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Production tracking with PI System
How can you improve plant efficiency in multiple areas without increasing complexity or decreasing flexibility? This was the challenge for a leading manufacturer of post-operative and complex wound dressing products.
Configuring scan class tags
A leading US independent power producer and new PI customer was implementing several PI interfaces at their coal-burning power plant. During the installation, the HMI would lock up when the Ethernet™ cable was connected to the business network.
The initial diagnosis seemed to indicate RSLinx™ gateway or the network was to blame. We found the interface points were originally configured in one scan class. Further investigation revealed the requests for data from the data-highway were taking too long. By adjusting the scan classes into groups, data bottlenecks were eliminated and the HMI stopped crashing. Read related tip.
Solving Modbus® addresses with modscan32
A PI customer was implementing several PI interfaces at their power plant. During install, we discovered slight differences in a vendor’s Modbus® implementations. No one knew the correct values to read. Using hardware documentation and the modscan32 application, we were able to find and configure the Modbus® based tags.
Having the correct addressing scheme and addresses would have saved the client several days of tedious work. Gathering the exact address of the tag to read can be the difference between extended debugging and easy installation. It’s always a good idea to attempt to connect to the expected address using a tool like modscan32 to verify the address is correct and the values are scaled correctly. Read related tip.
Migrating from PI2 to PI3
A global power generation and distribution company and long-time PI customer wanted to migrate their PI2 system to PI3 on Windows Server 2003. The RoviSys solution? Their points database was cleaned up and PI System optimized for the new platform. Interface points originally configured as float16 were converted to float32 to eliminate out-of-range errors. Points using the Performance Equations engine to perform totalization were moved to the PI3 Totalizer Subsystem, which is much more efficient. They are now taking advantage of the advanced features of the latest OSIsoft technology. Read related tip.
Aligning generation with power demand using PI System
Generation levels at power plants in the eastern United States are mandated through the PJM Interconnection, a regional transmission organization. A North American power generation company wanted to establish an automatic generation control (AGC) system using electronic instructions from PJM in their existing distributed control systems. The system needed to incorporate safeguards to keep levels and change rates within safe operating parameters.
The RoviSys solution? PI System. The AGC signal from PJM is received over Inter-Control Center Protocol (ICCP) via the AXS4-ICCP OPC Server and the PI-OPC Interface. This signal is saved to a corporate PI System server and then sent to the specific plant PI server via the PI-to-PI interface. The interface to the distributed control system at the plant then sends the signal from the plant PI System server to the DCS. If the request from PJM exceeds programmed parameters, it alerts operators for response. The plant generation output in megawatts is reported back to PJM for its demand balancing calculations.
Because the company already owned and was using PI System, this solution was straightforward to implement. It also allowed for a highly cost-effective solution. Read related tip.