the
Enterprise Agreement
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MAINTENENCE Maintenance
Improve assets utilization and reduce maintenance costs by providing indicators and trigger tags for preventive maintenance based on performance and operation conditions. Integrate process control data from the main equipment to calculate tags that trigger automatically work orders for preventive maintenance through the ERP.
Preventive Maintenance
Time-based Condition-based Performance-based
IMPLEMENTED USING PI Notifications
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MAINTENENCE
Plants Administrative Network
Maintenance Module
Plant PI Servers
CxNet
Plant PI Server
Solution Architecture
SAP Plant
Maintenance
PIJDE.PRN file
Using FTP
Equipment Daily Run Hours
Corporate Administrative Network
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MAINTENENCE Benefits
• Reduced maintenance engineers effort and time to manual input equipment run hours at ERP.
• Empowered preventive maintenance routines based on automatic run hours input.
• Improved resources costs increasing preventive maintenance instead of corrective maintenance (decreasing spare parts requirements and increasing maintenance engineers available time for analysis).
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PI Data to ERP (SAP)
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PI Data to ERP (SAP) Benefits
• Automated and validated data transfer to the ERP.
• Real-time operational indicator interaction between the PI System and SAP
• Ability to have tighter inventory control and automated work orders
• Up-to-date data for enterprise-wide decisions
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