Driving Business Value
with OSIsoft & Transpara
Michael Saucier
Transpara Corp
© 2008 OSIsoft, Inc. | Company Confidential
PI Gives You 360° Business Vision
Long-term Vendor
Partnering
And Contracts
Inventories,
Capacities,
& Process Knowledge
Operational Excellence,
Strategic Vision, …
Operating
History
& Real-time
Performance
2
Sales and
Operations
Planning,
CRM, …
Equipment,
Chemical, &
Vendor Performance
Transpara Operational Intelligence
DELIVER ACTIONABLE, COMPOSITE KPI’S TO DECISION MAKERS ANYWHERE
Business Challenge
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Hidden information
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Solving the Problem
Disparate data sources
Inconsistent data
No visibility across the
enterprise
Decision makers are not
always at their desk
Business Intelligence isn’t
enough
Employee actions and
business goals are not
aligned
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Leverage existing
technology investments
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Data sources / BI engines
Microsoft Office
IT infrastructure
Mobile technology
Align strategies
• Distribute consistent
•
•
information and objectives
Activate corporate strategy
through individual actions
Interconnect the enterprise
www.transpara.com – Live demo http://demo.transpara.com
Customer Value Points
“If we can’t analyze process performance second-bysecond, weekly and annually, we are at an extreme
disadvantage in improving operations. PI enables us to
maximize process efficiencies. Without PI, we’d be
naked.”
– Operations Superintendent
“Millions of dollars have been saved by using PI not only
to better understand the process, but to redesign the
entire operation to run optimally.”
– Automation Engineering Team Lead
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Customer Value Points
“With PI as the eyes and ears of our entire complex, we
are ‘Operationally Ready’ to manage and plan for any
situation. I can’t imagine operating without PI.”
– Refinery Supervisor
“PI enables more intelligent use of people’s time and
resources. It’s a very powerful advantage when people
can see into the operation in virtually any way they want
and find the data they need to improve operating
efficiencies.”
– Plant Manager
5
Technology Drivers in the PI System
 Layered Application Platform
 Fast rollout, Quick ROI
 Highly Available and Scalable
 Extensible by Customers and OSIsoft Partners
6
Business Value at DTE
7
Over 11,000 MW Delivered
Monroe – 3,135 mw
Belle River – 1,260 mw
Harbor Beach – 103 mw
Trenton Channel - 730 mw
Performance Center – 11,588 mw
St Clair – 1,417 mw
River Rouge - 527 mw
Greenwood
8 – 785 mw
Fermi – 1,100 mw
Layered, Incremental Applications
Drives Performance Excellence
Actionable
Information – KPI’s
KPI’s
Process Costs, Asset Health,
Dashboards
Operational Performance, Market Value,
Fleet Optimization
Fleet Optimization
15%
Relate all Data Sources
Analysis Framework
Business Intelligence
Reliability, 4-Block
Outage & De-rate (UCF)
Maintenance & Market
(PI, ProcessGuard, Maximo, SAP, UCF, P3M,
Predictive Monitoring, NeuCo, LIMS, Plant View ..)
25%
Advanced Analysis & Process Optimization
Expert Systems
Equipment and Process Monitoring
Closed Loop Process Optimization
Predictive Monitoring, Optimization
60%
System Dashboards
Fleet Status Assessment
Fleet Drill down
50%
Subject Matter Experts
WEB Visualizing
Standard User Interface
Plant Alarm, DCS Real-time WEB Graphics
WEB Visualization
Easy Access to Information
100%
Process Discrete Data
Engineering Applications
PMAX, Digital Fuel Tracking, Fuel Cost Framework
Discrete data
Limited value
Process Discrete to Data
90%
Post Event Analysis
Distributed Control Systems (DCS)
Distributed OSIsoft PI Historians
Large Population
9 of Data
PMAX, DFTS, eNote,
Fuel Cost Framework,
Alarm Management
DCS, PLC & PI
90%
% Complete
Raw Data Analysis
 Post trip analysis
 Process monitoring
 Optimization
 Early warning
 Alarming
$ 1,890,000
1st year savings!
10
Fleet Performance Analysis (PMAX)
Thermal Performance Calculation Engine
$500,000
Annual Savings!
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Digital Fuel Tracking System
$1,200,000
Annual Savings!
On-line
Fuel Analyzer
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NOx Emissions Strategy
$2,200,000
Annual Savings!
NOx Reduction with
Improved Heatrate
Before
Implementation
Primary
focus is NOx
reduction
only
Focus on
operating
near NOx
budget curve
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After
Implementation
Energy Management System (EMS)
$120,000
Savings!
 The Plant Energy
Management System
is used to
automatically control
unit dispatch
 Implements data
validation on all fields
 Performs several
calculations based
on PI data to
determine validity of
inputs.
 Transported to EMS
Ranger via PI
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$530,000
Annual Savings!
Fuel Cost Framework
Fuel Supply
Default Mode
Auto calculate & update Ranger
Analysis
and
Acquisition
ps-mon-pi
Improvements…
• 30 to 3 people
• Timely data entry
• Zero errors
Blend Calculations
Current
&
Historic
Data
Oil
3
Current
Fuel
Cost
2
ps-tch-pi
Blend Calculations
ps-rrg-pi
Blend Calculations
Gas & Oil Price at
Hubs
1
Gas -- Dawn &
Michcon City Gate
ps-blr-pi
ESO PI
4
ps-eso-pi
Blend Calculations
ps_hbh_pi
Market
Data
Hourly & Daily
Auto update
Blend Calculations
ps-grw-pi
Blend Calculations
ps-stc-pi
Blend Calculations
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5
Ranger
PI
Ann Arbor
PI to PI (AGC)
$200,000
Savings!
AGC – Automatic Generation Control
5 largest Fossil units & Peaking Units are ramped through PI Set Point control
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Layered, Incremental Applications
Actionable
Information – KPI’s
Annual Savings
KPI’s
Dashboards
Fleet Optimization
Fleet Optimization
$20,000,000
(Projected Savings)
15%
Business Intelligence
Reliability, 4-Block
Outage & De-rate (UCF)
Maintenance & Market
25%
Expert Systems
$11,000,000
Predictive Monitoring, Optimization
60%
System Dashboards
Fleet Status Assessment
$1,000,000
50%
WEB Visualizing
Easy Access to Information
$5,500,000
100%
Engineering Applications
$4,500,000
PMAX, Digital Fuel Tracking, Fuel Cost Framework
Discrete data
Limited value
Process Discrete to Data
90%
Distributed OSIsoft PI Historians
Large Population of Data
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$3,000,000
90%
Business Value at Cargill
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Over 100 Site Locations
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Fast Roll Out, Fast ROI
107 Sites
2 Days
Per Site
2 Sites
Per Week
Approximately
52 WEEKS
to complete full implementation of all sites
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5 Teams
Business Value at Microsoft
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Highly Available & Scalable
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High Performance Web Extensions
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Business Value at AEP
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AEP’s Footprint
 U.S. employees: 20,861
 States served: Arkansas, Indiana, Kentucky,
Louisiana, Michigan, Ohio, Oklahoma, Tennessee,
Texas, Virginia, West Virginia
 Service Territory: 197,500 square miles
 Miles of transmission lines: 38,953
 Miles of distribution lines: 207,632
 Generating capacity: 36,000 megawatts
 U.S. customers: More than 5 million
 U.S. electricity sales: Approx. 214 million megawatt
hours
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Same Displays on Desktop and PDA
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Business Value at Western
Power
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88,000 KM of Line to Manage
Electricity Networks
of
Western Australia
30th June 2000
6.6kV
11kV
22kV
33kV
South West
Interconnected Grid
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Generation
11-16kV
Generators
16kV - 330kV
Step up Transformer
EMS
Transmission
Transmission Line
330kV, 220kV, 132kV or 66kV
Terminal Substation
330kV, 220kV, 132kV, 66kV
Step Down Transformers
Transmission Line
330kV, 220kV, 132kV or 66kV
Zone Substation
132kV, or 66kV, 33kV, 22kV, 11kV
Distr
HV
or 6.6kV Step Down Transformer
Distribution Feeder
33kV, 22kV, 11kV or 6.6kV
Distribution Transformer
Distr
LV
6.6kV - 415/240V
11kV - 415/240V
22kV - 415/240V
Customer
33kV
- 415/240V
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DMS
Outage Management Enhancement
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Business Value at Tesoro
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Seven Major Refineries
 Acquired in a “roll-up”
strategy
 Anacortes, WA
 Mandan, ND
 All came with
different underlying
control and
information systems
 Kapolei, HI
 Martinez, CA
 Kenai, AL
 PI ties it all together
to make a unified set
of information
systems
 Salt Lake City, UT
 Wilmington, CA
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Business Value at Genentech
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Thousands of Data Sources
 Distributed, longrunning batches
 Reactors
 Fermenters
 VERY high raw
material costs and
VERY high value
products
 Freeze Dryers
 Mixers
 Purifiers
 Engineers keep
batches under control
even when away
from the plant
 Crystallizers
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Having PI Makes Things Possible
Companies that have an infrastructure in
place to manage and deliver operating
metrics and key performance indicators will
be able to react to the market faster and
ultimately outperform the others.
John Hagerty, Senior Analyst
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Transpara Background
 Founded 2005 by Michael Saucier
– Significant contributor to ISA standards, S88, S95
– Founded World Batch Forum in 1994
– Founder of PID in 1988, sold to Rockwell in 1998
– Founder of Sequencia in 1997, sold to OSIsoft in 2002
 Deeply coupled with OSIsoft at all levels
– Technically – ISV with HA, AF 2.0, SDK connectivity
– Personally – Pat Kennedy invested in PID and then
purchased Sequencia
– Spiritually – We simply love PI
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Customer Value Points
“Visual KPI is a must-have tool for us to improve our
operations, everyone from frontline SCADA support staff
and System Operations Managers, all the way up to the
CEO rely on it for real-time tracking of operational
performance data.”
– Power Company Executive
“With Visual KPI’s ability to deliver valuable information
about our assets to decision makers company-wide, the
software implementation will deliver an ROI of 35 million
dollars over its first 3 years.”
– Transmission Company Executive
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Customer Value Points
“It's about as simple as you can get, it took us longer to
get the purchasing in place than to launch the actual
project. And because the Transpara software has good
connectors to PI, the deployment took only a day”
– Operations Management
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KPIs Defined
Key – Only a subset of all possible viewpoints,
those which best reflect the state of an asset,
organization or financial entity
Performance – Metrics related to performing
ones job, or adhering to corporate or government
standards, or achieving customer satisfaction
Indicator – Not a closed-loop function, KPIs
are to be used by people to help them take correct
action
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Anatomy of a KPI
Status = GOOD
Actual
Min
Low Low
Target
Max
High High
High
Low
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Anatomy of a KPI
Status = HIGH
Actual
Min
Low Low
Target
Max
High High
High
Low
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Anatomy of a KPI
Status = HIGH HIGH
Actual
Min
Low Low
Target
Max
High High
High
Low
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Composite Measures Defined
 Re-purpose existing data
 Assembled not programmed
 Extend value of data already created
 Example: Production Rate
– Target value from ERP or Planning System
– Actual real-time data from AF / PI
– High and Low quality limits from SQL Server
– Max and Min of machine capability from MRO
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Anatomy of a single Scorecard
 A collection of KPIs related to each other in some
significant way at run-time
 Collection criteria can be a
combination of Dynamic and
Static KPI Attributes
 Some examples:
– All KPIs for Equipment Type 1300, With
Priority 1 Alarms in the Western Region
– All KPIs for Asset 67 with Status <> Good
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Dealing with Many KPIs is Hard
 Most companies have hundreds or even
thousands of KPIs
 Beyond a few dozen KPIs, the Scorecard Format
suffers. Enter the KPI Map
 KPI Map is good for up to
hundreds of KPIs
 Example:
– All KPIs from the NE region
– All Wind Farm Assets
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Even more KPIs – Use Rollups!
Rollups typically use “worst-case”
Overstates low-level problems
Transpara developed the True Roll-UpTM
concept to handle this problem
True Roll-Up (TRU) accurately reflects the
state of the entire hierarchy regardless of
the number of KPIs involved.
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What is True Roll-UpTM?
 Not “worst-case” but the entire state map of all KPIs
 TRU Chart as Percentage Bar or a
Percentage Pie chart.
 Drill-downs automatically adjust
for total number of KPIs in hierarchy
 The TRU Chart at any level in the
hierarchy shows the percentage in
any state for all KPIs below that level
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Roles at Various Customers
 Mechanic
 I&C Technician
 Control Room Operator
 Performance Engineer
 Regulatory Manager
 Test Engineer
 PPO Engineer
 Quality Assurance
 Mfg Sciences Engineer
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 Executive
 Field Supervisor
 Plant Engineer
 Operation Manager
 Control Manager
 Maintenance Manager
 Watch Supervisor
 Process Engineering
 Process Development
Visual KPI 3 Architecture
Data Sources
Any Mobile or Desktop Client
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Visual KPI Excel Editor
PI Historian

Meta Data

Equations
Any RDB

Existing Data

External KPIs
Any LOB App

Link to financials

Planned values

SAP, MRO, etc.

Configuration only, no runtime association or storage
Publish Scorecards
via Web Services
XML over HTTP
Web Services
Real-time Data
Excel 2003 or Excel 2007
with VSTO
Web Services


Visual KPI Server

Composite KPI Engine

All meta data in SQL 2005, 2008

Windows Server 2003, 2008

ASP 2.0 Web Site
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Visual KPI
Composite KPI Software
Easily repurposes data from PI, AF, Microsoft
SQL Server, Oracle and any ODBC data
source by delivering Scorecards, KPI Maps,
KPI rollups and Real-time trends to browsers
for decision makers ON THE GO
 Works with any desktop, tablet, or laptop and
almost any mobile device
 Leverages existing data from many systems
 Supports hundreds of real-time data sources and
hundreds of different mobile devices
 Gives stakeholders “one version of the truth”
 Reduces risk with more people are in the loop
100’s of
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Data
Sources
Mobile Enterprise KPIs
ENTERPRISE
Application
Servers
Portal
Servers
Business
Systems
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Joint Ventures
Employees
Regulatory Agencies
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`
`
`
`
`
Division HQ’s
`
``
`
`
Staffed
Asset
Unstaffed
Asset
(10’s of sites)
`
`
`
(100’s of sites)
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No Matter Where You Are
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Now You Know
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