Getting More Value with the PI System Over Time at RHI Presented by Neha Jain
Refractories indispensable for basic industry 2
RHI at a glance Sales Production Headquarters Technology centre Mines and raw material production Production site under construction Key facts Focus on production, sale and installation of high-grade refractory products 2013: Revenues of 1,745.7 and EBIT of 111 million/ 2012: Revenues of 1,835.7 million and EBIT of 167.6 million 33 productions sites and more than 70 sales and service sites roughly 8,100 employees Global partner for over 10,000 customers in more than 180 countries Technology leadership with close to market R&D facilities and tailor-made products Selected key customers Steel Cement Glass Nonferrous 3
Processes where PI System is implemented 4
Evolution of PI System at RHI Process visualisation PI ProcessBook Process analysis PI DataLink Key figures, Process Optimisation Process comparison & benchmarking PI Asset Framework 5
PI System Users @ RHI More than 22 production facilities More than 300 users across the globe 8 Global Admins Central Support PI System Application Ideas and experiences IT Know how Process Know how Production Plants Requirement and experiences Process Know how PI System Application IT Know how 6
Visualization of fast processes Enables visualisation of fast processes in real time & historical Process cycle 10-20 seconds Previously not possible 7
Visualization of slow processes Mixer visualisations PI Performance Equations deliver information which otherwise could not be seen 8
Improved mix quality using PI Systems Increasing the process stability with the help of better control of the process 5% cycles outside of before control limits Statistical formulae based on PI System analysis regulate the process after 9
Brick thickness Optimized pressing using PI System PIMS as tool to Locate the press that needs optimisation Search the cause Control the effectiveness of the employed corrective measures 10
Pressing pressure Comparison between production plants Differences in the pressing philosophy 2 Plants same total cycle time Difference in: De-aeration step Pressing time and speed Reasons Benefits Drawbacks 11
Comparison between products Presses cycle time per article Articles Deviation of 5-10 sec. within one article! Reduced cycle time, increased productivity 12
Reduced reaction time with PI Notifications Safety at high temperature furnaces, critical processes Timely maintenance Preventing critical data loss 13
PI Asset Framework for efficient navigation Standardize process and quality variables Overcoming the language barrier 14
Business Impact $$ Optimized burner settings Reduced gas consumption ENERGY MANHOUR Automatic data archiving Replaced manual data entry Mixers, presses, kilns Current consumption Personnel safety Time saving SUPERVISION Supervision of hard to access areas like chimneys MAINTENANCE Performance and wear based maintenance Substitute fixed time maintenance Robots, ball mills, presses 15
Summary Improved visibility Process data availability Standardization of production processes Reducing reaction time Continuously on a look out for new applications and benefits e.g. PI ANALYTICS 16
Neha Jain neha.jain@rhi-ag.com Getting More Value with the PI System Over Time at RHI RHI AG 17
Questions Please wait for the microphone before asking your questions State your name & company 18
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