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Value-Added Applications in the PI environment St-Laurent Paperboard, La Tuque By Yves Racette,...
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Transcript of Value-Added Applications in the PI environment St-Laurent Paperboard, La Tuque By Yves Racette,...
Value-Added Applications in the PI environment
St-Laurent Paperboard, La Tuque
By Yves Racette, Walsh Automation Inc., PI Systems Integrator
Agenda• Facts: La Tuque Mill
• Project and Systems History
• Systems Architecture
• Overview of Value-Added Applications
• Projected work
• Benefits
La Tuque Mill: Facts• ~ 1,200 Metric Tons/day - rolled board• ~ 50 different grades• 3 Kamyr Digesters, 19 Batch Digesters• 2 Bleach Lines• 2 Paper Machines• 2 Power Boilers, 3 Recovery Boilers• 3-line Recaust (slakers, lime kilns)• Coordination is a constant challenge
Systems History• Plant Information systems have been in
operation at the plant since 1967– IBM 1800– PDP-11– VAX (First version of WalshCIM)– PI
• Supervisory controls were progressively moved to the DCS
1967
IBM 1800
Systems History
1982 1986 1998
PDP-11
VAX
PI
Supervisory Controls DCS
Project History• Preliminary and detailed Engineering
– Needs analysis– Implementation Plan– Costs Estimation
• Main Objectives: – Replace VAX systems– Long Term Archiving with full resolution– Better diagnostic tools– Migration of VAX applications
Architecture (Phase I)
PI Server
Foxboro I/A Interfaces
VAXBleach.
VAXKamyrs
Functions:•Data Acquisition•Manual Entries
PDP-11I/O Subs.
Foxboro Machine 4
Foxboro Effluent
Foxboro Machine 3
Foxboro Steam
Foxboro Batch Cook
Existing VAXPINet
Control Network(Ethernet)
Plant Ethernet
MCS Max 1000 DCS
MCS Max 1 DCS
PI-APISpecificInterface
Functions:•Data Acquisition•Graphics•On-line calculations•Reports•Process Diagnostics
Architecture (Current)
PI Server
Foxboro Machine 4
Foxboro Effluent
Foxboro Machine 3
Foxboro Steam
Foxboro Batch Cook
Control Network(Ethernet)
Plant Ethernet
MCS Max 1000 DCS
MCS Max 1 DCS
Functions:•Data Acquisition•Graphics•On-line calculations•Reports•Process Diagnostics•Manual Entries
Foxboro Caustic
Max 1000 + Plus Gateway
Max 1000 + Plus Interface
Foxboro I/A Interfaces
MillWide Use• 80 Process Book
• 20 Datalink
• 15 Manual Entry Applications (API)
• 20 SQC
• 20 Batch View
• Increasing demand ...
Applications Design• Standards were defined at the beginning of the
project– tags and files naming conventions– display standards (color, font, frames, VB code)– reports presentation and automation– development methodology
• Implementation was done by Walsh Automation and St-Laurent Paperboard
Applications• Process Book Displays
• Process Diagnostics (advisors)
• PI Batch and PI SQC applications
• Operation Reports
• Manual Entries
• On-Line Calculations
• Specialized applications
Process Book Displays• Mill and Area Overviews + some details
• One single .piw file with links to .pdi files
• NT security implementation (read-only access to .piw and .pdi files)
• Process Book security: View only mode ProcessBook=Primary (procbook.ini)
• Navigation toolbar and Detail … menu
Process Book Displays• Secured PCs: Process Book is the only visible
application. All other programs executed from within Process Book
• VBA code in many display pages (e.g.: on-line calculation of pulp inventory, yesterday’s averages, double-clic assigned to Revert)
• French version of Process Book
Live Process Equipment Statuses
Navigation Toolbar
View Only Mode
Process Advisors• Specialized displays with visual indications
of abnormal process conditions
• Example: Mill water balance
Sewer with abnormal conditions
Get details ...
Tank Overflowing causing the problem
Suggested Steps and Actions
PI Batch Application• Coating kitchen monitoring
• Batch View OCX and VBA code– After selection of a specific batch, the display time is
set to start of batch– VB controls allow for batch “replay”
• VBA code validates presence of Batch View license before page is displayed
• Batch Query/Datalink batch report
Batch Selection with Batch View OCX
Replay Batch with (+/- delta seconds)
Go to Beginning/End of Batch
Batch Data (from selection)
PI-SQC Application• Monitoring of ISO related performance
indices
• VBA code validates presence of PI-SQC license before page is displayed
Operation Reports• Excel and Datalink combination • Created a library of reports automation functions -
saved as an Excel add-in (.xla)• Daily / Monthly Reports in same spreadsheet• ActiveX control for date/month selection• Data filtering based on process unit status - blank
if process is shutdown or if no manual entry values are available
Manual Entries• PI-Manual Logger data entry could not be used
- too complicated for required mill usage and available in english only
• Data entry application developed by Walsh using Visual Basic– Uses database as configured by PIML– Ease of use / French language– Supports all PIML functions (except HHT)
Tours Tour Runs
Validation bar for selected tag
On-line calculations• VAX legacy system included a long series of
Fortran calculation programs that had to be migrated - some were quite complex !
• Performance Equation was not appropriate
• On-line calculation server (NT service in PI server) was developed by Walsh
• Synchronized execution at various frequencies
• Applications are developed in Visual Basic (structured programming - not event)
• Programs can be easily developed by system engineers
• Allows for complete documentation with detailed comments
On-line calculations
• Uses VB enumerated tag list to allow use of tags by names instead of by ID with PI-API
• ActiveX applications are modified and replaced without restarting the schedule service
On-line calculations
Area Specific Applications• Area specific applications were developed
and integrated within the Process Book environment– Liquor tests– Lime kilns production rate calculations– Operation Log Book– Document Browser (access to reports, ISO and
reference documents, …)
Training• ~ 5 weeks of training by Walsh and
Cogexel:– La Tuque trainers (operation)– Users (PB, DL, Manual Entries) - use of
applications only– PI System Administrators
Projected Work for This Year• New PI Server for Profiles
• Communication link with MAJIQ Replix server (quality and finished product data)
• Expansion of PI-Batch for complete grades monitoring
Benefits• Mill users empowerment was immediate
• Improved personnel productivity
• Process Diagnostics: improved reaction, reduced duration of problems
• Improved tracking of equipment downtime
• Although not essential for production PI has become a critical tool for all users
Questions ?