PI System as an Aid for Prevention and Control of Pollution
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1 PI System as an Aid for Prevention and Control of Pollution Presented by Michele Albicocchi Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC.
2 PI System as an Aid for Prevention and Control of Pollution PI System tracks all warning or alarm events that must be justified by plant operators in the context of continuous improvements of plant environment impact and more over keeps people informed of the evolving situation. Business Challenge Solution Results and Benefits Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 2
3 Group profile who we are A major global player in Chemicals with compelling Created by Ernest Solvay in 1863, Solvay is a Global strengths company, with historical anchorage in Europe, and headquartered in Brussels. Our strengths 90% of sales in businesses among the top 3 global leaders 40% of sales in fast growing markets Balanced portfolio of activities A culture of sustainability, innovation and operational excellence 12.4bn NET SALES 2.1bn Adjusted REBITDA 111 MAJOR INDUSTRIAL SITES 13 MAJOR R&I 29,100 EMPLOYEES 55 COUNTRIES Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 3
4 Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 4
5 Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 5
6 Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 6
7 Historical notes Building start 1912 Production start 1917 Current situation Rosignano factory The factory occupies 2.2 km 2 Sales: 264 M Investments and maintenance: 35 M People: 628 directly employed 380 indirectly Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 7
8 Limestone Salt Productions Water Methane Energy Ethylene SODA & Deriv. PEROXIDE CHLORINE e Deriv. POLYETHYLENE (INEOS) Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 8
9 Production Capacity Soda ash 940 kt / year Sodium Bicarbonate 260 kt / Calcium Chloride 120 kt / Caustic Soda 190 kt/ Chlorine and derivatives 300 kt/ Hydrogen Peroxide 35 kt / Sodium Percarbonate 50 kt/ Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 9
10 Integrated Pollution Prevention and Control (IPPC) European Strategy to improve environmental performances European Directive 2008/1/EC and later 2010/75/EU List of Activities and Substances to keep under control Emission Limit Values based on Best Available Tech (BAT) Competent Authorities check all preventive pollution control measures have been laid down before granting a permit to any operation Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 10
11 Variables under Control (IPPC) Air Water Ground Competent Authorities Process Engineers Environment Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 11
12 PI System as an aid to control pollution Help for IPCC It keeps under control those process parameters that have a direct influence on emissions related to IPPC permit Help for Environmental Certification (ISO 14001) By registering all abnormal conditions you can analyze them and set a process of continuous improvement If you have an ISO certification you got a longest IPPC permit Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 12
13 Our solution (legacy PI System) PI Server To archive Process, Calculated and Alarm Tags PI Batch To register Events PI AlarmView To notify control room conductors PI DataLink To report warning or alarm events PI ACE To send Alarm Notifications via /sms/etc. Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 13
14 Batch and Alarm Periods Batch period Alarm period Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 14
15 Batch and Alarm Periods Batch Batch Batch Batch Batch Batch Batch + Alarm Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 15
16 Alarm/Warning Periods Possible risk for emissions Intervention required Warnings and Alarms differ only on the delay time (Δalarm > Δwarning) Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 16
17 Treatment Efficiency Treatment period Treatment period As an example, a Neutralization treatment is effective when a Delta Value is over a certain limit. ΔValue ΔValue If ineffective, an alarm condition is kept from the end of the treatment until the beginning of the next one. A similar control can be easily configured and reported in PI System. For configuration we mostly use PI PE and PI Alarm Tags. Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 17
18 PI AlarmView Final users (like control room conductors) are also notified via PI AlarmView. They must acknowledge any warning or alarm condition. Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 18
19 PI DataLink Main MS Excel Book for Notification and Reporting. Shift browsing (back/forth) buttons Enable/Disable auto update Enable/Disable automatic print Enable/Disable vocal message Alarm Status currently and during the selected shift Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 19
20 PI DataLink We got the list of all alarm events in the selected shift. Each event must be justified and discussed with process engineers to find out the reasons of abnornal behaviour. Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 20
21 PI DataLink + PI BatchView Filter on Year and Lenght of Time Parameter under control Summary per month Results We use some reports to look at all events passing thresholds for any possible length of time. Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 21
22 PI DataLink Some summary reports List of alarm occurrences for the selected month. Alarm testing can be disabled depending on the analyzer status. Such status is set at DCS/PLC level. Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 22
23 PI DataLink Enable/Disable Alarm Test Set 0 to disable 1 to enable Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 23
24 PI DataLink + PI SDK Alarm configuration editing made by the end user. Delays of the persistent conditions to generate warnings/alarms Alarm Limits Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 24
25 Notification means Send of with documents enclosed PI ACE Send of SMS Alarm Detection Messages on the Screen Setting Output Tags Turning on We built our PI ACE application when PI Notifications did not exist Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 25
26 Future Exploring PI AF/PI Event Frames + PI Notifications Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 26
27 Questions Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 27
28 Michele Albicocchi Industrial IT Supervisor Solvay Chimica Italia S.p.A. Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC. 28
29 Please don t forget to Complete the Online Survey for this session Share what you saw with friends on Twitter, Facebook or Linkedin! #UC2013 Eventmobi.com/emeauc13 Copyri g h t 2013 OSIso f t, LLC. 29
30 Brought to you by Copyri g h t 2013 S olvay Chimica Italia & OSIso f t, LLC.
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