Using Real-Time Data To Achieve Sustainability Excellence

Using Real-Time Data to Achieve Sustainability Excellence
Presented by: Andrew Fanara and Gary Wong
October 13, 2011
Contact Information
Andrew Fanara afanara@osisoft.com Gary Wong gwong@osisoft.com
Copyright 2011 OSIs oft, LLC.
Todays 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 cant manage what you dont measure.
Published: April 23, 2011
When Theres No Such Thing As Too Much Information
Todays 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.
Reporting Drives the Need for Timely, Accurate Information
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.
Serving Customers Across the Globe
Moscow Calgary, Alberta Toronto (2011) Frankfurt London Paris San Leandro, CA Phoenix, AZ Houston and Longview,TX Montral, Qubec Madrid Ostrava, CR Beijing Seoul (AID) Tokyo
Philadelphia, PA
Mayfield Heights, OH Johnson City, TN Savannah, GA Manama, Bahrain India (2011) Shanghai China
Mexico
Singapore
So Paulo, Brazil Chile (2011) Durban South Africa Perth, Australia Sydney, Australia
OSIsoft Offices Tech Support Centers OSIsoft Offices in development
Helping Organizations to Meet Their Sustainability Goals
Alcoas 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
The OSIsoft PI System

The Partner Ecosystem
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.
10
What is an Infrastructure?
Valuable delivers a recognized benefit Reliable & Secure always available, safe & trusted
Power Communication
Accessible Bring business silos together, easy to use Scalable Expandable across enterprise Contextual - organized to be effective, efficient, and extendable Enables other applications & technologies
11
Transportation
Water
> 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
CONNECT
Data Types
12
Why is an Infrastructure a Foundation for Sustainability?

BUSINESS SYSTEM
MONEY FLOW
BUSINESS GATEWAY
Real-time Infrastrucure for Monitoring

Finance SCO HSE, QM, IT Engineering R&D INFORMATION FLOW Quality Laboratory Operators Plant IT Executives Plant Management Asset Management
PI System
Performance Availability Security
Operational Excellence Production Excellence Plant Maintenance Maintenance Team Process Unit Managers I&C
INTERFACES
MATERIAL FLOW
OTHER
LAB
CONTROL SYSTEMS
DIAGNOSTICS DATABASES
MANUAL DATA
PUMPS
VALVES
HEx TRANSMITTERS ACTUATORS MOTORSTRANSFORMERSOTHER

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An Infrastructure is a Foundation for Real-time Decision Support

MONEY FLOW
BUSINESS SYSTEM
Business Data
Consequences
Capability to UNDERSTAND the Problem
Business Decision
Capability to ACT
INFORMATION FLOW
RELIABLE DATA
ACTIONABLE INFORMATION
? Real-time External ORIENTATION OPTIONS Data Infrastructure

Decision Support
PRODUCTION DATA
PROFITABLE, DECISIONS
DECISION
Decision Making
DECISIONS
ACTION
Realization
VALUE
PROFIT
ACTIONS
MATERIAL FLOW
PROCESSING PLANT
UTILITIES PROCESS UNITS OFFSITES
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The Granularity of Real-time Data

10 Minute Averages = Missed Events
PI System Data
(1-3 seconds)
SCADA Data
(10-minute average)
15
An Infrastructure to Span the Enterprise

Operations Monitoring Energy Management Maintenance Management (CBM) Asset Optimization
Real-time applications
Real-Time Data Batch Data Relational Data Quality Data Manual Data Structure/Asset Data Web Data Applications Data Maintenance Data ERP Data
Business Intelligence tools Business Systems
Enterprise
Agnostic Real-time Infrastructure

Across the Value Chain
Region Territory
Plant
Unit
MACHINE
Across the Infrastructure
Exploration
Production
Gas & Liquid Pipelines
NGL & LNG
Refining
Chemicals
Distribution & Marketing
Alternative Energy
R&D
Data Centers
IT Infrastructure
Trading
1000s of different real-time data sources and associated interfaces that propagate through the automation space
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PERTAMINAs Downstream Supply Chain

Assets:
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)
SABANG KRUENG RAYA LHOK SEUMAWE
IMPORT
One of the most complex Downstream Supply Chains in the world

TARAK AN TAHUNA BITUNG
MEULABOH UP. I - PKL. BRANDAN LAB. DELI SIBOLGA
P. NATUN A
G. SITOLI SIAK
P. BATAM
TOLI TOLI GORONTALO SINTANG MOUTO NG DONGGA LA PO SO PARI GI KOLONDA LE PALO PO PARE PARE KOLEKA KOTA BARU UJ. PLUMPA UP.VI BALONGAN SEMARANG SURABA YA UP. IV CILACAP CAMPLO NG PANDAN G RAHA BAU BAU LUWUK SANAN A BANGG AI KENDARI SUBUN G
TOBE LO TERNA TE
P. SAMBU TT. TLK. KABUNG JAM BI PONTIAN AK
BONTAN G SAMARIN DA BALIKPAPA N
PABU HA TT. WAY AME
SORON G MANOKWA RI
BIA K
CILIK SAMPIT BENGKU LU RIWUT P. PISANG BANJARMAS IN PANJA NG
SER UI NABI RE JAYAPUR A
PKL.BU N
NAMLE A
BUL A MASO HI
FAK FAK
T. SEMANGKA
TT.
TUAL
DOBO
NG
TG. GEREM/MERAK
KALBU T MENE
NG AMPEN TT. TLK AN MANG GIS
BADU NG BIM A
RE O
MAUME RE EN DE L. TUKA
KALABA HI DILI ATAPU PU
MERAU KE SAUMLA KI
WAINGA PU
KUPAN G
17
GPP Assessment - Smelting Operations

Enterprise Scope
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
Enterprise Issues: Enterprise Financial HR Mgmt Mgmt People Intensive Ledger (FTEs) Diversity Capital Global Voices Higher Potential for DIs Training
Multiple levels of Data Verification Capabilities Plant Intelligence

EHS Intelligence M&R Intelligence
Data Inaccuracies/Errors
OPS Intelligence
Financial
HR Intelligence
Intelligence
EHS Management
Waste Mgmt Air Performance Asset Monitor Confined Space
Maintenance
Predictive Maintenance Condition Monitoring
Production Management
Quality & Performance Transposing Resource Mgmt Raw Materials Inventory
HR Mgmt Time & Attendance SOP Certificatio n
Large Volume of Manual Data and Entry
Limited Automated Data Collection Operations Process Control & Automation Systems (PLC,SCADA,) Cast House Bake Fire Pot Control
Control Rectifier Station Utility Control Control Pot Lining
Raw Material Handling Scrubber Control
Green Mill Control Crucible Cleaning
Large number of site Bath and function specific Handling solutions Environment Limited Common Data Monitoring and Definitions
Laboratory and Materials Equipment testing Systems
18
GPP Pilot Plant Smelting Operations

Enterprise Scope
Enterprise EHS Mgmt Enterprise Asset Mgmt Enterprise Commercial Enterprise Financial Mgmt Enterprise HR Mgmt
Opportunities:
Plant Intelligence
EHS Intelligence
M&R Intelligence
Intelligence
EHS Management
Maintenance
Reduce People Processes OPS Intelligence Increase Data Integrity Financial HR Intelligence Increase Productivity Info When and Where It Is Needed Production HR Mgmt Single Version of Truth for Management Intelligent Decisions
Automated Data Collection, Summary and Aggregation

Operations
DATA HISTORIAN
Raw Material Handling Scrubber Control
Process Control & Automation Systems (PLC,SCADA,) Cast House Bake Fire Pot Control
Control Rectifier Station Utility Control Control
Green Mill Control Crucible Cleaning
Pot Lining
Laboratory and Materials Equipment testing Systems
Common Data Definitions and Model Process Bath Plant Handling Enterprise Environment Tools: Monitoring Asset Framework SQL Data Warehouse
19
Halifax Water Automatic Leak Detection

Water service to 325,000 people. $650,000 / yr savings by reducing water leakage (DMA Night Flows).
20
Halifax Water Water Loss Calculator
Quickly account for non-revenue water Data to validate back-charge to contractors
21
Halifax Water & Port Authority Collaboration Real-time Consumption Management

Sustainability, both sides of the meter. -Carl Yates, GM of HRWC Real-time water consumption dashboards for largest consumers
22
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
23
Real-time Energy Management

15% or $200,000+ Annual Energy Savings
24
Nalco: Knowledge Platform

The Nalco Refined Knowledge offering combines the best of the three industry leaders: OSIsofts 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
Customer Business Challenge

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
Solution
Used OSIsofts Operational Infrastructure Central Data Collection Tech View & Analysis Calculation Engine Value Generation Tool PI Notifications/OCS = Real-time alerting
Customer Results / Benefits

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 customers fingertips
25
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
Solution
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
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California ISO Control Room
27
CAISO PI System Display: Generation Hydro Conditions Summary
28
CAISO STI/PI Display: Wind speed contour & wind generation using PI System data
29
CAISO STI/PI Display: Solar generation summary with cloud cover using PI System Data
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Real-time
e-Field make data available for every user no matter where they are.
servers on all FPSOs Tot.150.000 datastreams
FOINAVEN PETROJARL FOINAVEN
Onshore
GLITNE
BANFF VARG
server replicating data from offshore servers
RAMFORM BANFF PETROJARL I
PETROJARL VARG
31
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
32
The PI System for UC San Diegos 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
33
Skanska Leveraging the PI System Infrastructure in Data Centers: Developing real-time feedback loops to deliver computing sustainably
34
CFE: Business Intelligence

We knew that OSIsoft and Microsoft could help us save money through superior BI. But we didnt appreciate the extent of the savings until we began to see what their solutions could do. Fernando Barradas Director of Information Application, CFE

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
Solution
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
35
Alcoa: Industrial-scale Demand Response

Warrick Operations is Alcoas 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
Solution
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
36
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
Solution
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
37
British Gas: Advanced Metering Infrastructure (AMI)

OSIsofts 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 governments target for smart metering 2020 Provide the customer with accurate and automated billing
Solution
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
38
IBM Burlington: Sustainable Water Management

pH, RO Feed X-Bar S Chart, 1 Day
DI Central, SPC SPC X-Bar Chart: pH, RO Feed Xbar UCL LCL USL LSL Com
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
Strt Date: 1/6/2009 End Date: 1/7/2009 Method: Modified Control Limits Data: 96 subgroups of 15 samples, 1 min. rate Status: Operations
pH 6.00 5.80 5.60 5.40 5.20 5.00 4.80 4.60 4.40 4.20
RO Feed pH 6 4 2 0
Common Carbon Outlet Flow 2000 1500 1000 500 0
4.00 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
Std Dev 0.5 0.4 Booster Pmp Dis. Pres. 0.3 0.2 0.1 0 1/6/09 00:15
SPC Sigma Chart: pH, RO Feed Std Dev UCL
200 150 100 50 0
LCL 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

Reduce water consumption
Solution
Implemented data collection &

IBM has achieved over $3.6M in
(& 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
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 IBMs Green Sigma methodology for reducing water & electrical power consumption & increase process efficiency
annual savings, reduced water usage by 27% while increasing manufacturing capability over 30%
39
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
Solution
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

New Climate Targets in the subgroups: Bayer MaterialScience -25% Bayer CropScience 15% Bayer HealthCare 5%
1 billion program for climate-related research, development & 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
40
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
Solution
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 KPIs
41
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
Solution
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
42
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
Solution
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
43
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.
FY09 Beater tons for Caliper/Moisture/Profile/2Sig
(as a % of total beater tons)
35.00% 30.00% 25.00%
% of total beater tons
20.00%
47% reduction
15.00%
10.00%
5.00%
Matt Corcoran RockTenn
0.00% Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09

Business Case Customers requiring a more consistent product not just in spec Shrinking Market Strategic positioning to be the prime supplier to the market
Solution
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
Healthy Customers A happy and healthy customer base is a prime ingredient for long term success Were not talking about just $$$ savings, were talking about staying in business
44
SunPower: Solar Monitoring and Operation

OSIsofts 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
Solution
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
45
EDF nergies 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 nergies 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
Solution
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
46
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
Solution
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
47
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 cant manage what you dont measure.
48

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

Copyright 2011 OSIs oft, LLC.

Published: April 23, 2011

When Theres No Such Thing As Too Much Information

Copyright 2011 OSIs oft, LLC.

Reporting Drives the Need for Timely, Accurate Information

Copyright 2011 OSIs oft, LLC.

Experience Across Diverse Industries

Copyright 2011 OSIs oft, LLC.

Serving Customers Across the Globe

OSIsoft Offices Tech Support Centers OSIsoft Offices in development

Copyright 2011 OSIs oft, LLC.

Helping Organizations to Meet Their Sustainability Goals

Copyright 2011 OSIs oft, LLC.

Alcoas Keys to Sustainability

Copyright 2011 OSIs oft, LLC.

The OSIsoft PI System

Copyright 2011 OSIs oft, LLC.

> 400 Interfaces to Collect Data

Copyright 2011 OSIs oft, LLC.

Why is an Infrastructure a Foundation for Sustainability?

Real-time Infrastrucure for Monitoring

HEx TRANSMITTERS ACTUATORS MOTORSTRANSFORMERSOTHER

An Infrastructure is a Foundation for Real-time Decision Support

Capability to UNDERSTAND the Problem

? Real-time External ORIENTATION OPTIONS Data Infrastructure

The Granularity of Real-time Data

Copyright 2011 OSIs oft, LLC.

An Infrastructure to Span the Enterprise

Business Intelligence tools Business Systems

Agnostic Real-time Infrastructure

Across the Infrastructure

Gas & Liquid Pipelines

NGL & LNG

Distribution & Marketing

Copyright 2011 OSIs oft, LLC.

PERTAMINAs Downstream Supply Chain

One of the most complex Downstream Supply Chains in the world

MEULABOH UP. I - PKL. BRANDAN LAB. DELI SIBOLGA

P. SAMBU TT. TLK. KABUNG JAM BI PONTIAN AK

BONTAN G SAMARIN DA BALIKPAPA N

PABU HA TT. WAY AME

CILIK SAMPIT BENGKU LU RIWUT P. PISANG BANJARMAS IN PANJA NG

SER UI NABI RE JAYAPUR A

KALABA HI DILI ATAPU PU

Copyright 2011 OSIs oft, LLC.

GPP Assessment - Smelting Operations

Enterprise Asset Mgmt

Multiple levels of Data Verification Capabilities Plant Intelligence

HR Mgmt Time & Attendance SOP Certificatio n

Large Volume of Manual Data and Entry

Raw Material Handling Scrubber Control

Green Mill Control Crucible Cleaning

Laboratory and Materials Equipment testing Systems

GPP Pilot Plant Smelting Operations

Automated Data Collection, Summary and Aggregation

Raw Material Handling Scrubber Control

Green Mill Control Crucible Cleaning

Laboratory and Materials Equipment testing Systems

Halifax Water Automatic Leak Detection