pi systems and deliberate process...
TRANSCRIPT
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Presented by
PI Systems and
Deliberate
Process
Improvement
Rick Smith
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Agenda
• About International Paper
• Business and Technical Challenges
• How Did IP Address the Challenges
– Production Calculation
– Overall Equipment Efficiency (OEE)
– Energy Consumption
• Future Plans
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About International Paper
• World’s Largest Pulp and Paper Company– Founded 1898 (116 Years Ago)
– 70,000 Employees
– $29 Billion Net Sales (2013)
• OSISoft Installed Base– 35 Facilities (70 PI Servers)
• US, Brazil, France, India, Poland, Russia
– 1.5+ Million PI Tags
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Challenges
• Business– Year-Over-Year Cost Reduction Goals
– Spend Capital Effectively (Low/No Capital)
– Retain Historical Cost Reduction Gains
• Technical– Single Version of the Truth
– Manage Through Systems
– Simplify IT Environment (Configure vs. Develop)
– Number of Implementations Grows Over Time
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I Certify This Calculation is Correct
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Single Version of the Truth
• Question: How Much We Make?
• The Answer Depends on Who You Ask…
– What Base-Line Time Period Selected?
– What PI Tags Were Used?
– How Was Data Filtered?
– What Calculations Were Used?
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Excel
Digester Production Calculations
DCSRaw PI Tags
PI AF (Future)
Environmental
Monitoring
ExcelExcel
Standardized Calculation Methods
Decision
Makers
Uncontrolled
1 3
2Coefficient
Changes
Implementation Timeline
1. Raw PI Tags
2. Excel Calcs From Raw Inputs
3. Daily Env. Calcs Added
4. Convert to PI AF (Future)
5. Convert Excel to PI AF
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4
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Digester Production (ADUBTPD)
Air-Dried Unbleached Tons per Day =Chip Meter Speed (rpms) * Bulk Density (lb/ft3) * Chip Meter Volume (ft3) *
Chip Meter Fill Factor * Yield * [1440 min/day] / [2000 lb/US Ton]
Yield = [A + B*(Kappa) + C * (Kappa)2 ]
PI PE -> '03SIC103.PV' * 10.65 * 24.6 * 1.0 * (0.4198 + 0.00155 * 'K1Kappa.PV' + 0.0 * 'K1Kappa.PV' * 'K1Kappa.PV') * 1440 / 2000
• Yield Coefficients and “Constants” Change
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Standard Calculations Via PI AF
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PI AF Calculation Conversion Benefits
• Standard Calculation Methodology
– Controlled By the PI AF Template
– Therefore, One Version of the Truth
• PI AF Becomes the One Stop Shop for…
– Enterprise Alias for Calculated Results
– Time Stamped Coefficient Changes
– DCS/PI Calculation Comparison
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Overall Equipment Efficiency (OEE)
• Overall Equipment Efficiency = Availability * Speed Efficiency * Quality
– Availability: Downtime/Slowback System (RTS)
– Speed Efficiency: Maximum Sustainable Rate
– Quality: A1 Tons Acceptance
• Reliability Tracking System (RTS)– Windows Service Reads PI Data and Writes State Information to PI
• 0=Normal; 1=Slow; 2=Down
• Event System Triggers Off State Tag
– Excel Report for Each Unit Operation
– ~300 Unit Operations Monitored
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Report Output
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Downtime Data Flow (2002-Present)
RTS Service
PI
Specifications & Events
AccessConfiguration
Current
Data
Specs
Event
Status
Events
0
5
10
15
20
25
1 10 19 28 37 46 55 64 73 82 91 100 109 118 127 136 145 154 163 172 181 190 199
Targe
Slowback
Downtime
A
B
C
D
E
F
G
H
Excel
Enterprise
Database
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Future Downtime Data Flow
RTS Service
Specifications & Events
AccessConfiguration
PI AF
PI
Current
Data
Specs
Event
Status
Events
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PI Event Frame Conversion Benefits
• Simplify Environment
– Eliminate Distributed Access Databases
– Eliminate Windows System Service
– Remove Specification/Event System Requirement
• Configuration with Standard PI Tools
• Will Work at All IP Manufacturing Facilities
• Simplifies Reporting Requirements
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Tracking Energy Consumption
• For Each Paper Machine– Summarize PI Data for 20-40 PI Tags
• Retrieve 1-Month of Hourly Averages
• Remove “Bad Data” (Sheet Break, Downtime, etc.)
• Allocate/Aggregate Data for “Missing” PI Tags
– Copy/Paste Values into Enterprise Spreadsheet
• Update Chart Ranges (Enterprise Spreadsheet)
• This Exercise Takes 2+Days/Month
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Steam Consumption (lb/Ton) (Low is Good)
‘01-’02
7/13-5/14
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Can We Reduce the Effort?
• OSISoft Paper Machine Demonstration– Jim Black (Industry Principal-OSISoft)
– Gopal Gopalkrishnan (Solutions Architect-OSISoft)
• PI AF Elements– Steam, Electricity and Sheet Break Status
• PI Analytics (For Each Element)– Value Adjusted For Sheet Break (Event-Triggered)
– Data Quality Check (Daily Event Frame)
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Monthly Summary
19
Monthly Averages
Monthly Totals
Date Range
1. 15-Second Refresh
2. Data Cleaned and Summarized
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• Reduce Monthly Task to < 4 Hours (est.)
– Data Transfer Time Reduced by > 98%
– Eliminate Data Cleaning Step
– Eliminate per Ton Calculation Step
• Simplify Reporting
– Single Version of the Truth
PI Event Frame Benefits
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Next Steps and Future Plans
• Switch PI Servers to Domain Security (In Progress)
• PI Asset Framework Projects (Proposed)
– PI Notifications
• Replace Home Grown Solution
– PI Event Frames
• Replace Home Grown Downtime Solution
• Daily/Monthly/Grade Analysis
– Identify and Configure Standard Plant Model
– … More to Come…
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Rick Smith
• Manufacturing PIM
• International Paper
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