Monitoring, tracing and analysing continuous and batch processes

INEA uses specialized PI System software of producer OSIsoft to monitor, trace and analyse continuous and batch processes.
OSIsoft is the leading global company in the field of process data processing and storage. PI system is the result of more than 20-year long development and testing of the technology in data collection and processing.
PI System is a set of program applications based on automated quick capturing and extremely efficient storage of process data. PI System enables an efficient view, processing and analysis of gathered data. The system is based on the server/client technology. Modular system structure enables the user to choose a configuration at his/her own need. And this configuration can be upgraded anytime with new modules without any problems.
Pyramid structure view of PI system functions. Individual technologies for the preparation and processing of inforThe pyramid image comprises:
- Capture of all data
- Assignment of contents to data
- Data analysis to provide information in decision support
- Data distribution to everybody that needs them on time for taking measures and decision-making
- Data visualization for a qualitative review of information and simple navigation in the system
- People support for implementing the control and taking actions
mation are well recognized due to the level structure.
PI System is classified among RtPM systems (Real-time Performance Management) or "Company Performance Management in real time". RtPM systems are intended to assist production process management in real time through the integrated KPI. It is a flexible program platform for managing the entire business decision-making cycle in a company. In performance management it comprises events in real time and enables the implementation of measures and planning at all levels of company organization.
In the following sections individual PI system modules are described in short.
PI Enterprise Server
- It executes real-time data collection from different sources and their distribution to users.
- Server is optimized to collect data with great frequency (microsecond order), it stores them in a compressed form and enables quick access to them (a few second order regardless of the fact whether we access data that are a few days or several years old).
- With the server are also provided program libraries (PI-API, PI-SDK, AF.NET), which enable the building of additional data management applications.
- The server contains additional subsystems (for making calculations, for alarms,...) as well as a very useful modular and batch data base.
- It enables a multi-server configuration.
PI Performance Equations (PE) & Recalculator
- They are integral parts of PI server applications.
- They provide a simple way to define different calculations based on other PI points (signals), on the current as well as on archive values.
- It contains a rich library of already built functions for the execution of numerical and text calculations (processing).
- Calculations are activated by time or event based on the PI point changes.
- Recalculator subsystem provides that calculation results comply with source data. If data come later or if an archive datum is corrected subsequently, Recalculator can automatically correct calculations based on this point.
PI Totalizer
- It is an integral part of PI server applications.
- It is a tool that executes calculations such as a sum, average values in a defined time interval, range, max, min, event counting, etc.
- Totalizer in contrast to PE avoids access to archive, which results in lower system load and more accurate results.
PI Alarm
- It helps users monitor, manage and confirm warnings caused by exceeding alarm limits set by the user.
- It can detect irregularities even before they have fatal influence on the process.
- Alarms are shown in the AlarmView client tool.
- This tool shows the hierarchical alarm structure for the entire company, details of individual alarm points and it enables alarm confirmation.
PI Module Database (MD)
- It enables building a hierarchical tree structure of the system and thus a process/company data model.
- Thereby modules that can contain submodules, nicknames for PI points and attributes are used.
- Properties can contain different simple and complex data types (documents, hyperlinks, texts,...)
- PI MD shares data with other applications.
- It enables connections between points themselves and between points and the associated equipment.
- Modules can archive changes. Thereby the traceability of data model changes through time is provided.
PI Advanced Computing engine (ACE)
- It is a tool for making advanced calculations in the entire company.
- PI ACE is used for analyses such as the calculation of the efficiency of means of production, or the calculation of accounts of costs in real time as well as for building data transfer programs and alarm applications.
- Any application that does not require user’s intervention can be built.
- It can link with any PI system in the network and thus enables us to introduce and manage common business rules for the entire company in one place.
- It makes complex calculations simple by using PI data and Visual Basic language.
- Calculation can be activated by time or event regarding the PI point state or change.
PI SDK
- Object library serves for object programming in C++, VB or VBA languages.
- Current functionalities are:
- Simple reading of archive/archival and current values
- Archive and current event objects
- MDB and Batch DB objects
- Point DB and Digital State Table objects
- User and User Group objects
- Message Log objects
PI ODBC
- It is used to access relational databases.
- Applications such as MS Query, MS Access, MS Excel support ODBC data sources.
- PI ODBC is a product that enables SQL queries in PI data archive.
- Users can continue to use their favourite client tools and they can simply access PI data.
PI OLEDB
- OLE DB is an open standard for universal data access.
- It enables a relational view of PI archive, PI point DB and other configuration data.
- It contains the SQL language, which enables relational queries in the PI system.
PI Batch and Event Framing Technology
- PI Batch is a set of tools for measuring, analysing, improving the reproducibility of batch processes.
- It enables:
- The reduction of batch duration times
- The increase of comparability of products from individual batches
- Detecting production bottlenecks
- It supports the ISA S88 standard:
- Batch, Unit, Operation, Phase,...
- Or any regular hierarchy
- "Smart Interface" enables monitoring batch events, even if batch activation/detection system is not available
- Simple use of add-ins for PB and Excel, which enables quick searching of batches, ideal batch analysis, trends, ...
PI Interfaces
- For data acquisition from DCS, SCADE, PLC, lab, and also other business information systems to the PI system.
- Record back in these systems that is based on a defined event of PI points (value change) or on user request is also possible.
- They enable quick links with more than 400 different data sources.
- One can link with practically any real-time data source.
- They enable data acquisition also in case of system failures. When the system (link) is generated, data are transferred to the PI system.
PI COM Connectors
- It enables access to data in foreign databases to PI clients.
- PI system flexibility means that you get more from your data irrespective of where they are.
- User does not notice the difference in accessing data in different databases.
PI ProcessBook in ActiveView
- The application contains one or several process books, which are collections of graphical views. These views contain process data from the PI data archive as well as other static and dynamic information from external sources.
- A library of graphic symbols is available to the user to build a view where graphic symbols can be entered.
- Process books can be divided among other users, which eliminates the need for making double views.
- The application also contains MS VBA, which enables us to automate special activities or routine tasks.
- PI ActiveView enables that users check views with current data from the PI archive or other ODBC sources on the internet or intranet.
- Data in the browser are thereby automatically updated with data coming into the PI database. Dynamic symbols such as trends, columns, values,... are updated the same way as if they were in PB.
PI Data Link
- It is a client tool used for data acquisition from the PI server to MS Excel or Lotus program.
- Beside data access it also enables entry in the PI database.
- Data Link is completely integrated. Menus can be used for defining one’s own queries, and calculations or formulas can be entered manually.
- Formula data link in a document is automatically updated as well as all the remaining formulas.






