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Using PI for Reporting

Regional Seminar Series. Using PI for Reporting. Skye Blair and Alan Polk Process Automation Engineers BASF. August 11, 2009. Environmental Applications. BASF – McIntosh Site. Washington County, Alabama Specialty Chemical Manufacturing 800 Employees 1,553 Acres.

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Using PI for Reporting

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  1. Regional Seminar Series Using PI for Reporting Skye Blair and Alan Polk Process Automation Engineers BASF August 11, 2009

  2. Environmental Applications

  3. BASF – McIntosh Site Washington County, Alabama Specialty Chemical Manufacturing 800 Employees 1,553 Acres

  4. OSI PI Installation Base 1 Enterprise PI Server 1 SQL Server 12 Collection Nodes 7 Novatech D3 (VMS) 3 Emerson DeltaV (Windows) 1 Schneider Modicon (Windows) 1 GE iFix (Windows) 39,000 PI Tags

  5. Mon/Mact Compliance What is MON/MACT? MON/MACT requires facilities that utilize Miscellaneous Organic NESHAPs (MON, typically solvents) to provide proof that permissible emission limits have not been exceeded utilizing Maximum Achievable Control Technology (MACT) The burden of proof lies with the facility to prove that emission limits were not exceeded, not on the government. Violations up to $27,500/day Went into effect May 2008

  6. Solution Overview Collect data on applicable sampling points in PI Condition data for Compliance Software Communicate conditioned data to Compliance Software Compliance Software handles alarming and reporting.

  7. Collect Data Data is collected via PI Collection node for any point pertaining to MON/MACT Compliance Temperature of Emission Burning Stacks Flows of Solvent Containing Streams Analyzer content of analyzed streams State of Relief Valve Where PI Collection is not redundant, a stand-alone chart recorder is attached to the sampling point for backup data collection

  8. Conditioning Data Mon/Mact Reporting is based on One Hour Averages Minimum 4 Points/Hour for compliance Data Integrity must be ensured. Data Integrity A Minutes Past the Hour tag was created in all DCS/PCL applications and trended in PI When data is collected over a 1 hour period, the minutes past the hour tag must be collecting over that period, if the tag is not, then communication with the control device has failed, and PI data is not reliable.

  9. Conditioning Data A PI Performance Equation is used to calculate the Rolling 1 Hour Average If data is uncertain, then a 99999 is trended, otherwise, the average is trended. E.g. if tagval('node-u_minutesph','*') = tagval('node-u_minutesph','*-10m') then 99999 else TAGAVG('FT19233A','-1h','*',90)

  10. Compliance Software Stand alone Compliance Software Server located off-site at vendor provided location OPC connection from Enterprise PI Server to Compliance Software Server For all collected points, emission limits are configured in compliance software If limits are exceeded, email notifications are provided Quarterly Reports generated for all excursions.

  11. Utility Applications

  12. Utilities Reporting Plant Structure 7 Production Units Stand alone utilities Stand alone waste water treatment The utilities and waste water treatment are metered to individual production units for transparent cost analysis.

  13. Gathering Data Utility flow data collected by dedicated PLCs in each production unit Data totalized daily in PLC Daily totalized values trended in PI separately from current flow value

  14. Calculation Process Daily totals are imported into Microsoft SQL Totals are run through a set of iterative calculations in SQL to determine where all utilities were consumed during the previous 24 hours SteamTOT = ΣSteamUnit + SteamLoss SteamUnit = SteamUsed + (SteamUsed/ SteamTOT)*(SteamTOT - ΣSteamUnit)Loop until Steam Loss is essentially zero. Results are placed back into SQL and then transferred back to PI

  15. Reporting Process From SQL database, daily utility usage reports are generated which are automatically FTP to ERP systems and imported. Utility Reporting used for billing of cost of production. Utility Reporting can also drive process changes. Waste water usage is transferred to environmental reporting suite.

  16. Future Plans FTP of comma delimited reports is unreliable Dedicated PI-ERP interface for automatic data transfer is planned. SQL database is complex and requires an extra server SQL calculations to be re-written as PI Performance Equations? Performance Equations have limitations Looking into using PI ACE

  17. Questions?

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