Improving Equipment Availability and Reliability Using the ... - OSIsoft

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Business challenge/problem addressed 3. There is no way to monitor real time data of other similar unit. We do not have the system to monitor the other unit parameters for comparison for improvement projects. Solution We can monitor real time and authentic data of all the manufacturing units of Ultratech Cement from any one of the manufacturing unit as well as from head office. DataLink is being used to compare data in the excel sheet. Similar units data are taken on excel sheet for comparison for bench marking and improvement projects. © Copyright 2011 OSIsoft, LLC 10
Case study # 1 Application : Cement Bag Counter and Dispatch Reconciliation Before ( Problem ) After ( Solution) 1 Earlier there was no System to reset the counter from site by Dispatch Supervisor(Person of PP operation) 2 Since the end of dispatch on daily basis was not identified at PI, the counts were never used to compare with actual dispatch and so the use of PI for bag counts was not effective. 3 The time at which dispatch fininsed changes day to day basis ,due to nature of operation and manual truck loading .So counter reading based on time ( ideally at 12.0 night )was never in match with dispatch.( Sample PI Graph enclosed) 4 Two bags going simultaneously and counted as one due to less gap between them. This happens sometimes due to misoperation /malfuction at packer Provided the Reset switch for counter ,taken into PI System and instructed the Supervisor to reset the counter at the end of each date when dispatch of the date is closed. Since the time at which the dispatch is closed is identified at PI , The counts in it can be used for comparison with actual dispatch. Even after change of time from sharp 12.0 night , due to operational constraints, the end of dispatch of the date can be identified in PI system and so the bag counts can be compared with actual dispatch. The problem is overcome by sensitive photosensor as it can detect even minor gap.( This problem shall not add in effectiveness of Bag counter system as in this condition , the bag counts will be less than the dispatch by number of times such phenomenon happened. Since the counts are less than actual dispatch, the challenge is over, ). The challenge is bag count more than the actual dispatch*20 © Copyright 2011 OSIsoft, LLC 11
Page 1 and 2: 23 September 2011 WESTIN GARDEN CIT
Page 3 and 4: Server-1 Ethernet Switch 1 Configur
Page 5 and 6: Screen developed by maintenance cru
Page 7 and 8: Process view of Coal Mill © Copyri
Page 9: Business challenge/problem addresse
Page 13 and 14: Case study # 2 Equipment name: Crus
Page 15 and 16: • LIMITATION • Point trend of a
Page 17 and 18: Manual Data entry for QC parameters
Page 19 and 20: © Copyright 2011 OSIsoft, LLC
Page 21 and 22: FLS OPC Server Crusher OPC Server C
Page 23 and 24: Performance Calculations Logging of
Page 25 and 26: Packing Plant Bag Counter Report 10
Page 27 and 28: Example 1 : Condition Monitoring On
Page 29 and 30: CONCLUSIONS © Copyright 2011 OSIso
Page 31 and 32: © Copyright 2011 OSIsoft, LLC
Page 33 and 34: Agenda OSIsoft products and service
Page 35 and 36: PI SYSTEM ARCHITECTURE A B Ethernet
Page 37 and 38: PI Utilization At KOTPUTLI How we u
Page 39 and 40: Business solution Mining SIO2 CAO M
Page 41 and 42: Process Optimization Case Study •
Page 43 and 44: Intangible benefits • Real-time q
Page 45 and 46: Questions © Copyright 2011 OSIsoft

Improving Equipment Availability and Reliability Using the ... - OSIsoft

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