Using the PI System to Aggregate, Analyze, and Visualize Datacdn.osisoft.com/corp/en/media/presentations/2014/UsersConference... · • Process Software Engineering (PSE) ... •

© Copyr i gh t 2014 O SIs o f t , LLC .

Presented by

Using the PI System

to Aggregate,

Analyze, and

Visualize Data

Robert A. Lane


Agenda

• Intro– Speaker, Hanford, WRPS

• Problem

• Solution

• Challenges/Results/Benefits

• Services

• Conclusion/Summary

• Thank you/Q&A

2


Robert A. Lane

• Software Engineer and Computer Analyst for WRPS.

• Process Software Engineering (PSE) group since August, 2011

• Functional roles: Project Manager, Software Engineer, Software Developer, DBA, and Systems Analyst.

• Previous Experience on the Optics Suspensions Team as a Testing Engineer, Quality Assurance, Parts Inspection, and Technical Writer for the Laser Interferometer Gravitational-wave Observatory in Richland, WA

• Electronics Engineer and Assistant Project Manager at NASA Ames Research Center for the SOAREX and ATROMOS missions.

3


The Hanford Project

4

• 586-square-miles of shrub-

steppe desert in Southeastern

Washington State.

• Started in 1943 in support of the

Manhattan Project.

• Hanford became one of the

leading producers of Plutonium

during its operation, including

the Plutonium used for the first

nuclear blast and the Plutonium

used in World War II.

© Copyr i gh t 2014 O SIs o f t , LLC . 5

Washington River Protection Solutions (WRPS) is

committed to the safe and efficient management,

retrieval, and treatment of Hanford’s Radioactive

and Hazardous Tank Waste, which poses a threat

to the nearby Columbia River.

A contractor to U.S. Department of Energy

Office of River Protection


Hanford Tank Farms• B-Reactor continued Plutonium

Producing Operations until 1987

• Hanford began a shutdown,

deactivation, maintenance, and clean-

up operation of the entire site in 1991.

• WRPS’ role in the Hanford Mission is

the operation and maintenance of the

Hanford Tank Farms

• The Hanford Tank Farms are made

up of 177 underground tanks that

store 56 million gallons of radioactive

and chemical waste.

6


Tank Farms Going Operational, again

• Ended production operations (circa 1991)

– Mission: Store and Maintain Waste Tanks

• Taking the next step towards cleanup

(circa 2009)

– New Mission: Feed the Waste Treatment Plant (WTP)

in 2019

7


Going from Maintenance….

• Geographically Isolated Systems

– Each with their own Control System

– Each with their own “Plant Historian”

• Separated and disconnected data systems

scattered throughout the site

• Network isolated repositories

• Most data entered manually

8


Going from Maintenance Cont.Effects of Disconnected Systems

• Disconnect between Teams

• Disconnected Operations

• Potential for Conflicting Operations

• Break in Information and Awareness

• Reliance on Procedures: Operations and Safety

9


Going from Maintenance Cont.Effects of Manual Data Entry

• Manual Transcription

– Incompatible interfaces

• Manual Rounds

– Unconnected systems

10

• Issues with Manual Data– Mountains of data

– Daily entered Weekly

– Legibility• Hand Writing in the field

• Writing with PPE

• Error Prone– Transcription Errors

– Interpretation Errors


Where are you?

• How are you able to make a decision when you don’t have all of the information?– To generate a single report requires retrieving data from

multiple databases with different interfaces and data schemas.

– The time it takes to generate a report means the information may be out of date

– If the information is manual, it may not “exist” yet

– The accuracy of error prone data is unknown

11


• Answer: You cannot make an informed decision,

or by definition, the decision is uninformed

12

You are not here


How do you make a facility production-

ready that has only been performing

maintenance for 20+ years?

13


My Mission and Vision

• Mission

– Cast the Vision for Automation and Information

Management for the Company … present the

information you need, when you need it, wherever

you need it.

• Vision

– Collect company data, package it as information, and

present it for timely and efficient decision making.

14


SOLUTION = PI SYSTEM

• Replace obsolete custom-developed solutions

• Upgrade existing interfaces

• Add any unconnected systems

15


The Legacy

Systems

16


Limitations of Aging Systems

• Vendor no longer exists

• Outdated and unsupported operating systems

• Outdated and unsupported hardware

• No source code

• No reading context– When was the reading actually recorded?

– How long has this reading been this way?

– Was it changing?

– Alarm and/or Event information?

17


Initial ArchitectureWhere we started

18

TFLAN

Firewall

702AZ

TMACS

SACS

TWINS

ABCASH

HMS

LOW

Evaporator

Ad Hoc

Continuous

Connection Legend

Evaporator

Firewall

SDDS

222S Labs

W314SY Ventilation

and Exhaust

1/10 min1/10 min

1/day

1/dayManual upload

1/10 min

Manual

Rounds

Manual Transcription

Industrial

Health


Legacy Systems

• Surveillance Analysis Computer System (SACS)– Long Term Archival, Stores one point per sensor per day

– Great For• Seasonal Trends

• Slow Leak Detection

• Measuring Evaporation Rate

• Surveillance Data Display System (SDDS)– Stored for 30 Days, Stores one point per sensor per 10 minutes

– Great For• Current Value

• Actively Changing Processes

• Operation Progress

19


Going From Maintenance to Productionwith Legacy Systems

• Multi-Project 24/7 Operations

– Examples

• Transfer

• Recirculation

• Evaporator Reduction of Waste

– Would it show a record?

– How to distinguish which operation is causal?

20


The Upgrade

21


Safety

Significant

Wireless

Current Architecture

22

TFLAN

Firewall

Tank Farms

MCS

HLAN

TMACS*

PI ServerTWINS

ABCASH

HMS

LOW

Evaporator

MCS

Evaporator

Firewall

Industrial

Health

Ad-hoc

Continuous

Connection Legend

Planned Future

Expansion

222S LabsVentilation Control

SLAN

Firewall

HOBO*

Public

Firewall

eSOMS

* To be consolidated at a later date


PI System – System Architecture

23

HOBOLink

242A

FIREWALL

242A

HLAN

TFLAN

FIREWALL

PI Network Enclave

PI

FIREWALL

TFLAN

TFMCS Primary

Information

ManagerPI OPC

Interface

TFMCS Secondary*

Connectivity

ServerPI OPC

Interface

PI Server

Collective

(2 Servers)*

PI AF

SQL Server

PI ACE

PI Manual Logger

Failover Communication

HLAN Users

with PI

DataLink & PI

ProcessBook

ABCASH

HMS

LOW

TWINS

HOBO

PI OPC

Interface

PI SystemSystem Architecture

Robert Lane

March 17, 2014

Version 1.5

PI SystemSystem Architecture

Robert Lane

March 17, 2014

Version 1.5

PI WebParts and

DataLink

(SharePoint Server)

PI Interface

Management

TMACSEvaporator

* High Availability may not be implemented due to data center availability requirements by LMSI

eSOMS

HLAN

FIREWALL

PI Coresight Web

PI Notifications


Challenges

24


Challenges

• Concurrent Product Updates

• Work Control Process Resource Availability

• Interfacing with ABB Ind. IT 800xA 5.1

• Multiple input networks

• Multiple naming and data formatting conventions

• Development Network

25


Concurrent Product Updates and/or

Consolidations

• Distributed Control System

• Enterprise Data Historian

• Work Control and Equipment Maintenance

• Document Control

26


Work Control Process Resource Availability

• Interface/Source System Engineer Availability

• Interface Schedule/Work Plan Availability

• Technical Support

– Third Party (LMSI)

– IIS, VM, DBA, Data Center Architects

27


Challenges



• Interfacing with ABB Ind. IT 800xA 5.1 (ongoing)




28


Multiple input networks

29

Data Source Source Architecture Interface Methodology Source Network

Evaporator NovaTech D/3 DCS PI Interface for GSE D/3 DBA ELAN

222S Labs Johnson Controls BACnetPI Interface for Building Automation and Control

Network (BACnet)SLAN

TFMCS ABB Industrial IT System 800xAPI Interface for OPC DA, PI Interface for OPC

HDA, and PI Interface for OPC AETFLAN

HOBO OnSet HOBO Data Loggers Web Service and PI SDK WWW

ABCASH SQLPI Interface for Relational Database (PI RDBMS

via ODBC)HLAN

TMACS SQL PI RDBMS via ODBC HLAN

eSOMS Ventyx eSOMS PI Interface for OPC HDA HLAN

Industrial Health SQL PI RDBMS via ODBC HLAN

TWINS (Output) SQL/.NET PI OLEDB Provider and PI SDK HLAN Enclave

HMS Flat FilePI Interface for Universal File and Stream Loading

(PI UFL)HLAN Enclave

LOW Flat File PI UFL HLAN Enclave


Multiple naming and data formatting conventions

Naming Standard:

Farm Location–System–Component–Identifier

A101-WST-LIT-106

Found:

A01-WT-LT-06

A101-LI-R016-106

A101-WST-LIT-101-06

A01/R16/ENRAF

30

U103-WST-TE-101

U03-WT-TT-01

U103-TI-R019-01

U103-WST-TI-116-01

SP1/Riser19/J Type/TC1


Challenges



• Interfacing with ABB Ind. IT System 800xA Ver. 5.1




31


Results and Benefits

• Productivity (Less time collecting data and more time analyzing)

• Visibility (Easier to get data in front of a decision maker)

• Data Integration (Single Data Repository for all surveillance process data and related info)

• Security (Independent User Access Control)

• Reliability (VM Solution, more stable interfaces)

• Compliance (Easier to verify compliance of data from an automated interface with acontrol system vs. manually collected field readings)

• Quality (Reduced opportunity for human errors)

• Scalability (Not limited by database size, report processing time, or data retrieval

limits)

• Availability (Ubiquitous access)

• Maintainability (Independent Reporting System, Asset Structure, and Data hierarchy)

• Extensibility (Supports collectives and cross firewall communication)

• Expandability (Ease of adding tags or interfaces)

32


Intangible Benefits

• Widely accepted and applauded by decision makers

and end-users alike

• Reduced developer costs

• Reduced time per development/upgrade lifecycle

– Simplified Requirements

– Simplified Documentation

– The scope of a change is proportional to the impacts of the

change

33


Future Plans and Next Steps

• Finish additional data interfaces– Develop an interface with TFMCS (ABB Industrial IT 800xA DCS)

– Develop the more complex interfaces

• Finish Development Network Infrastructure

• Develop new Reporting System (using SSRS and PI Data Access)

• Develop PI Notifications

• Develop PI Event Frames using PI Event Generator

• Finalize the PI Asset Framework database structure

• Import the remaining legacy data

• Install PI Server Collective– Install the Secondary PI Server on independent data center

34


OSIsoft Services

• Field Service

– PI System Installation

– Configuring PI Interface for OPC

DA, OPC HDA, and OPC AE

• TechSupport

– Phone

– Email

– Online

• OSIsoft vCampus

• Enterprise Client Licensing

35

• Training

– Instructor led in San Leandro, CA

• PI System Administrator for IT

Professionals

– Instructor led on-site

• Building PI System Assets and

Analytics with PI AF

• PI Advanced Computing Engine

• Visualizing PI System Data

– OSIsoft YouTube Learning

Channel


ConclusionFrom Maintenance to Production

• How do we get from maintenance to production

operations with a decades long technology gap?

• By providing a Best-In-Class solution to enable

informed decision making.

36


Conclusion Cont.

• A Best-In-Class Solution– What

• Gathers related data

• Supports understanding the problem

• Provides information to make technically sound decisions

– How• Ensure that we have the right information

• Ensure the information is current

• Ensure the users have available access

• Ensure the users can find the information

– Why• To keep the environment, our fellow workers, and the public (our families)

safe

37


• Widely accepted and applauded

by decision makers

• Increased visibility and

availability of information

• Ubiquitous access to process

data

• Reduced time per

development/upgrade lifecycle

Solution Results and Benefits

WRPS: Using the PI System to

Aggregate, Analyze, and

Visualize Data

Business Challenge

• Disconnected and

geographically isolated control

systems, data sources, and

data repositories

• Information for decision making

not available, difficult to retrieve,

or only in printed summary

• Site-wide upgrade effort to

support and supply waste to the

Waste Treatment Plant

• Bring all Information Systems

into a Consolidated Central

Enterprise Historian using the

PI System

Upgrading from decades-old custom-developed solutions

presents many growing pains and challenges that require

innovative solutions to solve. Integrating numerous

custom and COTS standalone solutions to a PI System

Solution allows for a central data repository enabling

levels of analysis, information, and data availability that

were not previously possible.

38

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Robert A. Lane

• [email protected]

• Software Engineer/Computer Analyst

• Washington River Protection Solutions

a contractor to the U.S. Department of Energy

39

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Using the PI System to Aggregate, Analyze, and Visualize Datacdn.osisoft.com/corp/en/media/presentations/2014/UsersConference... · • Process Software Engineering (PSE) ... •