Using Real-Time Data to Achieve Sustainability Excellence
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Using Real-Time Data to Achieve
Sustainability Excellence
Presented by: Andrew Fanara and Gary Wong
October 13, 2011
2 © Copyr i g h t 2011 OS Is o f t , LLC .
Contact Information
Andrew Fanara
afanara@osisoft.com
Gary Wong
gwong@osisoft.com
3 © Copyr i g h t 2011 OS Is o f t , LLC .
Today’s Topics • Why an infrastructure to collect real time data and
events should anchor the foundation of every
sustainability strategy.
• Why sustainability is a data rich opportunity and
challenge?
• Lessons and principles learned over 3 decades
leveraging an infrastructure to gain business value.
• Diverse industry examples demonstrating various
ways in which data is core to business sustainability.
• Challenge the mantra “you can’t manage what you
don’t measure.”
© Copyr i g h t 2011 OS Is o f t , LLC . 4 4
Published: April 23, 2011
When There’s No Such Thing As Too Much Information
“Today’s organizational judgment is in the midst of a fundamental change – from a
reliance on a leaders “gut instinct” to increasingly data based analytics”
Strength in Numbers: How Does Data-Driven Decision Making Affect Firm Performance., Brynjolfsson,
Hitt, Kim. April, 2011.
© Copyr i g h t 2011 OS Is o f t , LLC . 5
Reporting Drives the Need for
Timely, Accurate Information
© Copyr i g h t 2011 OS Is o f t , LLC . 6
Experience Across Diverse Industries
Utilities supply the electrical energy and water
infrastructure society cannot function without.
Oil and gas supply the energy source for many uses.
Very important in transportation
Strong, light-weight polymers and fibers required for efficient
transportation, renewable generation and many other
structures.
Extremely important for quality of life. Natural resources saved
through disease prevention and cure.
Fundamental to the modern infrastructure. Mechanical
structures, electrical conductors, catalysts.
True renewable resource. Very important to packaging and
communication.
Data and transactions for the information-driven economy.
© Copyr i g h t 2011 OS Is o f t , LLC . 7
Calgary, Alberta
San Leandro, CA
Phoenix, AZ
Houston and
Longview,TX
Perth, Australia
Singapore
São Paulo,
Brazil
Tokyo Seoul
(AID)
Manama, Bahrain
Shanghai
China
Montréal, Québec
Philadelphia, PA
Mayfield Heights, OH
Johnson City, TN
Savannah, GA
OSIsoft Offices
Mexico
Tech Support Centers
Durban
South Africa
Serving Customers Across the Globe
OSIsoft Offices – in development
Madrid Beijing
Moscow
London
Paris
Frankfurt
Ostrava, CR
Sydney, Australia
India (2011)
Toronto (2011)
Chile (2011)
© Copyr i g h t 2011 OS Is o f t , LLC . 8
Helping Organizations to Meet Their Sustainability Goals
9 © Copyr i g h t 2011 OS Is o f t , LLC .
Alcoa’s Keys to Sustainability
> Leadership, scorecards, roadmaps,
compensation, transparency and data
"One of the things we saw when we went after our CO2 goals, is we used
technology to give the guy or girl on the shop floor better data and faster data so
they could make real-time changes to the processes. This gave us lower energy
costs, lower carbon footprint and typically a higher output.“
Kevin Anton
Vice President
Chief Sustainability Officer
Alcoa
© Copyr i g h t 2011 OS Is o f t , LLC . 10
The OSIsoft PI System
The OSIsoft PI System is a highly scalable and secure
real-time data and event infrastructure that connects the
right people with the right operational and manufacturing
information to make fact based decisions that drive
collaboration and innovation throughout the enterprise.
The Partner Ecosystem
11 © Copyr i g h t 2011 OS Is o f t , LLC .
What is an Infrastructure?
• Valuable – delivers a recognized
benefit
• Reliable & Secure – always
available, safe & trusted
• Accessible – Bring business silos
together, easy to use
• Scalable – Expandable across
enterprise
• Contextual - organized to be
effective, efficient, and extendable
• Enables – other applications &
technologies Transportation
Communication Power
Water
12 © Copyr i g h t 2011 OS Is o f t , LLC .
> 400 Interfaces to Collect Data
Interfaces connect to hundreds of different sources out-of-the-box
to measure and aggregate a broad range of data types
• Handle both time-series data and events
• Secures the access and transmission of the data
• Can read or write multiple servers and collectives
• Auto Point Synchronisation with data sources
• Data collection redundancy and high availability
Data Types
CONNECT
© Copyr i g h t 2011 OS Is o f t , LLC . 13
Why is an Infrastructure a Foundation for Sustainability?
PUMPS VALVES TRANSMITTERS OTHER TRANSFORMERS MOTORS
LAB MANUAL DATA
CONTROL
SYSTEMS OTHER DIAGNOSTICS DATABASES
HEx
BUSINESS SYSTEM
BUSINESS GATEWAY
INTERFACES
PI System
Performance
Availability
Security
Real-time Infrastrucure for Monitoring
Maintenance Team
Process Unit Managers
I&C
Laboratory
Operators
Plant IT
Operational Excellence
Production Excellence
Plant Maintenance
Engineering
R&D
Quality
Executives
Plant Management
Asset Management
Finance
SCO
HSE, QM, IT
INFORMATION
FLOW
MONEY
FLOW
MATERIAL
FLOW
ACTUATORS
© Copyr i g h t 2011 OS Is o f t , LLC . 14
OPTIONS
An Infrastructure is a Foundation for
Real-time Decision Support
PROCESSING PLANT UTILITIES PROCESS UNITS OFFSITES
Co
nse
qu
en
ces
ACTION Realization
Busin
ess
Decis
ion
DECISION Decision
Making
!
VALUE PROFIT
Busin
ess D
ata
ORIENTATION Decision
Support
?
External
Data
BUSINESS SYSTEM
PR
OD
UC
TIO
N D
AT
A
AC
TIO
NS
RELIABLE
DATA
ACTIONABLE
INFORMATION
Capability to
UNDERSTAND
the Problem
PROFITABLE,
DECISIONS
Capability
to ACT
Real-time
Infrastructure
INFORMATION
FLOW
MONEY
FLOW
MATERIAL
FLOW
DECISIONS
© Copyr i g h t 2011 OS Is o f t , LLC . 15
The Granularity of Real-time Data 10 Minute Averages = Missed Events
SCADA Data (10-minute average)
PI System Data (1-3 seconds)
© Copyr i g h t 2011 OS Is o f t , LLC . 16
An Infrastructure to Span the Enterprise
Real-Time Data
Batch Data
Relational Data
Quality Data
Manual Data
Structure/Asset Data
Web Data
Applications Data
Maintenance Data
ERP Data
Across the Value Chain Across the Infrastructure
Exploration Production Gas & Liquid
Pipelines
NGL &
LNG Refining Chemicals
Distribution & Marketing
Alternative Energy
R&D Data
Centers IT Infrastructure Trading
1000’s of different real-time data sources and associated interfaces that propagate through the automation space
Real-time applications
Operations Monitoring
Asset Optimization
Energy Management
Maintenance Management
(CBM)
Business Intelligence tools
Business Systems
Agnostic
Real-time
Infrastructure
Enterprise
Region
Territory
Plant
Unit
MACHINE
© Copyr i g h t 2011 OS Is o f t , LLC . 17
PERTAMINA’s Downstream Supply Chain
BITUNG
SABANG
KRUENG RAYA
LHOK SEUMAWE
UP. I - PKL. BRANDAN
LAB. DELI
SIAK
MEULABOH
SIBOLGA
G. SITOLI
TT. TLK. KABUNG
BENGKULU
JAMBI
PANJANG
P. NATUNA
P. BATAM
SEMARANG
SURABAYA
CAMPLONG
MENENG
TT. TLK
MANGGIS
AMPENAN BIM
A
BADU
NG REO
EN
DE
WAINGA
PU
MAUMERE
L.
TUKA
KALABAHI
ATAPUPU
DILI
KUPANG
SAUMLA
KI
DOBO TUAL
FAK - FAK
NABIRE
MERAUKE
JAYAPURA
BIAK
SER
UI
MANOKWARI
SORONG
BULA
MASOHI
NAMLE
A
SANANA
PABUHA
UP. IV CILACAP
PONTIAN
AK
SINTANG
SAMPIT
CILIK
RIWUT
PKL.BUN
P. PISANG
BANJARMAS
IN
BALIKPAPAN
SAMARINDA
TARAKAN
TOLI - TOLI
MOUTO
NG
DONGGALA
PARIGI
POSO
GORONTALO
KOLONDA
LE
PALO
PO
TAHUNA
KOTA
BARU
PARE -
PARE
P. SAMBU
TT.
TG. GEREM/MERAK
BONTAN
G
PLUMPA
NG
UP.VI
BALONGAN
LUWUK
KENDARI
KOLEKA
RAHA
BAU -BAU UJ.
PANDAN
G
SUBUNG
TT. WAY AME
TOBELO
TERNATE
BANGGAI
KALBUT
IMPORT
T. SEMANGKA
• 6 Refineries:
1,034 Million
bbl/day
• 120 + Depots
• 98 Vessels
• 3,400 Fuel
Stations
• Sales Volume:
1,200 Million
bbl/day
(92% Market
Share)
Assets: One of the most complex
Downstream Supply Chains
in the world
© Copyr i g h t 2011 OS Is o f t , LLC . 18
Process Control & Automation Systems
(PLC,SCADA,)
Scrubber
Control
Cast House
Control
Bake Fire
Control Bath
Handling
Green Mill
Control
Pot
Lining
Rectifier
Station
Utility
Control Environment
Monitoring
Crucible
Cleaning
Raw
Material
Handling
Pot Control
Laboratory and Materials Equipment testing Systems
EHS Management
•Waste Mgmt
•Air Performance
•Asset Monitor
•Confined Space
Maintenance
•Predictive Maintenance
•Condition Monitoring
Production Management
•Quality & Performance
•Resource Mgmt
•Raw Materials
• Inventory
Enterprise EHS Mgmt
•Compliance & Task Mgmt
• Incident
•Occupational Health
Enterprise Asset Mgmt
•Maintenance WO
•Engineering Drawings
•Parts Inventory
Enterprise Commercial
•Customer Orders
•Purchasing
•Energy Management
Plant Intelligence
Enterprise
Financial Mgmt
• Ledger
• Capital
• DIs
Enterprise
HR Mgmt
• Diversity
• Global Voices
• Training
HR Mgmt
• Time & Attendance
• SOP Certification
Limited Automated Data Collection
• Large number of site
and function specific
solutions
• Limited Common Data
and Definitions
Issues:
• People Intensive
(FTEs)
• Higher Potential for
Data
Inaccuracies/Errors
Op
era
tio
ns
In
tell
ige
nc
e
En
terp
ris
e S
co
pe
EHS Intelligence M&R
Intelligence OPS Intelligence Financial HR Intelligence
Multiple levels of
Data Verification
Capabilities
Large Volume of Manual Data
Transposing and Entry
GPP Assessment - Smelting Operations
© Copyr i g h t 2011 OS Is o f t , LLC . 19
Process Control & Automation Systems
(PLC,SCADA,)
Scrubber
Control
Cast House
Control
Bake Fire
Control Bath
Handling
Green Mill
Control
Pot
Lining
Rectifier
Station
Utility
Control Environment
Monitoring
Crucible
Cleaning
Raw
Material
Handling
Pot Control
Laboratory and Materials Equipment testing Systems
Op
era
tio
ns
In
tell
ige
nc
e
En
terp
ris
e
Sc
op
e
EHS Intelligence M&R
Intelligence OPS Intelligence Financial HR Intelligence
Enterprise
Financial Mgmt
Enterprise
HR Mgmt
Enterprise Commercial
Enterprise Asset Mgmt
Enterprise
EHS Mgmt
HR Mgmt Production Management
Maintenance EHS
Management
Plant Intelligence
DATA HISTORIAN
Automated Data Collection,
Summary and Aggregation
GPP Pilot Plant – Smelting Operations
Common Data
Definitions and
Model
•Process
•Plant
•Enterprise
Tools:
Asset Framework
SQL Data Warehouse
Opportunities: • Reduce People Processes
• Increase Data Integrity
• Increase Productivity – Info When
and Where It Is Needed
• Single Version of Truth for
Intelligent Decisions
© Copyr i g h t 2011 OS Is o f t , LLC . 20
Halifax Water – Automatic Leak Detection • Water service to 325,000 people.
• $650,000 / yr savings by reducing water leakage (DMA Night Flows).
© Copyr i g h t 2011 OS Is o f t , LLC . 21
Halifax Water – Water Loss Calculator
• Quickly account for non-revenue water
• Data to validate back-charge to contractors
© Copyr i g h t 2011 OS Is o f t , LLC . 22
Real-time Consumption Management
“Sustainability, both sides of the meter.” -Carl Yates, GM of HRWC
Real-time water consumption dashboards for largest consumers
Halifax Water & Port Authority Collaboration
23 © Copyr i g h t 2011 OS Is o f t , LLC .
Moulton Niguel Water – Energy Costs
• Safe, Reliable, Efficient Operations
• Increase Pumping Efficiency
• Reduce Rates Beyond Time of Use (TOU)
• Minimize Demand Costs
• Optimize Rate Schedules
• Make Operators “Energy” Knowledgeable
• Maintain a “Continuous Improvement” Environment
Make Energy Management a Business Process
© Copyr i g h t 2011 OS Is o f t , LLC . 24
Real-time Energy Management
15% or $200,000+ Annual Energy Savings
25 © Copyr i g h t 2011 OS Is o f t , LLC .
Nalco: Knowledge
Platform
The Nalco Refined Knowledge offering combines the best of
the three industry leaders: OSIsoft‟s operational infrastructure
SharePoint and Nalco as the Solutions Provider
“„Actionable Knowledge from Refined Data with PI System &
Microsoft Business Intelligence”
John Schlitt - Business Manager
Automation COE, Nalco
• Process data held in various
“islands of information”
• Performance data was
collectedly manually
• Personal Service Reports
(PSRs) were time-consuming
• The goal: Centralize data
collection to bring greater value
to the service Nalco provides
Used OSIsoft‟s Operational
Infrastructure
• Central Data Collection
• Tech View & Analysis
• Calculation Engine
• Value Generation Tool
• PI Notifications/OCS =
Real-time alerting
• Centralized data collection
• Condition based maintenance
and performance optimization
• Role-based visibility into plant
operations and performance
• On-demand Summary & KPI info
to customers & Nalco
• Actionable data now at
customer‟s fingertips
Customer Business Challenge Solution Customer Results / Benefits
26 © Copyr i g h t 2011 OS Is o f t , LLC .
Metro Vancouver: Sustainable
Water Management “Our mission is to deliver safe water to the people of
Vancouver and in order to do that we need data and
information.”
Judy Smith
Superintendent of Water Quality and Microbiology
• Supplies water to 2.2 million
people
• Data access to information to
minimized demand on the
environment
• Large volumes of data from
diverse data sources needs to
integrated with quick &
efficient access
• PI System, PI WebParts,
PI DataLink
• Microsoft SharePoint &
Excel Services
• Optimized plant energy &
maintenance resulting in
lower costs
• Lessen impact on the
environment through more
efficient operations
• Advance warnings of supply
disturbances
• Empowered users
Customer Business Challenge Solution Customer Results / Benefits
© Copyr i g h t 2011 OS Is o f t , LLC . 27
California ISO Control Room
© Copyr i g h t 2011 OS Is o f t , LLC . 28
CAISO PI System Display: Generation Hydro Conditions Summary
© Copyr i g h t 2011 OS Is o f t , LLC . 29
CAISO STI/PI Display: Wind speed contour & wind
generation using PI System data
© Copyr i g h t 2011 OS Is o f t , LLC . 30
CAISO STI/PI Display: Solar generation summary with
cloud cover using PI System Data
© Copyr i g h t 2011 OS Is o f t , LLC . 31
PETROJARL
FOINAVEN
FOINAVEN
RAMFORM BANFF
BANFF
PETROJARL VARG
PETROJARL I
GLITNE
e-Field make data available for every
user no matter where they are.
VARG
• Real-time
servers on
all FPSO‟s
Tot.150.000
datastreams
• Onshore
server
replicating
data from
offshore
servers
32 © Copyr i g h t 2011 OS Is o f t , LLC .
CEMEX: Smart Monitoring on Cement Plants
Problem Addressed – Need of tools and indicators to
accurately measure and control all the
energy being consumed by each piece
of equipment.
– “You can control only what you can
measure”
Problem Details – Detailed energy consumption not
available for control purposes
– Calorific consumption detail available
only in certain cases
– Electrical energy measurement only for
control demand and billing purposes
– Need of a tool to make operational
process adjustments for the efficient use
of total energy (calorific & electrical),
avoiding waste
33 © Copyr i g h t 2011 OS Is o f t , LLC .
The PI System for UC San Diego’s 42 MW
Campus Microgrid
• With a daily population of over
45,000, UC San Diego is the size
and complexity of a small city
• As a research and medical
institution, the energy density is
twice that of commercial buildings
• 11 million sq. ft. of buildings
• Self-generate 80% of annual
demand
– 30 MW natural gas cogen plant
– 2.8 MW of fuel cells contracted
– 1.2 MW of solar PV installed,
additional 2 MW planned
© Copyr i g h t 2011 OS Is o f t , LLC . 34
Skanska Leveraging the PI System
Infrastructure in Data Centers: Developing
real-time feedback loops to deliver computing sustainably
35 © Copyr i g h t 2011 OS Is o f t , LLC .
CFE: Business
Intelligence
“We knew that OSIsoft and Microsoft could help us save
money through superior BI. But we didn‟t appreciate the
extent of the savings until we began to see what their
solutions could do.”
Fernando Barradas
Director of Information Application, CFE
Customer Business Challenge Solution Customer Results / Benefits
• Higher costs, difficult economy &
the need to make decisions across
mix of energy sourced
• Need to make optimal decisions on
the mix of energy sources to make
electricity at the lowest cost
• Need better communication &
collaboration
• High IT costs for management of
data cubes & reports
• PI System for collection &
storage of real-time data
• Microsoft Power Pivot
tables, charts, slicers, data
analysis
• Microsoft SharePoint &
PI WebParts
• Improved decision making could
save CFE US $4.7 million/year
• IT Staff can be redeployed to
create self service applications
• Time savings, increased
collaboration & business
decisions in real-time
36 © Copyr i g h t 2011 OS Is o f t , LLC .
Alcoa: Industrial-scale
Demand Response
Warrick Operations is Alcoa‟s Largest Operating U.S. Smelter
• 330,000 MT capacity/year
• Energy is 30-40% of Aluminum Production Costs
• Generates power for Aluminum Smelter and Rigid Packaging
Brian Helms
Power Markets Coordinator
Alcoa Power Generation
• Faced with competition in a worldwide
commodities market
• Business took a major hit due to
economic downturn
• Needed to find a way to sustain the
business; keep it from going under
• Uses the PI System for energy
regulation – generate electricity &
feed it back into Midwest ISO (MISO)
• Monitor MISO for energy demand
notifications, & respond accordingly
• Submit forecasted load data from the
PI System
• Focused on selling regulation (20MW)
and spinning reserve (40MW)
• Total project cost was $700,000
• Project payback was in 4 months
• System runs efficiently
• Gets a weekly check from MISO for
the power they generate in the grid
• Use this money to sustain their
Aluminum business – revenues are
now above their competition
Customer Business Challenge Solution Customer Results / Benefits
37 © Copyr i g h t 2011 OS Is o f t , LLC .
PSE&G: Condition-based
Maintenance “We get a detailed breakdown on equipment
costs and man/hours to service that gives us
important business benefits. Without the use of
the PI System, it would have taken us several
months to gather and analyze the information.”
Angela Rothweiler
Principal Engineer
• Providing the highest reliability
Power Distribution is requirement
• Minimize Maintenance Costs
• Implemented automatic data
collection and notifications to
SAP PM
• Set up standard business rules for
condition based maintenance using
PI System Analytics
• Provided focused view into
equipment
• Provided Financial access to data
by Business Objects query
• Holds Reliability award for Mid
Atlantic States for last 7 years
• Named most reliable Power
Company in America
• Focused maintenance
expenditures on needed targets
Customer Business Challenge Solution Customer Results / Benefits
38 © Copyr i g h t 2011 OS Is o f t , LLC .
British Gas: Advanced
Metering Infrastructure (AMI)
“OSIsoft‟s MDUS is positioned to be a core technology
for Smart Metering at British Gas, and we will be able
to leverage the time-series data management
infrastructure across other areas of the company.
This makes it a strategic product for the company.”
Petter Allison
Director of Smart Metering
British Gas
• Enable customers to cut down on
energy use as well as reduce fuel
bills and carbon emissions
• Meet government‟s target for smart
metering 2020
• Provide the customer with accurate
and automated billing
• Develop consortium of
companies to provide the
technology for the high-profile
project
• OSIsoft MDUS for Advanced
Metering
• SAP Utilities & AMI for billing
• SAP HANA
• Largest Smart Meter trial in the
U.K.
• Planned rollout of 2 million smart
meters by 2012
Customer Business Challenge Solution Customer Results / Benefits
39 © Copyr i g h t 2011 OS Is o f t , LLC .
IBM Burlington: Sustainable
Water Management Advanced Industrial Water & Energy Management saves
$10 M annually
Advanced Water Management Case Study:
IBM 200 mm Wafer Fabricator
Jeff Chapman
Ultra Pure Water Engineer, Senior Technical Team Leader
Center of Excellence for Enterprise Operations
• Reduce water consumption
(& associated need for energy,
chemicals, maintenance and labor) to
reduce operating cost & minimize
environmental impact
• Leverage end-to-end data acquisition,
storage and visualization techniques
to monitor water usage & improve
efficiency
• Implemented data collection &
storage infrastructure: sensors, IT
network and servers
• Statistical process control
techniques used to continually
analyze vast amounts of operational
data and present information in
efficient, concise interface
• IBM‟s Green Sigma methodology –
for reducing water & electrical power
consumption & increase process
efficiency
• IBM has achieved over $3.6M in
annual savings, reduced water
usage by 27% while increasing
manufacturing capability over 30%
pH, RO Feed X-Bar S Chart, 1 Day
Strt Date: 1/6/2009 DI Central, SPC
End Date: 1/7/2009
Method: Modified Control Limits
Data: 96 subgroups of 15 samples, 1 min. rate
Status: Operations
Common Carbon Outlet Flow
0
500
1000
1500
2000
Booster Pmp Dis. Pres.
0
50
100
150
200
SPC X-Bar Chart: pH, RO Feed
4.00
4.20
4.40
4.60
4.80
5.00
5.20
5.40
5.60
5.80
6.00
1/6/09
00:15
1/6/09
02:15
1/6/09
04:15
1/6/09
06:15
1/6/09
08:15
1/6/09
10:15
1/6/09
12:15
1/6/09
14:15
1/6/09
16:15
1/6/09
18:15
1/6/09
20:15
1/6/09
22:15
Subgroup Time
pH
Xbar
UCL
LCL
USL
LSL
Com
SPC Sigma Chart: pH, RO Feed
0
0.1
0.2
0.3
0.4
0.5
1/6/09
00:15
1/6/09
02:15
1/6/09
04:15
1/6/09
06:15
1/6/09
08:15
1/6/09
10:15
1/6/09
12:15
1/6/09
14:15
1/6/09
16:15
1/6/09
18:15
1/6/09
20:15
1/6/09
22:15
Subgroup Time
Std Dev
StdDev
UCL
LCL
RO Feed pH
0
2
4
6
Customer Business Challenge Solution Customer Results / Benefits
40 © Copyr i g h t 2011 OS Is o f t , LLC .
Bayer Material Science:
Emissions Tracking
• Emissions track record 1990-2007:
37% absolute reduction in green house
gas (GHG) emissions
• Improvement in energy efficiency and
change in corporate portfolio
• Best-in-class ranking by Carbon
Disclosure Leadership Index
• New Climate Targets in the subgroups:
• Bayer MaterialScience -25%
• Bayer CropScience – 15%
• Bayer HealthCare – 5%
• €1 billion program for climate-related
research, development & projects
• Uses the PI System as a new
instrument to reduce CO2 in
production by monitoring and
analyzing 100 production plants
worldwide
• Company-wide CO2 emission &
energy efficiency check
• 85% of greenhouse gas emissions
covered
• Also applied to new technology &
investment projects
• The PI System enables Bayer to provide
production units with detailed and real
time information from utility provider
• Calculate KPIs: Costs, Energy Quality,
Peak Consumption
• Support aggregated reports: month, site,
organizational entity, & type of energy
• Employees use the PI System data to
ultimately reduce GHG emissions to
meet the new climate targets
Customer Business Challenge Solution Customer Results / Benefits
41 © Copyr i g h t 2011 OS Is o f t , LLC .
NiSource: Gas Transmission
and Storage
“At the core data must be transformed into
knowledge and connected to tangible actions for
risk mitigation.”
John Cox,
Team Leader
Optimization and Gas Quality
• Largest Pipeline east of the
Mississippi
• Industry Drivers – aging equipment,
new share production for gas on east
coast, need for people in the field to
be informed
• Need for defect elimination &
reliability growth
• PI System with PI WebParts,
PI Manual Logger, PI
Notifications, PI DataLink
Server, PI ACE
• Sigmafine
• SharePoint
• Target is to exceed customer
requirements
• Assessment strategy for ranking
project impact on safety,
regulatory issues, integrity
• On-line condition monitoring for
strategic compression stations
• Front line workers connected to
KPI‟s
Customer Business Challenge Solution Customer Results / Benefits
42 © Copyr i g h t 2011 OS Is o f t , LLC .
Harvard Medical School:
Facility Management
Use of the PI System in 3 major areas:
• Facilities management - 18,000 maintainable assets, 24/7 call
center, 200 Node BMS
• Energy usage - 15 MW Electric, 70K lbs/hr Steam, 10k+ tons
chilled water
• Research Support - Research trending, infrastructure
changes, alarm monitoring
• $44.5 Million operation budget- $25 Million spent on annual
utilities
• Sustainability Commitment: Reduce
Green House Gas (GHG) by 30% in
2016 (over 10 year period)
Background:
• 2006 - 57,266 Metric Tons
Carbon dioxide (MTCDE)
• 2008 - 57,592 MTCDE
• Goal - 2016 - 40,086 MTCDE
Uses the PI System to:
• Gather meter & BMS data & analyze
energy usage
• Create Daily Energy Report
• Predict maintenance, event analysis
• Automatic Load Shedding
• Report real-time energy use on web for
public
• Model Building Performance
• Trend “Creep”
• View impact of sequence / strategy
change
• Increased O&M efficiency by providing
key operational data effectively to
managers & technicians
• Reliable science trending helps
researchers reach their goals
• The PI System is the foundation of
HMS‟ energy management process
Customer Business Challenge Solution Customer Results / Benefits
43 © Copyr i g h t 2011 OS Is o f t , LLC .
Saudi Aramco:
Performance Monitoring
Proactive Performance monitoring with Dashboards
Saudi Aramco needed a proactive solution to monitor and
improve performance. After implementing PI WebParts, the
impact on performance improvement meant multiple millions of
dollars in additional revenue.
Rayan Hafiz
Saudi Arabian Oil Company
OSIsoft UC 2010
• The process is not fully monitored
• Final products selling prices are highly
sensitive to mercury levels in the
process and need to be better
monitored
• Needed a proactive solution to monitor
and improve performance
• Implemented PI WebParts as a way
to see into the process from
anywhere
• Built dashboards and KPI screens
to fully monitor the process
• Built a predictive model to prevent
problems in the process
• Complete monitoring & management
with proactive tools
• Solutions template could be used for
other functionalities/applications
• The integration/utilization of OSIsoft
tools removed layers of complication
• Impact on performance improvement
means multiple millions of dollars in
additional revenue
Customer Business Challenge Solution Customer Results / Benefits
44 © Copyr i g h t 2011 OS Is o f t , LLC .
RockTenn: Enhancing Six Sigma
Projects
RockTenn is a leading manufacturer of paperboard, containerboard,
and consumer and corrugated packaging. PI was used in their plants
to enhance six sigma methodology and ideals. As a result, they
experienced a 47% reduction in beater tons due to sheet variation and
out of spec material. This went straight to the bottom line as a
reduction in wasted energy, labor, and profit opportunity.
Matt Corcoran
RockTenn
Business Case
• Customers requiring a more consistent
product not just in spec
Shrinking Market
• Strategic positioning to be the prime supplier
to the market
Healthy Customers
• A happy and healthy customer base is a
prime ingredient for long term success
• We‟re not talking about just $$$ savings,
we‟re talking about staying in business
• Used PI for data collection from various
data sources as well as archiving.
• Used PI DataLink for filtering data and
exporting data to Minitab for analysis.
• Access to such data was nearly
impossible before PI was installed.
• With fiber feed managed stock
consistency variation decreased
• Run stock refiners in automatic rather
than manual
• Utilize PI ProcessBook and RtAlerts to
provide real time information and
process alerts
• More consistent product for customers
• More consistent process for better
production efficiency
• 21.2% over all improvement in caliper
process capability
• 10.4% over all improvement in moisture
process capability
• 47% reduction in beater tons due to
sheet variation and out of spec material.
This went straight to the bottom line as a
reduction in wasted energy, labor, and
profit opportunity
FY09 Beater tons for Caliper/Moisture/Profile/2Sig(as a % of total beater tons)
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09
% o
f to
tal
be
ate
r to
ns
47% reduction
Customer Business Challenge Solution Customer Results / Benefits
45 © Copyr i g h t 2011 OS Is o f t , LLC .
SunPower: Solar Monitoring and
Operation
“OSIsoft‟s PI System is a proven, robust, scalable
architecture with event detection and notifications that
allowed us to meet our business objectives.”
Steve Hanawalt
Vice President O&M
SunPower
• To compete, need to effectively
manage and optimize the large labor/
many generators cost structure
• Implemented PI system to
provide critical secure data for
high speed Data Collection
• Solar Alarm System
• Engineering tool for diagnostics
• SharePoint Portal with
PI WebParts
• Customer visibility via web portal
• 24/7 monitoring
• Able to compete by minimizing
labor for asset-monitoring while
managing performance of many
generators
Customer Business Challenge Solution Customer Results / Benefits
46 © Copyr i g h t 2011 OS Is o f t , LLC .
EDF Énergies Nouvelles: Solar
and Wind Farm Operation
“The PI System has allowed us to remotely support
and monitor Solar and Wind Assets providing better
asset utilization and cost reductions.”
Louis Blais
EDF Énergies Nouvelles
• Allow a uniform and consistent
supervision system
• Allow feedback on performance
problems with better data for
investigation with visibility to
management
• Provide services that allow the owner
to increase revenues on wind & solar
assets
• Implemented PI system to
provide critical secure data for
high speed Data Collection
• Developed standardized
architectures based on type of
site for easy roll-out
• PI Notifications for power alerts
• Developed Reports and
graphics
• 24/7 monitoring system
• Asset bill generation
• Condition based monitoring of
assets resulting in reduced
downtime
• Remote detection of hardware
failures in solar panels
Customer Business Challenge Solution Customer Results / Benefits
47 © Copyr i g h t 2011 OS Is o f t , LLC .
UltraTech Cement: Improvement
Case Studies
“A PI System for data acquisition is the first step
towards a fully integrated plant management
system”
R.R. Mehta
General Manger India
• Large number of plants
• Development of plan for improvement
cases across plants
• Improve Production Rates
• Achieve High Energy Efficiency Rating
by International Organizations
• Six Sigma on Processing Units
• Increase Production runs
• PI System with PI DataLink,
PI ProcessBook
• SAP for plant maintenance
currently manual integration
• Improvement cases have resulted in 1
million in savings in single plant
• Case – Idle Running of compressors hrs
reduction saved KW
• Case – Kiln Feed Consistency from
model developed for PI System data
increased hrs of operation
• Case Equipment Availability- root cause
analysis reduced process disturbance
and operating temperatures
• Plants receive high energy efficiency
ratings
Customer Business Challenge Solution Customer Results / Benefits
48 © Copyr i g h t 2011 OS Is o f t , LLC .
Final Take Aways • Hopefully we have demystified what an
infrastructure for data and events is and why its versatility can be valuable to every sustainability strategy
• Sustainability is a data rich opportunity and
challenge
• The lessons and principles to leverage an
infrastructure to gain business value are well
established
• Challenged the mantra “you can’t manage what
you don’t measure.”
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