Improving Equipment Availability and Reliability … Equipment Availability and Reliability Using...

© Copyright 2011 OSIsoft, LLC 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

Agenda

2

* PI system in UTCL-NCJW plant network * Specific Utilization of various PI utilities * Latest Development * Problems and Limitations

PI server

Server-1 LAN- PCs ( USERS )

Configuration of PI Network at NCJW Server-2

PLG server

Ethernet Switch 1

Ethernet Switch 2

QCX server

PLC 1 PLC 7 PLC 6 PLC 5 PLC 4 PLC 3 PLC 2

Fire wall

Ether net swt.

Ethernet to OFC

converter

OFC to Ethernet converter


Business challenge/problem addressed

4

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.


Screen developed by maintenance crue


Process view of kiln


Process view of Coal Mill


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.


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.



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.

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.

Solution


Case study # 1

11

Application : Cement Bag Counter and Dispatch Reconciliation

Before ( Problem ) After ( Solution)

1 Earlier there was no System to reset the counter from site by Dispatch Supervisor(Person of PP operation)

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.

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.

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


Cement Bag Counter recorded in PI with reset

12


Case study # 2

13

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.


• 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.


NCJW CRU & REC CURRENT LS CRSHR MOT B7

A

Ad-Hoc Trend

7/27/2008 8:00:00 PM 7/27/2008 11:00:00 PM3.00 hours

10

20

30

40

50

0

6017.859


Manual Data entry for QC parameters

18

Connecting PI System with Colony TV Network

Plant Ethernet Network

Internal LAN Network

PLC

PI Server PI Terminal

CCR SERVER ROOM TV ROOM

MODULATOR

TV

TV

TV

CABLE NET WORK

COLONY

Way forward….

WIRELESS LAN Network Internal LAN Network

AGP CARD

6 Kilometer



Improving Equipment Availability and Reliability Using the PI System

UltraTech Cement Limited Unit: Aditya Cement Works - Shambhupura

Presented by: Manu Singh – Senior Engineer (Instrumentation)


PI-Server

Office LAN- PCs

PLC Network Office LAN

FLS OPC Server

Crusher OPC Server

CBA OPC Server

LINE-2 OPC Server

EMS OPC Server TPP OPC Server

Web Clients

First Unit to use PI System in Cement

PI System Architecture at Ultratech Cement Ltd (Aditya Cement Works Shambhupura )


PI ProcessBook Application

PFCC Cooler Status monitoring


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

Performance Calculations


Logging of Quality Lab Parameters


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.


Manual Discharged Bag Counter Report

• Helps while maintaining and achieving six- sigma level • History data can be called by altering date Excel formula


2

On line monitoring of critical parameters ( Current data )

Example 1 : Condition Monitoring


Kiln - Unit 1

Sl. No PI Tag No Descriptor Eng

Unit Alarm 1 Alarm 2 Trip Time of

best achieved

Best achieved 1 2 3

Kiln support Rollers

1 ACS KN TEMP KILN ROLLER1 1

KILN ROLLER BEARING STATION 1 TEMP-1 0C 55 68 13-Jan-10

11:42:39 41.5 45.6 47.1 45.9



11:39:56 31.7 43.1 44.1 41.6



11:39:56 33.3 43.2 45.8 42.8



11:39:56 34.9 48.7 48.4 47.9

Kiln main drive & Girth gear

5 ACS KN TEMP KN301 MTR DE BRG KILN MTR 301 DE BRG 0C 75 95 08-Mar-10

07:31:48 40.5 49.3 49.4 48.1

6 ACS KN TEMP KN301 MTR NDE BRG

KILN MOTOR 301 NDE BRG TEMP 0C 85 95 14-Jan-10

03:09:28 40.2 62.1 62.3 59.2

7 ACS KN TEMP KN301 GB 1 KILN GEAR BOX TEMPERATURE - 1 0C 75 90 10-Jan-10

05:24:30 52.2 60.1 57.8 55.4

8 ACS KN TEMP KN301 GB 2 KILN GEAR BOX TEMPERATURE - 2 0C 75 90 07-Aug-10

16:19:43 47.6 45.3 44.0 42.5


11:39:56 58.5 62.0 61.9 59.8


11:39:56 58.7 64.6 64.9 63.6

On line monitoring of critical parameters ( Historic data ) Example 2 Condition Monitoring


CONCLUSIONS


RC IV at Karnataka GCR 2 at Raipur KARUR at TN

Migration to PI 2010 Platform

Provision of PI-ERP Connectivity

NEW PROJECTS TO HAVE INTEGRATED INFO SYSTEMS FROM DAY 1

FUTURE PLAN



Applying PI System – For Improving Process Condition & Process Optimization

UltraTech Cement Limited Unit: Kotputli Cement Works ,Raj

Presented by: Lalit Pokharana - Senior Engineer (Instrumentation)


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.

Agenda


Overview of Kotputli Cement Works

We are committed to Green, Clean and Safe environment.

PI SYSTEM INSTALLED IN THE

2011 JAN.

MTPD Year Status 10,000 2009 Greenfield plant.


PI SYSTEM ARCHITECTURE

PI Server FIREWALL

Redundant DCS Servers

SWITCH

A B

Client 1 Client 2 Client 3 Client 4……… ...Client n

Ethernet LAN

Aditya Birla Group Other Units Remote PI Server & Client

QCX

(5000 Tags)

XRF XRD CBA


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

PI Utilization At KOTPUTLI


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


•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.

Business Challenges


Business solution

39 03/11/2009

CB

A

Mining

Crushing Stacking & Reclaiming

Raw Meal Milling

Q XRF

SiO2=30.66 ,CaO=29.83, MgO=30.34 K2O =15.20,LSF=29.13,Na2O=29.67

Q XRD

CB

A

SIO2 CAO MGO

PI Notification (SMS ALART)

Mines engineers take corrective action without information from QC.

QCX


Results

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• 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.


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.


Process Optimization Report


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.

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Future plans and next steps

44

• 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.


Questions

45

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