PI Implementation on a Brown Field Aluminium Smelter ...€¦ · – Version 9.2.0.6 – Sector...

1© 2005 OSIsoft, Inc. – Company Confidential

PI Implementation on a

Brown Field Aluminium

Smelter Project:

Total Integration

Approach

Andre Noel, Robert Pelletier


AGENDA

Aluminerie Alouette and Hatch

Project overview

Brownfield integration

PI applications:

– Production Intranet

– PI-ACE

– Batch tracking

– Environmental system

– Real time production data integration

– System monitoring

Conclusions


COMPANY OVERVIEW

Alouette originally started production in June 1992

Single plant = Pechiney AP-30 technology

Located in Sept-Îles, Québec

Approximatively 900 employees

One of the most efficient aluminum producers in the world

Owned by five partners:

Alcan (Canada 40 %)

Austria Metal (Austria, 20 %)

Hydro Aluminium (Norway, 20 %)

SGF Québec ( Canada, 13,33 %)

Marubeni (Japan, 6.67%)


ALUMINERIE ALOUETTE


EXPANSION PROJECT OVERVIEW

Expansion project (1B$ USD) began in mid 2002 and will be completed mid 2005

Phase II expansion will add 307,000 tpy capacity, bringing the total plant production over 550,000 tpy

Alouette will become the largest aluminum smelter in the Americas

594 aluminum reduction pots will be in operation

Total electric power consumption will be 895 MW

Brownfield expansion of existing facilities:

– Challenge: keep existing operations running efficiently

Project scope included modernization of IT and control systems

EPCM

– SNC Lavalin HATCH Joint Venture

– Lead System Integrators


ALUMINUM MAKING PROCESS


ANODE BAKING

Anode baking: batch process; 14 to 17 days

at a maximum temperature of 1200 C


ALOUETTE PHASE 2 : New Pot Room

•Plant includes:

•New pot lines include 312 pots

•Power supply: 350 kA in series

•Total power consumption is more than 800 MW


Product : Pure Aluminum Sows

Product:

•High quality pure aluminum

•Multiple end-user in Canada, US and the world


Aluminum smelting business context Primary aluminum is a commodity

Business factors

– Operating costs are critical

– Alouette produces pure aluminum in a make to stock operation

– Total world production: 31.5 Mtons.

• Alouette: 0,5 Mtons

– Mature process

Alouette is one of the most efficient smelter in the world

– Process optimization is an important factor


ABOUT HATCH

Established in 1955: worldwide leader in consulting, information systems, project management and construction and engineering for metallurgy, infrastructure and energy

Innovative organization

Head office located in Canada; over 60 global offices on all continents

6,000 professionals worldwide, 500 in control and systems

Currently managing over US $15 Billion dollars in projects

Work closely with OSIsoft since 1996


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking




Conclusions


PROJECT ORGANIZATION : OBJECTIVES

Hatch played a key role as lead system

integrator providing key advantages:

•Integration in Engineering workflow

•Simplifies change management

•Reduces costs

Strong emphasis on:

•Development methodology

•Reducing maintenance cost through

program uniformity

Alignment to Alouette business objectives


DEVELOPMENT METHODOLOGY

Transfert chantier & VPO(PIN-SC-08)

-Preparation

-Needs assessment (meetings)

-Wrting the specification

-Specification review with users

-Specification adjustments

-Approval by AAI (sector resp.)

-Programming following standards

-Code review by client

-Programming adjustments

Test d’intégration(PIN-SC-06)

Programmation(PIN-SC-05)

Analyse(PIN-SC-04), (PIN-SC-15)

-Unitary tests

-Integrated Tests

-Approval by AAI (OK for VPO)

-

-

-

Ges

tion

des

Déf

icie

nce

s (P

IN-S

C-0

7)

Transfert chantier & VPO(PIN-SC-08)

-

-

-

-

-

-

-

-

-

Test d’intégration(PIN-SC-06)

Programmation(PIN-SC-05)

Analyse(PIN-SC-04), (PIN-SC-15)

-

-

-

-

- VPO

-

Implementation(PIN-SC-08)

-

-

-

-

-

-

-

-

-

Integration Test(PIN-SC-06)

Programming(PIN-SC-05)

Analysis(PIN-SC-04), (PIN-SC-15)(PIN-SC-04), (PIN-SC-15)

-

-

-

- Implementation at the plant

-

- Approval by AAI

Def

icie

nci

es M

anag

emen

t


SYSTEMS ALOUETTE VISION

« Provide a simple, efficient,

integrated and scalable Plant

Information System »


PRODUCTION SYSTEM : VISION

Interface

Interface

SAP

Pro

du

cti

on

IT

Sy

ste

ms

Op

era

tio

nM

an

ag

em

en

t IT

Sy

ste

ms

Supervisor

Process Eng.

Maintenance

Plant operator

Management

FinancesOther

Business

applications

Equipment

Control

Data Reconciliation

& Adjustments

Process & Operation

Historical data

Trends, Analysis

Tracability

Technical Data

Recording

Operational Data

Recording

Operational

Reports

Corporate

Reports

Pro

du

ctio

n In

fo

rm

atio

n

Validated data

Plant Historian

Collecting data

in real time

LIMS

Lab Data recording


IMPLEMENTED TECHNOLOGIES

Automation & Control

– Siemens PCS7

– ABB MicroScada

– Proprietary systems:

• Pechiney and Schneider: ALPSYS (pot regulation)

• Innovatherm ProBake (Anode Baking Furnace), etc…

• Invensys: Vision system (anode defect inspection)

OSIsoft PI Systems real time data base

– PI ProcessBook, PI-SQC, ActiveView, Batchview, …

– PI-ACE

– PI-OLEDB

– PI-BATCH including PI Batch Generator interface


IMPLEMENTED TECHNOLOGIES Oracle Relational Database

– Version 9.2.0.6

– Sector databases storing all transactional production data

– Oracle Application Server (OAS) for Web reporting and interface and also scheduled Reports

Uniface

– 4GL development tool highly platform and database independent

– Programming tool used to develop production IT applications through all plant areas

Legato (co-standby server – AAM)

– Redundancy of the PI acquisition node

– A single server running Legato provides redundancy for all acquisition nodes


PI IMPLEMENTATION

4 Plant Data Historian servers

– Carbon plant, Services, Electrolysis, Casthouse

More than 60,000 tags in use

6 acquisition nodes with redundancy

– 4 OPC (Siemens) for process control

– 1 OPC (ABB) for energy management system

– 1 OPC for anode baking furnace

– 1 BatchFl for meteorological data

Project includes the purchasing of Rlink for future integration with SAP.

– Maintenance information will be transferred to SAP using Rlink.


TECHNOLOGY MODEL PROPOSED

SAP

BUSINESS SYSTEM

PHASE II

PROCESS CONTROL (REAL TIME)

(PCS7)

DATA ACQUISITION NODE

BY AREA

PI PLANT DATA

HISTORIAN

SERVER

DATA VALIDATION

RLINK INTERFACE

TRENDS

PROCESS

ANALYSIS

PRODUCTION

REPORTING

ANALYSIS

ORACLE RELATIONAL

DATABASE

BY AREA

PLANT FLOOR UNIFACE APPLICATIONS

OPERATOR DATA ENTRY, LAB INFO, ...

OST DATABASE

ANALYSIS

UNIFACE

Data Transfer

Maintenance equipment data:

ex: motor runtime

Production data

Sows and ingots

production

INTRANET & EXTRANET

WEB ACCESS TO

PLANT DATA

TRENDS

REPORTS

REAL TIME TRANSACTIONAL

Aggregated Data


SYSTEM ARCHITECTURE (global)

SGEFNDELE

Atelier à PâteStockage, Manutention des

anodes, FACScellement Électrolyse série 1 Électrolyse série 2 Centre de coulée Matières premières

OSM OSM OSM OSM OSM OSM OSM

ES OSS

VLAN GESTION

VLAN PRODUCTION

Serveur Historien

UDA

Serveur Historien

ELE

Serveur Historien

SGE

Serveur Historien

FND

RÉSEAUTIQUE ET SYSTÈMES PHASE II

RÉSEAU OPÉRATION

RÉSEAU OPÉRATION

RÉSEAU CONTRÔLE D'ÉQUIPEMENT

Router

Atelier à Pâte

OSC

ES OSS

Stockage, Manutention des Anodes et FAC

ES OSS

Scellement Électrolyse série 1 Électrolyse série 2 MMP: PR1, PR2SGE: Compresseurs et SEE

OSS OSS

Centre de coulée

ES OSSNAH ES OSSNAH ES OSS

Services généraux

OSM

OSS

OSM

OSS OSS OSS OSS OSS OSSOSS

S. Picard (30 Novembre 2004)

OSM

OSM

Serveur Sectoriel

UDA

Serveur Sectoriel

ELE

Serveur Sectoriel

FND

Serveur Sectoriel

SGE

Serveur OST Existant

Alpha VMS-Rdb

OSC OSC OSC OSC OSCOSC

OSC

FAC

OSC OSC OSC OSC OSC OSC OSC OSC OSC OSC

ES

OSC OSC OSC OSCOSC

NAH

PR1

PR2

OSM

NAH Redondant (Legato)

NAH

UDA

4 - AS +

1 AS Temp.6 - AS

1 - AS

OSM

1 - AS

OSM

6 - AS

OSMOSM

OSM

3 - AS

6 - AS

3 - ASOSM

OSM

OSM

2 - S5

2 - AS1 - AS

OSMOSM

OSM

2 - AS

2 - AS

1 - AS

OSM

4 - AS 1 - AS

10 - S5

OSMOSM

2 - AS 2 - AS2 - AS

MSE Futur

OSM

3 - AS

1 APC Temp.

RÉSEAU OPÉRATION

NAH

Implanté En cours d'implantation Planifié

Serveur OST Unix

Dépôt de données

Existant

RÉSEAU CONTRÔLE D'ÉQUIPEMENT

23 OSC

RÉSEAU ADMINISTRATIF

OSC OSC OSCOSC OSC

1 - S5 Phase I

1 - AS

Synchronisation

des horloges

Serveurs SAP Firewall

SYSTÈMES CORPORATIFS

Serveurs de fichiers

OSM

OSM

OSM

OSM

1 - AS

2 - S5

1 - S5

OSM

1 - AS

OSM

1 - AS

OSM

1 - AS

OSM

Serveur LIMS

Serveur Hist. Dév.

DEV

Voûte - Source

Intranet ProductionAutres

secteurs

FND

Serveur de rapports

Oracle Apps. Server

Serveur Monitoring

SNMP Trap


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking




Conclusions


BROWNFIELD INTEGRATION Challenges

– Existing system provides critical information to operation

• Reports

• Data storage

• Trends

– Existing systems merge Operator interface and data management

– System must be migrated without extended downtime to new systems

• New Control platform (Siemens PCS7)

• PI RTPM

– Due to operational constraints:

• For each plant area: system are migrated individually

• Maximum plant shutdown duration is one week

– Production data must be available at all times


EXISTING PRODUCTION SYSTEMS ARCHITECTURE

C ProgramsPRODUCTION

RDB

VXL/VMS

X- Terminal

PC-emulator

ALOUETTE LIMS

File Exchange

Proprietary

interface

Control Network

PLANT AUTOMATION SYSTEM

PLANT AREAUNIFACE

Siemens S5

Paper report

UNIFACE

PRODUCTION

INTERFACE

File Transfer


C ProgramsPRODUCTION

RDB

VXL/VMS

X- Terminal

PC-emulator

ALOUETTE LIMS

File

Exchange

Proprietary

interface

Control Network


PLANT AREAUNIFACE

Siemens S5

Paper

report

UNIFACE

PRODUCTION

INTERFACEFile Transfer

TRANSITION ARCHITECTURE

-Based on VXL PI developed interface

-Allows progressive system migration

API Node

PI-ACE SERVER

CALCULATIONSPI ModuleDatabase

RtPMPI SERVER

PI ActiveViewPI OLE DB

Interface

ORACLE

PI OPC ClientInterface

Siemens WinCCOPC Server

Control Network


PLANT AREAUNIFACE

PI ProcessBookClient

Siemens PCS7

PI BaGenInterface

VXL-PI

With BatchFl


TAG STANDARD IDENTIFICATION

EXAMPLES:

Moyenne aux heures: 2831LIT001:MOY.H

Volume Evénement: 2831LIT001:VOL.E

Maximum: 2831LIT001:MAX.J.DEBUT_FIN

Envoie de consigne: 2831LIT001.PC:OUT

PLC Siemens Server PI API Node PI Data Historian

Server

Transmitter

Equipement

Shop Floor

2831-TK-001

2831-LIT-001 2831_LIT_001

2831_LIT_001

Client

ClientTagInstrumentTag

2831-LIT-001

2831-LIT-001


AUTOMATIC TAG CONFIGURATION Tools were developed in order to

automatically retrieve all tags information and properties from the Siemens PCS7 database.

Imported information from PCS7 is exported to an Oracle database for validation.

Validation rules have been developed in order to ensure that the standards were respected.

The editing of the result is done through excel using SQL queries.

All tags have editable fields in order to insert notes, add reference etc….

Generation of a comparison report between tags in a PI server vs the Siemens PCS7 in order to process only the variation.

PI information have priority over the basic Siemens configuration database

SIEMENS_OS

PI TAGS

PI_POINTS

SQL Database

Configuration

database

S1

P1

PI Server

(Configuration)

Siemens PCS7

OSS server

S4

S4 S3

P2

S2

P3 P4

P6

Excel

(Edition /

Visualisation)

result screens

Comparaison

Synchro

P5

P5

S4

P5

Importer OS-Siemens Importation......... S1 + S2 (Efface le chiffrier et les info. du serveur OS dans Siemens_OS

Edition OS-Siemens............................... S2

Sauvegarder OS-Siemens...................... S3 (Mise à jour Siemens_OS)

Comparer OS-Siemens et base............. S4 + S2

Transfert OS-Siemens avec Base.......... P1 (Vide partiellement Siemens_OS et mise à jour PI_Points)

Edition de la base................................... P2

Sauvegarde de la base.......................... P3 (Mise à jour PI_Points)

Synchroniser la base avec un serveur... P4 + P5 (Import SMT + Mise à jour de PI_Points)


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking




Conclusions


PRODUCTION INTRANET

Objectives:

– Provide an easy access to plant information for every authorized users and from anywhere in the plant

• Alouette has over 100 occasional users

– Provide a central location for the distribution of plant information: trend (activeview), production reports (html, pdf), …

Technology used:

– IIS and standard Internet Explorer as a browser

– PI Activeview (Activex to visualize PI PDI)

– Adobe acrobat viewer, …


PRODUCTION INTRANET


USER AD-HOC QUERY (Intranet ActiveView)

User tool: Ad-Hoc query

– Provide a simple way to rapidly create trend in order to monitor closely the process or …

– Methods: Through a browser from the production intranet (Activeview)

– Between 10 and 50 users could access it

– Approximately 10 concurrent users

– Available from any PC or thin client in the plant, office


USER AD-HOC QUERY (Active View)


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking




Conclusions


CALCULATION VALIDATION (PI-ACE)

Approach to ensure calculations quality in case of communication loss due to a PI server shutdown:

Calculation Clock Based

Calculation are based on time period (such as: 1 min, 5 mins, etc)

Standard algorithm that allows to automatically restart calculation from the last stop of the PI-Ace scheduler or server shutdown

Use the date of the last result in order to restart the calculation. Will increment according to the calculation.


Calculation Event Based

Calculation based on events (send data to the relational database, send e-mail, etc)

Standard algorithm that allows the calculations to be restarted after any type of loss of communication with the server

Use the date of the last result in order to restart the calculation will increment based on new events found.

Recalculation

Use the manual option "Recalculate" from PI-ACE. Allows to restart all calculations for any period of time.

Very useful feature when for any reason we have a gap in the data calculation. The project standard algorithm only allows to recalculate from the last result.

CALCULATION VALIDATION (PI-ACE)


ENERGY MANAGEMENT SYSTEM

PI-ACE validating and processing methodology:

Complex calculations are executed for the energy consumption reports

Critical information and results must be validated using this methodology:

Gross accumulator ---> Filter ---> Summations --> Infinite accumulator

Filter = Remove Bad Calc, IO Timeout, etc...

Summations will add the gross value to the infinite accumulator (type int32). Reset will be done at 2,2 billion)

Infinite accumulator will facilitate the calculation of consumption on long periods of time because it does not require to be reinitialized.

This approach simplifies calculations

Use of annotation field to track manual changes


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking




Conclusions


Batch Tracking : Carbon Plant System

Carbon anode baking furnace batch tracking:

• The baking furnace uses a complex moving fire system that generates different production batches

• With PI we follow the process variables during the baking process. It affects the performance in the reduction cells

• PI assists in providing information and trends that are required for analysis and optimization of production

• PI records the baking conditions

• Anode tracking process information: All the anodes produced are created in a relational database (Oracle)

• In the anode tracking system we provide in a PI trend information coming from various sources: PI database and Oracle database.


Anode Baking Furnace (Batch Visualization)


Anode Tracking Information System


Anode Production Information System


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking

– Environmental systems



Conclusions


Environmental Systems

PI was used in order to develop environment monitoring applications:

Objective:

– Provide real-time information on gas and… so that everyone can take action toward reducing gas emissions

– Information is accessible from any browser, PI .pdi are displayed on screens located on the plant floor ex: pots room


ENVIRONMENTAL SYSTEMS (HF emissions)


ENVIRONMENTAL SYSTEMS (on plant floor)


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking




Conclusions


Real Time Production Data Integration

PI interacts with the PLC in a bi-directional way :

– Transmits lab results to the PLC in order to provide information on the level of Fe, Si for the bar code printing on the sow.

– PI receives data from the PLC, such as the stabilized weight of the sow. After, that information is sent to an Oracle database. That information will be used by other applications developed in Uniface.


Casthouse Systems (Sow quality: heights and weights)


AGENDA


Project overview


PI applications:


– PI-ACE

– Batch tracking



– PI System monitoring

Conclusions


SUPPORT – DIAGNOSTIC TOOLS

PI Diagnostic applications were developed in different plant areas in order to monitor:

– Communication between the various interfaces

– Status and activity of applications on different equipment

– Status of the communication between different servers


SUPPORT – DIAGNOSTIC TOOLS


CONCLUSIONS


BENEFITS

Some of the benefits encountered with PI:

– Best visibility on plant operation and process

– Better information in order to facilitate process improvement and operations. Better control of the different plant process variables

– Assists management in the decision making process

– Facilitate problem resolution by providing real time information

– PI helps in tuning and optimizing process and equipment

AAI is experimenting a fast and efficient start-up

Integrated EPCM system integration team provided:

– Smooth system migration: Minimum impact on plant

– Systems integration is under budget


QUESTIONS

Robert Pelletier, Aluminerie Alouette [email protected]

André Noël, [email protected], (514) 861-0583

PI Implementation on a Brown Field Aluminium Smelter ...€¦ · – Version 9.2.0.6 – Sector...

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