Improving Equipment Availability and Reliability Using the PI System

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Mervyn Boyd
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1 23 September 2011 WESTIN GARDEN CITY, MUMBAI Improving Equipment Availability and Reliability Using the PI System Presented by: Mr. KP Srivastava - Senior Manager UltraTech Cement Limited Unit: Narmada Cement Jafarabad works Copyright 2011 OSIsoft, LLC 1

3 Configuration of PI Network at NCJW Server-1 Server-2 LAN- PCs ( USERS ) Ethernet to OFC converter OFC to Ethernet converter Ethernet Switch 1 Ethernet Switch 2 Ether net swt. PLG server Fire wall PI server QCX server PLC 1 PLC 2 PLC 3 PLC 4 PLC 5 PLC 6 PLC 7

4 Business challenge/problem addressed Process and QC data not available to maintenance and operation team at their workplace. Process and QC data have been available in SCADA or Quality control system server. Operation and maintenance persons has to call to CCR operator for process data and chemist for quality related data. It creates lot of nuisance which leads to mistakes and communications failures. Solution Process and QC data made available to maintenance and operation team at their workplace through PI System ProcessBook application. Copyright 2011 OSIsoft, LLC 4

8 Benefits 1. Plant operation and Quality related data can be view by maintenance crew and operating crew at their work place on their own PC through LAN connection. Process flow diagram can be developed for each section separately and process and quality parameter can be shown in flow diagram for better understanding. 2. Customized screens can be developed by maintenance team to monitor their ownership equipment related data for better maintenance practices and proactive approach. 3. Nuisance to operator and chemist are reduced by minimizing unnecessary communication and chances of error in verbal communication. Copyright 2011 OSIsoft, LLC 8

9 Business challenge/problem addressed 2. There is no way to find process and quality parameter after certain time. Many parameters are required to refer over a period of time for improvement / analysis purpose. SCADA has limitations and it can save historical data for a small period of time. Solution PI Server archived the Data in compressed form and stored the data in large amount for a longer period. We can get each parameter value for every second for last 3 years. It can be view in the form of trend or it can be retrieved in the excel sheet. Copyright 2011 OSIsoft, LLC 9

10 Business challenge/problem addressed 3. There is no way to monitor real time data of other similar unit. We do not have the system to monitor the other unit parameters for comparison for improvement projects. Solution We can monitor real time and authentic data of all the manufacturing units of Ultratech Cement from any one of the manufacturing unit as well as from head office. DataLink is being used to compare data in the excel sheet. Similar units data are taken on excel sheet for comparison for bench marking and improvement projects. Copyright 2011 OSIsoft, LLC 10

11 Case study # 1 Application : Cement Bag Counter and Dispatch Reconciliation Before ( Problem ) 1 Earlier there was no System to reset the counter from site by Dispatch Supervisor(Person of PP operation) 2 Since the end of dispatch on daily basis was not identified at PI, the counts were never used to compare with actual dispatch and so the use of PI for bag counts was not effective. After ( Solution) Provided the Reset switch for counter,taken into PI System and instructed the Supervisor to reset the counter at the end of each date when dispatch of the date is closed. Since the time at which the dispatch is closed is identified at PI, The counts in it can be used for comparison with actual dispatch. 3 The time at which dispatch fininsed changes day to day basis,due to nature of operation and manual truck loading.so counter reading based on time ( ideally at 12.0 night )was never in match with dispatch.( Sample PI Graph enclosed) Even after change of time from sharp 12.0 night, due to operational constraints, the end of dispatch of the date can be identified in PI system and so the bag counts can be compared with actual dispatch. 4 Two bags going simultaneously and counted as one due to less gap between them. This happens sometimes due to misoperation /malfuction at packer The problem is overcome by sensitive photosensor as it can detect even minor gap.( This problem shall not add in effectiveness of Bag counter system as in this condition, the bag counts will be less than the dispatch by number of times such phenomenon happened. Since the counts are less than actual dispatch, the challenge is over, ). The challenge is bag count more than the actual dispatch*20 Copyright 2011 OSIsoft, LLC 11

13 Case study # 2 Equipment name: Crusher H.T. Motor( B7 ) Problem Faced Whenever H.T. motor gets tripped on Thermal Overload, Sometimes it was found that the current value in the SCADA point trend was normal. So it was very difficult to convince the MINES as well as PROCESS dept., that it was an actual tripping due to rise in current value above specified value. Copyright 2011 OSIsoft, LLC 13

15 LIMITATION Point trend of any analog value gets updated in the present SCADA system after every 10 sec. But the delay for Thermal Overload tripping of the crusher Motor is 3sec. So the actual current value at the time of tripping, is some times not recorded. Advantage of PI System Updating time of PI System is 01 sec Resolution of PI System is higher than SCADA system. The ACTUAL Current Value at the time of tripping is recorded in PI. Copyright 2011 OSIsoft, LLC 15

18 Way forward. Connecting PI System with Colony TV Network CCR SERVER ROOM Internal LAN Network TV ROOM WIRELESS LAN Network Internal LAN Network COLONY PI Server 6 Kilometer PI Terminal AGP CARD CABLE NET WORK TV TV MODULATOR Plant Ethernet Network TV PLC 18

20 23 September 2011 WESTIN GARDEN CITY, MUMBAI Improving Equipment Availability and Reliability Using the PI System Presented by: Manu Singh Senior Engineer (Instrumentation) UltraTech Cement Limited Unit: Aditya Cement Works - Shambhupura Copyright 2011 OSIsoft, LLC 20

21 FLS OPC Server PI System Architecture at Ultratech Cement Ltd (Aditya Cement Works Shambhupura ) First Unit to use PI System in Cement Crusher OPC Server CBA OPC Server PI-Server Office LAN- PCs LINE-2 OPC Server EMS OPC Server TPP OPC Server PLC Network Web Clients Office LAN Copyright 2011 OSIsoft, LLC

23 Performance Calculations Logging of Quality parameters Generating process log sheets Logging of Quality lab parameters Run Hours and Batch Counters report Bag Counter and Dispatch report Equipment condition monitoring Daily power and output analysis Shift Operator Performance report Copyright 2011 OSIsoft, LLC

25 Packing Plant Bag Counter Report 10 Nos of PI tags + PI DataLink features makes the report available on a single click, By entering date in a cell, history data can be called. Copyright 2011 OSIsoft, LLC

Example 1 : Condition Monitoring On line monitoring of

28 Example 2 Condition Monitoring On line monitoring of critical parameters ( Historic data ) Kiln - Unit 1 Sl. No PI Tag No Descriptor Eng Unit Alarm 1 Alarm 2 Trip Time of best achieved Best achieved Kiln support Rollers 1 ACS KN TEMP KILN ROLLER1 1 KILN ROLLER BEARING STATION 1 TEMP-1 0C Jan-10 11:42: ACS KN TEMP KILN ROLLER1 2 KILN ROLLER BEARING STATION 1 TEMP-2 0C Jan-10 11:39: ACS KN TEMP KILN ROLLER1 3 KILN ROLLER BEARING STATION 1 TEMP-3 0C Jan-10 11:39: ACS KN TEMP KILN ROLLER1 4 KILN ROLLER BEARING STATION 1 TEMP-4 0C Jan-10 11:39: Kiln main drive & Girth gear 5 ACS KN TEMP KN301 MTR DE BRG KILN MTR 301 DE BRG 0C Mar-10 07:31: ACS KN TEMP KN301 MTR NDE BRG KILN MOTOR 301 NDE BRG TEMP 0C Jan-10 03:09: ACS KN TEMP KN301 GB 1 KILN GEAR BOX TEMPERATURE - 1 0C Jan-10 05:24: ACS KN TEMP KN301 GB 2 KILN GEAR BOX TEMPERATURE - 2 0C Aug-10 16:19: ACS KN TEMP KN301 GB 3 KILN GEAR BOX TEMPERATURE - 3 0C Jan-10 11:39: ACS KN TEMP KN301 GB 4 KILN GEAR BOX TEMPERATURE - 4 0C Jan-10 11:39: Copyright 2011 OSIsoft, LLC

30 FUTURE PLAN RC IV at Karnataka GCR 2 at Raipur KARUR at TN NEW PROJECTS TO HAVE INTEGRATED INFO SYSTEMS FROM DAY 1 Provision of PI-ERP Connectivity Migration to PI 2010 Platform Copyright 2011 OSIsoft, LLC

32 23 September 2011 WESTIN GARDEN CITY, MUMBAI Applying PI System For Improving Process Condition & Process Optimization Presented by: Lalit Pokharana - Senior Engineer (Instrumentation) UltraTech Cement Limited Unit: Kotputli Cement Works,Raj Copyright 2011 OSIsoft, LLC 32

33 Agenda OSIsoft products and services. Overview of Kotputli Cement Works. PI System Architecture at Kotputli Cement Works. PI Utilization as Kotputli Cement Works. Business Challenges & solutions. Examples - Process Optimization. Case Study Process Optimization. Results & benefits. Future Plans. Copyright 2011 OSIsoft, LLC 33

Overview of Kotputli Cement Works MTPD Year Status 10,000 2009 Greenfield plant.

35 PI SYSTEM ARCHITECTURE A B Redundant DCS Servers QCX FIREWALL SWITCH (5000 Tags) PI Server XRF XRD CBA Ethernet LAN Aditya Birla Group Other Units Remote PI Server & Client Client 1 Client 2 Client 3 Client 4...Client n Copyright 2011 OSIsoft, LLC 35

36 PI Utilization At KOTPUTLI Functionalities to cover: Data extraction (interface) Plant configuration and templates manager Reports generation Interfaces to another systems (e.g. QCX,XRF,XRD,FUZZY SYSTEM) Process scope includes: Raw mill Kiln Coal mill Cement mill Copyright 2011 OSIsoft, LLC 36

37 PI Utilization At KOTPUTLI How we use the PI System at our plant PI Clients installed in all maintenance departments Quality, Production, Mechanical, Electrical, Instrumentation & MID. Real time data monitored at Quality Control and Mines department. Monitoring of other cement units process parameters. SMS notification for real time monitoring of plant running status and the PGNAA Data to Mines Department in mines area through SMS :- SiO2=30.66,CaO=29.83, MgO=30.34 K2O =15.20,LSF=29.13,Na2O=29.67 Quality has been one of our priorities Copyright 2011 OSIsoft, LLC 37

38 Business Challenges Correlate quality and operations data. Time to consolidate quality data from lab equipment to mines & process. Incorporate quality data to a real-time platform. Standardize and simplify access to data. Reduction of Total Cost. Reducing Fossil Fuel & Electric Power costs involves efforts from different process areas, with the majority falling on the Cement Making Operations. In addition, a better mix of alternative and fossil fuels could reduce the environmental footprint even more. Copyright 2011 OSIsoft, LLC 38

39 Business solution QCX Mining Crushing CBA Stacking & Reclaiming Raw Meal Milling CBA SIO2 CAO MGO Mines engineers take corrective action without information from QC. PI Notification (SMS ALART) SiO2=30.66,CaO=29.83, MgO=30.34 K2O =15.20,LSF=29.13,Na2O=29.67 XRF Q XRD Q 03/11/2009 Copyright 2011 OSIsoft, LLC 39

40 Results 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 in internal units of grasim. Copyright 2011 OSIsoft, LLC 40

41 Process Optimization Case Study Communication with Central Control room minimized. PI DataLink Helps in breakdown analysis. PI ProcessBook help in real time data monitoring. Effective equipment health monitoring. Huge Databank for analyzing plant behavior in different process conditions. Copyright 2011 OSIsoft, LLC 41

43 Intangible benefits Real-time quality measurement results ensure high-quality cement/clinker production. Production and quality data correlation. Automatically generated notifications at mail & phone(sms). Validated production information; verified data quality; monitoring and reporting of exactly where losses occur; calculation of monthly reconciled recovery. Reduction in total energy consumption. Integrate X-ray(QCX,XRF,XRD) equipment from different vendors. Eliminate risk of technology obsolescence. Copyright 2011 OSIsoft, LLC 43

44 Future plans and next steps Connectivity of PI Server over OPC for : QCX SYSTEM. Thermal Power Plant. Energy Management System. Linking PI data to SAP. Understanding and Implementation of latest OSIsoft products. Copyright 2011 OSIsoft, LLC 44