Powered by PI

A primary goal for OSIsoft is to help our customers obtain maximum value from their PI System deployments. This section contains a multi-industry knowledge base of successful Powered by PI solutions that have been developed by existing PI System users, complete with a short summary description for each solution. This knowledge base is designed to help PI System users benefit from the combined expertise of others as they roll out their PI Systems across their facilities and organizations.

Users are invited to submit a summary description of their favorite Powered by PI solution for inclusion in this on-line knowledge base. To maintain customer confidentiality, we do not publish or include any company or contact names. Please contact marketingrequest@osisoft.com for further information.

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   Alarm Management
The PI System provides coordinated management of all alarms generated by the various control systems (Distributed Control Systems, Programmable Logic Controllers, Supervisory Control And Data Acquisition, etc.) and identifies opportunities to improve alarm management in the plant or distributed operations. Use PI System Alarm Management products (RtAlerts, AlarmView) to keep alarm histories, calculate alarm frequencies, exception reporting of alarms and sort alarms by type (operator, system, hardware, software).
Related Resources
Case Studies: QNI
   Analyzer Performance
The PI System provides statistical information on the accuracy and performance of advanced control quality analyzers against the designated calibration method of either calibration samples or laboratory measurements. This information is delivered intuitively, enabling users to easily understand current and historical performance. An ethanol manufacturing plant used the PI System to correct a quality analysis instrument (instead of misadjusting their process) subsequently avoiding quality problems that saved tens of thousands of dollars.
   Automated Reports
The PI System report tools (RtReports, PI DataLink) automatically generate product quality real-time reports, shift and daily production reports, environmental and regulatory compliance reports, and weekly or monthly plant or enterprise-wide performance reports. The RtReports tool is specifically designed to satisfy the stringent electronic reporting requirements in pharmaceuticals and biotech.
   Balanced Scorecards
Organizations are increasingly using balanced scorecards to define key operational objectives and translate them into measures, targets and initiatives that drive the company's strategy. The PI System captures and displays operations data in real-time, allowing strategic decisions to be made continually, instead of at end-of-cycle strategy review sessions, which can be the difference between profit and loss.
Related Resources
Case Studies: QNI
   Baseline Best Practices
Organizations are using the PI System to develop Standard Operating Condition (SOC) applications and establish best practices even where performance is not a constant, but depends on many variables such as the type of products or the environment. Users can easily identify key variables throughout a facility, evaluate business rules on a timer or exception basis and report rule violations.
   Batch Quality Monitoring
The RtPM Platform products (PI Batch, BatchView, Process Templates) are used to track and record the real-time composition of batch products including intermediate batch processes. Batch-to-batch comparisons are made by overlaying trends of the same parameter from different batches to troubleshoot issues such as why the quality of one batch is "good" while the other is "unacceptable."  As an example, one coated paper manufacturer used PI Batch to improve the manufacturing process in the coating kitchen. In another example a chemicals manufacturer achieved a 40% reduction in cycle time by using PI Batch to collect and analyze batch phases and operations. Enterprise-wide RtPM Platform systems are used to do corporate-wide benchmarking of batch processes identifying opportunities to reduce costs and improve quality.
   Certificate of Analysis
The PI System is being used to prepare certificate of analysis (COA) that accompany shipped products. For example, a paper mill used the PI System to pull paper machine reel data out of a quality information system and parse the data into customer roll information, correcting for time delays and rewinds. This was combined with web scanner data that was pulled directly from the quality control system and also parsed into customer rolls to create the COA.
   Condition Based Maintenance (CBM)
The PI System moves reliability-centered asset management from calendar-based to condition-based maintenance. You can monitor and alarm on vibration and temperature limits; schedule maintenance based on process conditions; monitor and alarm based on actual running hours to trigger maintenance work orders; consolidate equipment variables for analysis and improvement of plant performance in conjunction with process conditions; and manage and compare maintenance costs across the enterprise. On a paper machine, the PI System can monitor equipment data (temperatures, flows, vibrations, etc.) and quality data  (basis weight, moisture, etc.) then couple this data with manufacturing requirements to determine when to schedule and perform maintenance to maximize operational efficiency.
Related Resources
Case Studies: Arkema, PSE&G
   Continuous Emissions Monitor (CEM)
Organizations have used the PI System to develop CEM solutions that use complex rules and calculations to detect process conditions that would violate an environmental permit. These violations are reported to internal environmental personnel and the results are automatically stored in the PI System for controlled access and distribution to anyone inside or outside the corporation who needs that data.
Related Resources
   Control Loop Monitor
Most large process plants have several hundred control loops in operation and, in many cases, many of these loops are not performing at optimum levels. A major integrated pulp and paper mill uses the PI System (Control Monitor product) to perform a daily inspection of the performance of all control loops and, via an email alert, report to maintenance the loops that are not performing correctly. Typically 5-10 non-performing loops are flagged for attention each day.
   Corporate Data Warehouse
Corporations are using the PI System as the real-time component of their corporate data warehousing. Time series operational data is collected from various PI System servers located in their plant operations and stored in a PI System corporate server where the data can be accessed by any authorized user in the corporation. The PI System servers and visualization tools can connect to business relational databases to interactively analyze and display the real-time operations data in conjunction with business transactional data. 
Related Resources
   Customer Load Management
T&D companies have begun to allow their large customers to do power load management over the Web by using the PI System to maintain a secure real-time performance management system while giving customers access to real-time views of their specific power consumption patterns. A large mining operation was constantly inquiring about their systems loading (average and peak power consumption) to determine, for instance, how their consumption changed as a large shovel was brought on line. Using the PI System they are directly monitoring their power consumption via the Web and making real-time decisions about how to manage their power peaks.
   Data Reconciliation
The PI System (Sigmafine) provides a framework for finding and displaying documents that describe the input/output of a plant, such as receipts, shipments, and inventories. The data can then be used to validate and create an audit trail to document any changes put in place by accounting to balance the numbers.
Related Resources
Case Studies: QNI
   Downhole Systems in Oil & Gas Production
The PI System is used to capture the temperature and casing pressure at the bottom of the well, along with the choke position.  A more recent development is the user of fiber-optic sensors, which provide both temperature and pressure data along the entry length of a well. This data can be correlated with lift gas (steam or natural gas) injection to analyze the field configuration.
Related Industries Oil & Gas,
   Downtime Monitoring
Operations with hard-running, expensive machinery need to be vigilant about down-time. Defining down-time and measuring it accurately can make a huge difference in the effectiveness of machiner and profitability derived from it. As an example, a PI System monitoring application for paper machine down-time generates events from sheet break detector signals then allows operators to log the down-time reasons and add comments.
Related Resources
Case Studies: QNI, The Roche Group
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