OSIsoft Project Reference List
As an OSIsoft integrator since 1995, ACE has implemented the OSIsoft PI System on VMS, VAX, Windows NT, and Windows Server operating systems. Please contact your Applied Control Engineering, Inc. representative if you require additional information.
Abbott Bioresearch Center
ACE interfaced an existing site PI 3.x Historian and two dozen fermentors controlled by legacy B. Braun and Applikon controllers. The resulting configuration included use of PI-OPC interface, Braun OPC server, and a Kepware UCON OPC server. The B. Braun controllers were networked with RS-422 to a dedicated API node. The Applikon controllers were networked via RS-485 to Ethernet converters and then placed on a LAN with another dedicated API node. The customer was able to leverage their existing knowledge of PI client tools to analyze run data and move away from multiple, disconnected historians.
Astoria Energy, LLC
While ACE was at the facility performing NERC CIP implementation, corporate IT expressed interest in upgrading the site PI server. Since the server and interface nodes interacted with the Electronic Security Perimeter (ESP), ACE was involved in upgrade discussions. ACE provided phone and email support to assist IT with the upgrade of the PI Historian. Once that process was complete, ACE designed and implemented a more robust architecture for the interface nodes to allow for uninterrupted data collection from the plant. Site personnel also sought ACE’s support to configure the site historian to communicate with a new EtaPRO installation.
ACE developed and installed a PI Historian to store process, utilities, and emissions information. A PI server was interfaced to multiple Moore Products distributed control systems, local instrument links, and single loop digital controllers for process and event data acquisition. Using the PI client applications, manufacturing and corporate management reports were configured. Uses for this information include energy usage optimization, an on-demand totalization report, daily natural gas distribution, and environmental compliance monitoring.
This project involved a distributed PI system for a pharmaceutical plant. The system integrated data into a central PI server from a separate third-party PI server (DeltaV) and PI API nodes in several different process buildings. One of the PI API nodes replaced an existing Wonderware InSQL historian. A major part of ACE's scope was to backfill years of existing data from the Wonderware system into PI.
ACE designed, developed and installed a 20,000 tag PI system at the Edge Moor facility. A single VMS server using PI 1.6 collected data from an ABB Infi 90 DCS. Utilizing both PI ProcessBook and custom logs, reports were configured for plant and corporate use. Conectiv employees were formally trained on PI DataLink and PI ProcessBook client applications.
ACE retrofitted controls on simple cycle and combined cycle turbines, and integrated them with a plant-wide PI 3.0 Historian for the Hay Road facility’s new combustion turbine plant. The PI Historian runs on an MS NT 4.0 server, polling data from an ABB Infi 90 DCS. The historian was connected to all process areas, including the site waste water treatment plant. Custom reports were developed by ACE detailing energy consumption, production levels, process up-time, and environmental compliance. ACE’s scope also included development of a functional specification, detailed design specification, factory acceptance test, and site acceptance test, as well as training for operations and engineering personnel.
ACE developed and executed validation protocols to support IQ/OQ activities for an existing PI 3.x Historian. The overall system consisted of a single PI Historian, PI API node – obtaining data from both Honeywell TDC 3000 and Rockwell PLCs, and a dozen client stations running PI ProcessBook and PI DataLink.
The PI system at the King of Prussia and Collegeville facilities had remained stagnant for a couple years. ACE worked with GSK staff to design a new architecture with an up-to-date server and redundant interfaces throughout the two campuses. ACE performed the upgrade, cutover, and provided documentation to administer the system. ACE added additional interfaces to energy monitoring systems and developed PI performance equations to feed into site KPIs.
ACE developed a new portal site using Microsoft SharePoint Services and RtWebParts. Over a hundred displays were converted from ABB ConductorNT to PI ProcessBook and SVG screens. The site navigation leveraged an extensive PI Module database. The project included reconciling the existing point configuration versus the points required to fully animate the screens and provide process information. A survey of the PI network, including PI Historian and PI interface configurations, was also completed and documented as a starting point for future validation activities.
ACE provided engineering services for an existing PI 3.0 Historian at the King of Prussia facility. The single VAX server acquired HVAC data from approximately 40 pharmaceutical research and manufacturing buildings on-site to conform to GMP and GLP standards. ACE added a significant number of points from an ABB distributed control system to enhance data collection, troubleshooting, and reporting capabilities.
Over a three year period, ACE provided loading analyses, configuration, and support services for Hershey’s PI system to correct data collection and reporting problems. Over 20 critical reports were verified to ensure the data was accurate and that it matched actual plant operating data. Additionally, ACE developed an Excel-based interface to those reports thereby making them easily accessible to all appropriate personnel. Hershey personnel are now able to request any number of reports by time period and have assurance that they are both complete and accurate.
ACE provided two one-day training classes on PI tools: PI ProcessBook, PI DataLink, PI SQC, and PI BatchView. Students were provided with a station for hands-on training and a manual for future reference. Each class was given twice with up to 10 students per class. The training and manual were developed in-house by leveraging previous training and OSI resources. The training was delivered at ACE facilities.
Monroe Energy, LLC
The facility had been shutdown and purchased by a new owner. ACE was asked to perform a quick assessment of the current state of the server and interfaces and provide an upgrade path for the server to the latest stable version of PI Historian. Due to the startup activities occurring at the plant, ACE worked after hours to setup, configure, and cutover a new server PI historian. Working with site IT, we migrated from a physical server to a virtual environment. As part of the upgrade, ACE provided improved archive management, automated backups, and documentation of the historian and interface settings.
NRG Indian River
Due to un-explained issues with the site's PI server, NRG reached out for help to assess their system. In response, ACE conducted a survey of the plant PI server and interfaces through remote and local access. ACE then developed a document for NRG which detailed the current configuration of the system and reviewed each component with regards to best practices and recommendations for improvement.
ACE assembled and conducted a two-day PI administrator course and several sessions of a one-day PI user training course for a number of engineers and operators at this chemical plant.
Philadelphia Energy Solutions (formerly Sunoco, Inc.)
The customer has a number of large customized PI-ACE installations at refineries throughout the Delaware Valley region. ACE provided programming support to modify, test, and deploy existing PI-ACE modules and to add new modules.
Voith Hydro Inc.
On short notice, ACE setup a pair of PI servers and interfaces in a redundant configuration (PI-HA) to collect data from a Siemens control system. The effort included creating about 2000 points, setting up client nodes, and providing installation documentation for all components.
Two PI servers were installed at separate facility monitoring stations over five miles apart. Each site had a dedicated data acquisition node (PI-API) that communicated with local Bristol Babcock OPC servers to buffer and push data up to the local PI Historian. The two PI Historians were configured to synchronize data between each other across a dedicated DSL line using the PI-to-PI add-on. This allowed clients at either facility to view points from either system without overloading the limited site-to-site bandwidth. ACE configured seventeen client stations between the two facilities including several portable laptops. The client stations were configured with PI ProcessBook for visualization and PI DataLink for reporting. Operators were formally trained on both applications and how to configure their own trends and reports. The laptop clients were able to access data from the servers over a secure VPN connection. ACE also configured Microsoft SharePoint server with RtWebParts to provide future thin-client access to the historian information.