PI System Implementation Experiences in Different Industries

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1 PI System Implementation Experiences in Different Industries Presented by László Arany I.T.O ENGINEERING Ltd Copyr i g h t O S Is o f t, L L C.

2 Agenda ITO s Introduction PI as a System Integrator Suggests ITO s PI References 2 Copyr i g h t O S Is o f t, L L C.

3 I.T.O ENGINEERING Ltd. Engineering and System Integration (design, development, delivery, installation, maintenance, support and development): DCS systems SCADA, PLC systems Asset management systems PI PLANT INFORMATION systems 3 Copyr i g h t O S Is o f t, L L C.

4 DCS System MOL US, Algyő: Gas Production Plant Copyr i g h t O S Is o f t, L L C 4.

5 DCS System MOL US, Algyő: Compressor Plants (31 pcs) Copyr i g h t O S Is o f t, L L C 5.

6 SCADA System ANTENNA HUNGÁRIA: TV and Radio Transmitter Control System Copyr i g h t O S Is o f t, L L C 6.

7 SCADA System E.ON KÖGÁZ: Control System of Pressure Reduction Stations (30) Copyr i g h t O S Is o f t, L L C 7.

8 Asset Management System MOL DS, ROMPETROL, (SLOVNAFT): Calibration and Laboratory Subsystem of Special Instruments Copyr i ght O SIs oft, LLC. 8

9 WEB-ENABLED MAINTENANCE MANAGEMENT SYSTEM FGSZ area N FGSZ area 2 FGSZ area 1 FGSZ ZRt. - Intranet Asset Management System Sation 1 RFID tag Station 2 RFID tag gyszm ex PDA (Windows Mobile) PDA (Windows Mobile) WLAN FGSZ WAN Third Party systems: FÉTIS, KAR, SAP CMMS, SCADA WEB clients (Web browser) FGSZ NATURAL GAS TRANSMISSION Station n RFID tag Smart phone (Windows Mobile) Nokia mobil (Micro Java) RFID group, personal ID tags GSM network (GPRS) Firewall PDA dock WEB / RFID server 6 areas 1000 objects System Structure 120 maintenance and operation groups (PDA) 350 Web clients, 60 at the same time I.T.O. Engineering Kft. Copyr i g h t O S Is o f t, L L C 9.

10 PI as a System Integrator Suggests ITO as PI Distributor and SI Partner since 1996 PI: What? PI: Where? PI: To whom? PI: Why? RESULT: LIKE A MOBILE PHONE, ESSENTIAL 10 Copyr i g h t O S Is o f t, L L C.

11 Enterprise PI System Plant group Plant Unit Loop Process Control Systems Business systems, Applications Plant Information System PI What? Where? Sec. Min. Hour Day Week Month Year Copyr i g h t O S Is o f t, L L11 C.

12 IT Monitor KPI Logistic LIMS PI System Operation Maintenance Development PI Process Investigation To whom? Production Accounting Environment protect. Planning Yield Investigation Copyr i g h t O S Is o f t, L L12 C.

13 Process Improvement Priorities Regulatory compliance PI System 20% Acquisition of time series data from the plant floor 15% Aggregation of data from multiple plant floor sources Multi-site performance analysis PAT (Process Analytical Technologies) 11% 10% 13% Why? Multi-site aggregation of data from production assets Production management visibility of KPIs Enterprise visibility of production financial performance Centralized repository for multi-site data 8% 8% 7% 7% AMR Research Copyr i g h t O S Is o f t, L L13 C.

14 Employees get 50%-75% of their relevant information directly from other people. PI System More than 80% of enterprise's digitized information reside in individual hard drives and in personal files. Why? Individuals hold the key to the knowledge economy and most of it is lost when they leave the enterprise. Copyr i g h t O S Is o f t, L L C.

15 Planning Reporting & Analytics Supplier Management Supplier Collaboration Strategic Sourcing eprocurement Warehouse Management Supply Planning Human Resources Procurement Inventory Control Network Design Data Warehouse IT Core Transactions Manufacturing Planning Contract Manufacturing Management SCADA Demand Planning Custom Query and Reporting Manufacturing Execution System Transportation and Distribution Planning Finance Order Management Fulfillment Plant Maint. Customer Management Customer Collaboration Customer Service Sales and Marketing Warehouse Management DILEMMA Manufacturing Execution Transportation Mngt & Exec. PI System Why? Regulatory Compliance Change Cntr Training Mngt -TBD Batch Record Management Document Management Tracking & Trending Compliance Management QC Data Collection LIMS Quality Control CAD Engineering Project Management Document Management Design & Simulation Process Science Product Lifecycle Management LIMS Clinical Supplies Clinical Supplies Systems Copyr i g h t O S Is o f t, L L15 C.

16 Copyr i g h t O S Is o f t, L L16 C.

17 ITO s PI references: delivery, application development, system integration, training, support MOL DS, Danube Refinery: TAG, SIGMAFINE, >20 interfaces, ~ 350 clients MOL US, Algyo: TAG, 6 interfaces, ~ 35 clients MOL US, Hajduszoboszlo: TAG, 2 interfaces, ~ 25 clients MOL US, Kiskunhalas: TAG, 6 interfaces, ~ 25 clients MOL US, Kardoskut: 5000 TAG, 2 interfaces, ~ 15 clients MOL US, Gellenhaza: 5000 TAG, 2 interfaces, ~ 15 clients MOL headquaters: Szolnok, Budapest: ~ 10 clients Dunamenti Power Plant (Electrabel): 5000 TAG, >15 interfaces, ~ 30 clients E.ON Foldgaz Storage/MFGT: TAG, 6 interfaces, ~ 30 clients Slovnaft, TAG, SIGMAFINE, 4 interfaces, ~ 350 clients (50 concurrent ones, web type) TVK Power Plant, Tiszaujvaros: 5000 TAG, 1 interface, 1 client (SIEMENS delivery) E.ON Nyiregyhazi Power Plant: 1000 TAG, 1 interface, 2 clients (Emerson delivery) Magyar Horizont Energia: 1000 TAG, 6 interfaces, ~10 clients MMBF: 8000 TAG, 3 interfaces, 10 clients MVM-GTER: Embedded PI in GE DCS system (GE delivery) Copyr i g h t O S Is o f t, L L17 C.

18 Üzemi KTIR kliensek CC2, C2 FIX, PI-FIX I/F CC2 Ethernet Üzemi PI kliensek Algyő PI információs rendszerének felépítése (tervezett és javasolt) Kompresszor üzemóra Router NF DIMS Novell szerver NF üzem ROS Olajmérleg RS3-RNI KTIR ÜB-SQL szerver EE, DD ROS Ethernet PI kliensek RS3-RNI ROS SZOLNOK IT-SQL szerver PI-RDBMS I/F E, LTEX, D ü. olaj. Fisher-Rosemount Peerway MOL WAN ROS RS3-RNI NetBuilder Ügyviteli busz (Ethernet, IPX, TCP/IP) 2 db PI-RS3 RNI I/F RS3-RNI RS3-RNI PI szerver Labor hálózat Irányítástechnikai busz (Ethernet, TCP/IP) FIX, PI-FIX I/F E-10 FIX, SQL Szintmérő rendszer ENRAF E-10 diszpécser LIMS szerver SZG-1,..6 Ferencsz. Üllés Kiskundor. Maros-1 gt. PI egyedi I/F (SZEAK épület) Labor EXCEL bevitel FIX, PI-FIX I/F 3 db FIX Vasúti és közúti (SQL) terméktöltő PI System MOL US, Algyő Algyő olaj Olajdiszpécser Algyő gáz "0 pont" EE, DD üzem E üzem LTEX üzem D üzem, BSB U R H E-10 mérésadatgy. SIEMENS 135U Atm. PB tároló U R H FIU (3 db) Meződiszpécser (NF épület) LGA ifix, PI-FIX I/F ifix U R H Kénmentesítő DeltaV DeltaV MOTOROLA MOSCAD Ethernet Olajgyűjtő tankállomások, Főgyűjtő SZT1-11 MOSCAD, DeltaV M O D B U S DD ü. adatkonc. FIX, PI-FIX Ethernet EE-D techn. FIX D hűtő, műszerlev. FIX Fáklya SCAN 3000 (S9000) (2 db) EE-D, DD hűtő FIX TeleGyr DataServer (MS SQL Server) PI-RDBMS I/F SWTICH EFIR munkaállomások MULTISWITCH2000 SWITCHING HUB Rev.1 EFIR Vill.Energ. EFIR PI kliens 2. sz. melléklet I.T.O. ENGINEERING Kft Copyr i g h t O S Is o f t, L L18 C.

19 PI System MOL US, Algyő Copyr i g h t O S Is o f t, L L19 C.

20 PI System MOL/EFS/MFGT: UGSs Demo data Copyr i g h t O S Is o f t, L L20 C.

21 Turn-key project: EPC: design development commissioning Project time: 6 moths Modification in the DCS, etc. systems > 20 data connections All power station I/O measurements: oil, gas, steam, water, generated power, power generation timetable (setpoints), emission, imission PI System Dunamenti Power Copyr i g h t O S Is o f t, L L21 C.

22 Turn-key project: Collecting all important process I/O values Dispatching system based on PI system Existing reports Manual data entry Data validation Production accounting Technical calculations Complex reports KPIs Flexible, open TOOL for nearly everything PI System Dunamenti Power Copyr i g h t O S Is o f t, L L22 C.

23 All-in-One: DCS/SIS PI AMS/RFID ITO parts (under OLAJTERV and EMERSON): Design all systems DCS: application development PI: EPC RFID subsystem of AMS: EPC PI System MMBF, Szőreg: UGS Copyr i g h t O S Is o f t, L L23 C.

24 PI and SIGMAFINE System MOL US: Integrated Yield/Production Accounting System Copyr i g h t O S Is o f t, L L24 C.

25 PI at More than just dessert! Copyr i g h t O S Is o f t, L L C. 25

26 László Arany Managing Director I.T.O ENGINEERING Ltd Copyr i g h t O S Is o f t, L L C. 26

27 Brought to you by Copyr i g h t O S Is o f t, L L C.

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