Transcript PI at Pan Pac Pulpmill

PI at Pan Pac Pulpmill
James Bell and Roger Jones
OCEANIA
TECHNOLOGY
SEMINAR
2008 2008
OCEANIA
TECHNOLOGY
SEMINAR
© 2008 OSIsoft, Inc. | Company Confidential
© 2008
© 2008
OSIsoft,
OSIsoft,
Inc. |Inc.
Company
| Company
Confidential
Confidential
INTRODUCTION
• Introduction to Pan Pac Pulpmill
• Describe use of PI at Pac Pac
• Electricity Market Interfacing
• Future values in PI
• Other Interfaces
• Redundancy
– PI Server
– Interfaces
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Pan Pac Pulpmill
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Forest Owner and Forest Product Manufacturer
Operational since 1973
100% Japanese owned
All pulp sold to Shareholder, Oji
Pulp Capacity 260,000T
Revenue > 250m
• Thermo-mechanical process
– 80MW peak load. Annual usage ~2% NZ power
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PI Background
• 5000 tag system operational since November 2001
• Upgraded to 10,000 tags in 2004
• Upgraded to 15,000 tags in 2007
• Operating PI Professional Server (HA) with PI-ACE
• Interfaces
– OPC
– RDBMS
– HTML
– PerfMon
– SNMP
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PI Background
Standardising Control Systems
– Started with many
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ABB AC800
ABB AC410
Allen Bradley PLC network
Rosemount RS3 (RNI interface)
Bailey
– Changing major control systems to DeltaV
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PI Background
Standardising Control Systems
– Now we have:
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ABB AC800
ABB AC410
Allen Bradley PLC network
Rosemount RS3 (RNI interface)
Bailey (interface via DeltaV)
DeltaV
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System overview
Internet
Corporate LAN
Firewall
RDBMS
ACE
Perfmon
HTML
SNMP
COMIT
Web Services
Weather Station PC
Firewall
PIServer1
(Primary)
Particulate
Monitor
PI ACE
PIServer2
(Secondary)
Control LAN
Cooling Tower
Control System
GE Multilins
PLC Network
ABB OPC Server
PIControl1
DeltaV OPC Server1
PIControl2
PIRefining
DeltaV OPC Server2
DeltaV LAN
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PI at Pan Pac - Electricity
Electricity is significant to our business
– Electricity makes up ~40% of product cost
– Annual Power bill $30M to $40M
• Electricity Data Interfacing
– HTML interface
– Web services
– Comit interface built for Pan Pac
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HTML interface
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New electricity market load charge system in July 2007
– Regional coincident peak demand (RCPD)
– Highest 100 ½ hour peaks for lower North Island
– Occur in winter, June to August
– Cost >$60,000/MW.pa. Potential cost >$4.5M pa
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Reduce load in the “100 peaks”, significant savings possible
Problem:
– Forced on industry with little warning (applied retrospectively)
– Web based RCPD load data not available until 24 June 2007
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Discovered free website
– Possible to estimate RCPD
– 5 minute update (better than official information)
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HTML interface
• Solution - HTML interface (Web scraper)
• Strips text off web
• Issues
– No control of websites
– Only HTML
• Shut plant at right time
• Saving >$2M in 2007/08
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Web Services
• Web Services
• ACE gets Web Service Data
• Web Service supplied by EM6
– Scada
– RCPD on trial
– One minute updates
PI ACE
Web Service
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Comit Interface
• COMIT
– A custom interface by OSIsoft NZ
– Two step process
• WebFetch queries website and returns csv file
• COMIT interface processes csv and sends data to PI
WebFetch
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COMIT Interface
PI
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Future Data
• Electricity Market
– Provides forward prices (up to 4h in future)
• Used for decisions on plant operation
– Need to see future data
• Workaround 1
– ProcessBook VBA
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Future Data
• Workaround 2
– Writing week-ahead interruptible load market offers
• We send data to PI with timestamps –365d!
• Custom PB display for operators
Future SIR Bids
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(ignore year)
M:IR.BID.Future.30m.MWh
20.00
MW
70
60
50
40
30
20
10
0
12-Apr-07 10:21:21.17
7.00 days
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Interface to Proprietary Device
• Particulate Monitor (Air Quality) –
proprietary device
• Problem: no comms to device, manual
download required
• Solution! Serial to wireless Ethernet + PI
ACE
• Using VB.NET, send command, return
data
• Now we can alarm on breach, and
monitor with ease
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Air Quality
160
80
30
-20
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More options…
Cooling Tower Control System
– Required Modbus TCP/IP interface, for 9 points!
• Workaround
– Use third party Modbus TCP/IP to OPC Server
(cheap!)
– Use existing OPC Interface Node to get data into
PI
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Redundancy
• We heavily rely on PI
• PI critical to operations-$1000 decisions often every ½ hour
• 3 Points of Failure PI Server, PI Interface, OPC Server
• Interface level failover
– OPC Interface level failover to DeltaV OPC Server
– It works! We never lose data from DeltaV due to Interface shutdown
• OPC server level failover
– Single DeltaV OPC server was largest risk for data loss
– Now dual OPC servers are used, failover is in place and has already
prevented data loss from OPC server failure
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Redundancy - HA
• High Availability
– Installed PI Server PR1 (HA)
– Primary and Secondary PI Servers
• Good Stuff
– Server Maintenance
– Seamless failover
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Issues with HA’s Buffer sub-system
Recalculation-can’t overwrite an existing value
• We use preliminary results before recalc on final
values
• Delivery of fix Oct 2007, we could have used different
method but decided to wait for fix …..but still no
patch release.
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Issues with HA’s Buffer sub-system
• Our custom interfaces don’t use Buffer SS = no data to
Secondary Server
• Manual data entry = no data to Secondary Server
• Fallback to Primary PI Server
– HA clients (PB, DL) don’t ‘fallback’ to Primary
when it becomes available
– With the above missing data this can mean users
don’t see all data until reconnection to Primary
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Looking to the Future
• PR2 looks like it will resolve most of the
issues we have.
• Future data in PI will be great!
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