© 2008 OSIsoft, Inc. | Company ConfidentialOCEANIA TECHNOLOGY SEMINAR 2008OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

© 2008 OSIsoft, Inc. | Company ConfidentialOCEANIA TECHNOLOGY SEMINAR 2008

PI at Pan Pac PulpmillPI at Pan Pac Pulpmill

James Bell and Roger JonesJames Bell and Roger Jones

2OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

INTRODUCTIONINTRODUCTION• 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

3OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

Pan Pac PulpmillPan Pac Pulpmill• 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

4OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

PI BackgroundPI 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 BackgroundPI Background

Standardising Control Systems

– Started with many

• ABB AC800• ABB AC410• Allen Bradley PLC network• Rosemount RS3 (RNI interface)• Bailey

– Changing major control systems to DeltaV

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PI BackgroundPI Background

Standardising Control Systems

– Now we have:• ABB AC800• ABB AC410• Allen Bradley PLC network• Rosemount RS3 (RNI interface)• Bailey (interface via DeltaV)• DeltaV

7OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

System overviewSystem overview

PIServer1(Primary)

PIServer2(Secondary)

Internet

PIControl1 PIControl2

PI ACE

Firewall

Corporate LAN

Control LAN

Firewall

PIRefining

DeltaV LAN

DeltaV OPC Server1DeltaV OPC Server2

ABB OPC ServerPLC Network

GE Multilins

Cooling TowerControl System

Perfmon

HTML

COMIT

Web Services

SNMP

ACE

Weather Station PC

RDBMS

ParticulateMonitor

8OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

PI at Pan Pac - ElectricityPI 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

9OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

HTML interfaceHTML interface• 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

• 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

• Discovered free website

– Possible to estimate RCPD

– 5 minute update (better than official information)

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HTML interfaceHTML 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 ServicesWeb Services• Web Services

• ACE gets Web Service Data

• Web Service supplied by EM6– Scada– RCPD on trial– One minute updates

Web Service

PI ACE

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Comit InterfaceComit 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

COMIT Interface PIWebFetch

13OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential

Future DataFuture 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 DataFuture Data

• Workaround 2– Writing week-ahead interruptible load market offers

• We send data to PI with timestamps –365d!• Custom PB display for operators

M:IR.BID.Future.30m.MWh

MW

Future SIR Bids - (ignore year)

12-Apr-07 10:21:21.17 19-Apr-07 10:21:21.177.00 days

10

20

30

40

50

60

0

7020.00

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Interface to Proprietary DeviceInterface 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

Air Quality

30

80

-20

160

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More options…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

• Support OSIsoft!

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RedundancyRedundancy• 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 - HARedundancy - HA

• High Availability– Installed PI Server PR1 (HA)– Primary and Secondary PI Servers

• Good Stuff– Server Maintenance– Seamless failover

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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.

Issues with HA’s Buffer sub-systemIssues with HA’s Buffer sub-system

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Issues with HA’s Buffer sub-systemIssues 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 FutureLooking to the Future

• PR2 looks like it will resolve most of the issues we have.

• Future data in PI will be great!