5 Replies Latest reply on Jan 17, 2019 5:05 AM by osvaldo

    A Digital Plant Template for transforming raw data into Operational Insights.


      A Digital Plant Template example.


      These operational insights are generated automatically using PI Analytics and Event Frames. All process units for an industrial complex are evaluated for their operating modes. These are based on the production variance, which is calculated from the scheduled production and actual performance using PI Analytics. The operating modes are used to estimate the production and operating cost losses similar to an OEE strategy but much more powerful.

      The results are visualized using PI Vision and Microsoft PowerBI with Cortana (Artificial Intelligence). In addition, it provides the necessary data for developing machine learning predictive analytics using Excel with PI Datalink and Analysis ToolPack add-ins, Microsoft Machine Learning (ML) Studio, or Anaconda Python.

      In the last part of the session, based on the current industrial practice, implementation tips are provided for the students to implement for their own use. The Academia-Industry students will get the Digital Plant Vision Template in a PI Asset Framework XML file template, PowerBI Template, PI DataLink Template data classification and multilinear regression, and the ML Studio step-by-step processes to get the extracted data into a multilinear regression model.

      The example simplifies the implementation and adoption of the latest data science technologies. It takes less than hour to the get the plant simulator configured and running.

      After it is running as simulation, it can be re-purpose and configured with real tags.


          • Re: A Digital Plant Template for transforming raw data into Operational Insights.

            PI Vision Refinery Overview 314 Capture.PNG

            Overview of the operational state for all process area at the plant.

            If there is Trouble mode this means that the operator has slowed the process feed rate to the unit based on the plant programed schedule.  This means we will be loosing money based on the program.

            To find our details we can select the process area with this trouble mode.

            PI Vision Refinery 314 Capture.PNGMIN PROC EVENT Frame Energy and Water Consumption Capture.JPG

            This display shows the basic operational state and the consumables.  Most importantly the EVENT Frame table shows us all the critical problems to go and identify the consequences.

            Once you click on the event frame PI Vision provides directly into the time that this happened and at the bottom left shows you the energy, water and production losses for that time frame.

            if you can want to see the summary of the aggregated data for the year, month, week or shift you can import the event framed  into PowerBI.

            PowerBI Desktop data access Oil Ref example Capture.JPG

            PowerBI Template presented in the TechCon Lan showing the PI Event Frame data on the right and the many options to inspect the business performance of the operating plant.

            Steel Overal Production Performamce Capture.JPG

            The same template can be used for an industrial Steel Complex.  Here you can see the Overall Production Effectiveness for all the units showing a summary of the Trouble, Down, Idle, Maintenance and Productive time of the UNITS.

            Many queries can be posed to PowerBI.  The most interesting are the ones that are answered using Cortana.  (see the top: Ask a question about the data.... This is very powerful using your iPhone.  Check the Cortana examples in PI Square.

            PI Vision Refinery Crude Unit State and Events Details Capture.JPG

            This screenshot shows the automated answer from PI Vision once you click the Event Frame summary table. Shown in the next screen capture.  This is the power of PI Vision. This is where you start collaborating with team.

            Answer or sending notifications to resolve root cause issues. Just let us know if you have any questions or suggestions.

            • Re: A Digital Plant Template for transforming raw data into Operational Insights.

              Hi Jason:


              Did you get to import the Digital Plant Template?

              You can follow the instructions to learn.  Then, you can reuse it to configure it using your own data.

              To which industry wouñd you like to use it?

              Warm Regards,


            • Re: A Digital Plant Template for transforming raw data into Operational Insights.

              Nice Information. Do you have any example which is applicable to Pharma Industry?

                • Re: A Digital Plant Template for transforming raw data into Operational Insights.

                  Hi Sarang:


                  The Digital Plant Templare can be reused by changing the name of the elements.  Do you have a Process Flow Diagram of your plant?

                  I do not know if someone as applied this template to pharma.

                  With additional information about your specific needs I could have a better answer.

                  This template compares the daily schedule with current production to generate the operational events.  The event frame subsystem aggregates the data based on these events to catch the invisible production losses, downtimes and idle times.

                  In essence, we are using the PI Batch for continuous processes.

                  Warm Regards,