Developing a Millwide system using PI System™ Data Historian

摘要

Australian Paper operates a complex integrated manufacturing site at Maryvale Mill in Gippsland, Victoria. Key operational units include 3 fibre lines, 5 paper machines, 5 boilers, 4 turbines, 2 recycling plants, 2 lapping machines 2 rewinders, 2 cut size lines, 4 water treatment plants and extensive effluent treatment systems. One major challenge facing management is good coordination of operations on the complex site. Key to good coordination is visibility of the status of each production unit and their interconnecting elements. Because Maryvale mill has a long history, the age and type of automation is varied across the site, from minimal PLC control to multiple branded DCS controlled processes. Each of these processes can be complex in their own right. The development of a comprehensive Millwide system has required connecting the PI System™ to each of the DCS computers, PLCs and lab databases. The next step involved selecting the right process data to collect and creating PI tags that provide appropriate level of information resolution. Visibility of the data was achieved using PI-ProcessBook™ where many dashboard type displays have been developed. Given the massive volume of data available, the design of these dashboards is a crucial factor in building a successful system. Examples of some of these will be presented and some design elements discussed. The overall goal has been to provide better coordination, better decision making, and better troubleshooting and to assist in preventing problems. The system provides cross area visibility where none previously existed and has also been used as educational tool and had real benefits to the bottom line. One of the greatest benefits of a good millwide System, like that deployed at Maryvale mill, is the ability to take isolated pockets of data, combine them in meaningful ways and make that information available across the site.