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The PI System – A Vital Technology

The PI System – A Vital Technology. Todd McQuiston Senior PI Integration Specialist Dow Corning Corporation. Agenda. Introduction to Dow Corning Corp. DCC’s History with PI PI System Rundown / Details

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The PI System – A Vital Technology

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  1. The PI System – A Vital Technology Todd McQuiston Senior PI Integration Specialist Dow Corning Corporation

  2. Agenda • Introduction to Dow Corning Corp. • DCC’s History with PI • PI System Rundown / Details • Where the new (and sometimes old) PI user invariably finds oneself • Tools we ALL have • ProcessBook • Datalink • PI-ACE • How we made PI work better for us • PI Health Monitor

  3. Agenda (Continued) • How we made PI work better for us (continued) • PI-TEEP • Quality Notifications • Rlink • Training, TRAINING, TRAINING • Key Technologies / Services that help us • Managed PI (mPI) • Enterprise Agreement (EA) • Future of PI at DCC • Sigmafine • AF / EF • Collectives / VM’s

  4. Dow Corning Corporation in a Nutshell • One of world’s leaders in silicon-based chemistry • Silicone fluids, rubber, sealants • Semiconductor and Solar-grade silicon metal • $US 5 billion in sales in 2007 • Using SAP R/3 for our global ERP system since 1998. • Approximately 11,000 employees globally • More than 45,000 products split across two brands – Dow Corning and Xiameter.

  5. Dow Corning in the World

  6. PI at Dow Corning Corporation • First installed in 1992 – VMS-based PI 1.x • Completed transition to NT (PI 3.2) in 2000. • 12 production PI servers around the world • 4 in Asia, 3 in Europe, 5 in the United States • 1 network monitoring server on each continent • Approximately 500,000 tags globally • Over 1,500 users • At any given time, key U.S. PI servers are handling 400+ simultaneous clients

  7. PI at Dow Corning Corporation • Data sources to PI: • Fischer & Porter / Bailey • Allen Bradley PLC • Siemens PLC • Intellution SCADA • Foxboro I/A • Fisher/Rosemont • Batch Execution Systems (Batch Engines) • Radio Frequency and Bar-coding for Manual Data Entry • PC Based Manual Data Entry • Rockwell

  8. Where you may find yourself today: • “I’ve bought PI, now what?” • “I have had PI for five years, now what?” • “Someone needs me to make PI do (insert request here), now what?!?” • “Please kill me.”

  9. Tools we all have right now:

  10. So…use PI more, or better • Monitoring • PI Health Monitor • Topview from Exele Information Systems • PIANO from OSIsoft (future) • PI-TEEP • Batch processes – are batches running too long, or down for too long? • Continuous processes – are they running? If so, are they running hard enough? • Latest version uses xMii (SAP Portal) as a front end – universally available

  11. Making PI Work for You • Quality Notifications – using simple ACE 2.1 code • Each note like this can save approximately $500 in testing. 11 Mixers, four batches per day per mixer.

  12. Stretching the Limits of the PI System • Rlink – PP/PI • Automated production recording • Calculations run every four hours, posting results to SAP within 20 minutes. • Before Rlink was implemented, operators spent 2-4 hours per week manually entering productions and consumption, with an average error rate of 5.8%. • After Rlink, manufacturing engineers spend approximately 2 hours per month validating data, using PI Processbook. Error rate is effectively 0%. • End result: more granular, and more ACCURATE inventory data.

  13. And the Best Way to Improve Your System • TRAIN THOSE OPERATORS/ENGINEERS (you can skip the engineers) • Seriously, users will surprise you with a) the stuff they figure out, or b) the stuff they ask YOU to accomplish. • Seriously, skip the engineers:

  14. To What Do We Owe Our Good Fortune? • Enterprise Agreement (EA) • Effectively eliminates the time spent “counting licenses” • Permits us to expand our PI server grid, turning small satellite sites into full PI sites for the simple cost of harware. • Ideal for small sites who expand beyond their WAN bandwidth to Midland. • No more tag limits. (!) • This seems small, but licensing/cost based on tag limits was a very large headache. • The upside: we build pretty much every tag out there on the control system(s). • The downside: we build pretty much every tag out there on the control system(s).

  15. Big Brother is Always Watching, Comrades • Managed PI (mPI) • Round-the-clock monitoring by the OSIsoft NOC (Network Operations Center) • The alert notes sent to Dow Corning can be specially formatted to auto-generate tickets in our problem management system (Service Center) • Single point of contact – one person who can hear all your hopes, dreams, and sleep deprivation-induced nightmares about the PI system.

  16. Where Next for PI at DCC? • Application Frameworks • The new structure of PI will permit us to achieve the following: • Plant-scale material and energy balances • Further integration with SAP using Sigmafine in conjunction with Rlink • High availability across the Enterprise using VM’s (virtual machines)

  17. WAKE UP!!! Questions? Todd M. McQuiston, Dow Corning Corporation t.m.mcquiston@dowcorning.com

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