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

2 © Copyr i g h t 2011 OS Is o f t , LLC .

Contact Information

Andrew Fanara

[email protected]

Gary Wong

[email protected]

mailto:[email protected]

mailto:[email protected]


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


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.


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)


Helping Organizations to Meet Their Sustainability Goals


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


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


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


> 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


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


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


The Granularity of Real-time Data 10 Minute Averages = Missed Events

SCADA Data (10-minute average)

PI System Data (1-3 seconds)


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


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

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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


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


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


Halifax Water – Automatic Leak Detection • Water service to 325,000 people.

• $650,000 / yr savings by reducing water leakage (DMA Night Flows).


Halifax Water – Water Loss Calculator

• Quickly account for non-revenue water

• Data to validate back-charge to contractors


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


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


Real-time Energy Management

15% or $200,000+ Annual Energy Savings


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


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



California ISO Control Room


CAISO PI System Display: Generation Hydro Conditions Summary


CAISO STI/PI Display: Wind speed contour & wind

generation using PI System data


CAISO STI/PI Display: Solar generation summary with

cloud cover using PI System Data


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


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


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


Skanska Leveraging the PI System

Infrastructure in Data Centers: Developing

real-time feedback loops to deliver computing sustainably


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


• 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


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



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



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



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



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



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


http://www.nisource.com/


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



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



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



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



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



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



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.”

Documents

Using Real-Time Data to Achieve Sustainability Excellence