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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
3 © Copyright 2011 OSIsoft, LLC.
Yes, Business Processes Do Matter
HARVARD BUSINESS REVIEW ARTICLE
4 © Copyright 2011 OSIsoft, LLC.
Production Maintenance Inventory Quality C
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Rep
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PI System
http://videostar.osisoft.com/UC2010/presentations/PPT/UC2010_PT1893_Enterprise_Integration_Gopal_Verhoeff.pdf
5 © Copyright 2011 OSIsoft, LLC.
ISA 95 Functional Model
PI System
6 © Copyright 2011 OSIsoft, LLC.
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
7 © Copyright 2011 OSIsoft, LLC.
Production Maintenance Inventory Quality C
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Rep
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Lab
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PI Notifications
PI OLEDB Enterprise
PI JDBC
PI Web Services
PI System
8 © Copyright 2011 OSIsoft, LLC.
Use cases
• Maintenance (Asset Management)
– IBM Maximo – condition-based maintenance
• Quality
– SAP QM (Quality Management) via MII
• Costing
– EPS (Enterprise Performance Solutions)
9 © Copyright 2011 OSIsoft, LLC.
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
10 © Copyright 2011 OSIsoft, LLC.
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
11 © Copyright 2011 OSIsoft, LLC.
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
12 © Copyright 2011 OSIsoft, LLC.
XML Data Flow
OCS
XML XSL Transform
PI Notifications
Maximo
Office Communicator
XML Delivery Channel (PI Notifications toolkit – OSIsoft vCampus)
13 © Copyright 2011 OSIsoft, LLC.
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
15 © Copyright 2011 OSIsoft, LLC.
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
16 © Copyright 2011 OSIsoft, LLC.
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
17 © Copyright 2011 OSIsoft, LLC.
Benefits of using PI System data in Maintenance
• Save maintenance $$
• Reduce equipment downtime
– Catch equipment failures before they happen
• Improve reliability
18 © Copyright 2011 OSIsoft, LLC.
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
19 © Copyright 2011 OSIsoft, LLC.
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
$270,000 for 6 sites
20 © Copyright 2011 OSIsoft, LLC.
Use cases
• Maintenance (Asset Management)
– IBM Maximo – condition-based maintenance
• Quality
– SAP QM (Quality Management) via MII
• Costing
– EPS (Enterprise Performance Solutions)
21 © Copyright 2011 OSIsoft, LLC.
About Klabin • Leading paper producer in Brazil
– Packing paper and board – Corrugated boxes – Industrial sacks
• 10,000+ employees • 2010 Sale - US$ 3.7 Billion • 17 manufacturing sites • 110+ years old company
22 © Copyright 2011 OSIsoft, LLC.
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
23 © Copyright 2011 OSIsoft, LLC.
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
24 © Copyright 2011 OSIsoft, LLC.
SAP MII
25 © Copyright 2011 OSIsoft, LLC.
SAP MII screen – Action blocks
26 © Copyright 2011 OSIsoft, LLC.
Jumbo Roll Data in PI System
• PI BatchView
• PI ProcessBook
27 © Copyright 2011 OSIsoft, LLC.
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)
28 © Copyright 2011 OSIsoft, LLC.
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.
29 © Copyright 2011 OSIsoft, LLC.
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
30 © Copyright 2011 OSIsoft, LLC.
Use cases
• Maintenance (Asset Management)
– IBM Maximo – condition-based maintenance
• Quality
– SAP QM via MII
• Costing
– EPS (Enterprise Performance Solutions)
31 © Copyright 2011 OSIsoft, LLC.
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
33 © Copyright 2011 OSIsoft, LLC.
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.
36 © Copyright 2011 OSIsoft, LLC.
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.
37 © Copyright 2011 OSIsoft, LLC.
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
38 © Copyright 2011 OSIsoft, LLC.
Demo - integration w/EPS (costing) at RockTenn
http://vcampus.osisoft.com/live_2010/m/live2010/7826.aspx
39 © Copyright 2011 OSIsoft, LLC.
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)
40 © Copyright 2011 OSIsoft, LLC.
Production Maintenance Inventory Quality C
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plia
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Rep
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Lab
C
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rati
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ERP
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Man
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Sys
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PI Notifications
PI OLEDB Enterprise
PI JDBC
PI Web Services
PI System
41 © Copyright 2011 OSIsoft, LLC.
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.
43 © Copyright 2011 OSIsoft, LLC.