1. Value-Added Applications in the PI environment
St-Laurent Paperboard, La Tuque
By Yves Racette, Walsh Automation Inc., PI Systems Integrator

2. Agenda Facts: La Tuque Mill Project and Systems History
Systems Architecture
Overview of Value-Added Applications
Projected work
Benefits

3. La Tuque Mill: Facts ~ 1,200 Metric Tons/day - rolled board
~ 50 different grades
3 Kamyr Digesters, 19 Batch Digesters
2 Bleach Lines
2 Paper Machines
2 Power Boilers, 3 Recovery Boilers
3-line Recaust (slakers, lime kilns)
Coordination is a constant challenge

4. Systems History
Plant Information systems have been in operation at the plant since 1967
IBM 1800
PDP-11
VAX (First version of WalshCIM) PI
Supervisory controls were progressively moved to the DCS

5. Systems History 1967 1982 1986 1998 PI VAX IBM 1800 PDP-11
Supervisory Controls
DCS
1967
1982
1986
1998

6. Project History Preliminary and detailed Engineering Main Objectives:
Needs analysis
Implementation Plan
Costs Estimation
Main Objectives:
Replace VAX systems
Long Term Archiving with full resolution
Better diagnostic tools
Migration of VAX applications

7. Architecture (Phase I)
Foxboro I/A Interfaces
Functions:
Data Acquisition
Graphics
On-line calculations
Reports
Process Diagnostics
Foxboro Steam
Functions:
Data Acquisition
Manual Entries
Foxboro Batch Cook
PI-API
Specific
Interface
Existing VAX
PINet
Foxboro Effluent
PI Server
Foxboro Machine 3
Plant Ethernet
PDP-11
I/O Subs.
VAX
Bleach.
VAX
Kamyrs
Foxboro Machine 4
Control Network
(Ethernet)
MCS Max 1000 DCS
MCS Max 1 DCS

8. Architecture (Current)
Foxboro I/A Interfaces
Functions:
Data Acquisition
Graphics
On-line calculations
Reports
Process Diagnostics
Manual Entries
Foxboro Steam
Foxboro Batch Cook
Foxboro Effluent
PI Server
Foxboro Machine 3
Foxboro Machine 4
Plant Ethernet
Max Plus Gateway
Max Plus Interface
Foxboro Caustic
MCS Max 1000 DCS
MCS Max 1 DCS
Control Network
(Ethernet)

9. MillWide Use 80 Process Book 20 Datalink
15 Manual Entry Applications (API)
20 SQC
20 Batch View
Increasing demand ...

10. Applications Design
Standards were defined at the beginning of the project
tags and files naming conventions
display standards (color, font, frames, VB code)
reports presentation and automation
development methodology
Implementation was done by Walsh Automation and St-Laurent Paperboard

11. Applications Process Book Displays Process Diagnostics (advisors)
PI Batch and PI SQC applications
Operation Reports
Manual Entries
On-Line Calculations
Specialized applications

12. Process Book Displays Mill and Area Overviews + some details
One single .piw file with links to .pdi files
NT security implementation (read-only access to .piw and .pdi files)
Process Book security: View only mode ProcessBook=Primary (procbook.ini)
Navigation toolbar and Detail … menu

13. Process Book Displays
Secured PCs: Process Book is the only visible application. All other programs executed from within Process Book
VBA code in many display pages (e.g.: on-line calculation of pulp inventory, yesterday’s averages, double-clic assigned to Revert)
French version of Process Book

14. Live Process Equipment Statuses
View Only Mode
Navigation Toolbar

15. Process Advisors
Specialized displays with visual indications of abnormal process conditions
Example: Mill water balance

16. Sewer with abnormal conditions
Get details ...

17. Tank Overflowing causing the problem
Suggested Steps and Actions

18. PI Batch Application Coating kitchen monitoring
Batch View OCX and VBA code
After selection of a specific batch, the display time is set to start of batch
VB controls allow for batch “replay”
VBA code validates presence of Batch View license before page is displayed
Batch Query/Datalink batch report

19. Batch Selection with Batch View OCX
Replay Batch with (+/- delta seconds)
Batch Data (from selection)
Go to Beginning/End of Batch

20. PI-SQC Application Monitoring of ISO related performance indices
VBA code validates presence of PI-SQC license before page is displayed

21. Operation Reports Excel and Datalink combination
Created a library of reports automation functions - saved as an Excel add-in (.xla)
Daily / Monthly Reports in same spreadsheet
ActiveX control for date/month selection
Data filtering based on process unit status - blank if process is shutdown or if no manual entry values are available

23. Manual Entries
PI-Manual Logger data entry could not be used - too complicated for required mill usage and available in english only
Data entry application developed by Walsh using Visual Basic
Uses database as configured by PIML
Ease of use / French language
Supports all PIML functions (except HHT)

24. Validation bar for selected tag
Tours
Tour Runs
Validation bar for selected tag

25. On-line calculations
VAX legacy system included a long series of Fortran calculation programs that had to be migrated - some were quite complex !
Performance Equation was not appropriate
On-line calculation server (NT service in PI server) was developed by Walsh
Synchronized execution at various frequencies

26. On-line calculations
Applications are developed in Visual Basic (structured programming - not event)
Programs can be easily developed by system engineers
Allows for complete documentation with detailed comments

27. On-line calculations
Uses VB enumerated tag list to allow use of tags by names instead of by ID with PI-API
ActiveX applications are modified and replaced without restarting the schedule service

29. Area Specific Applications
Area specific applications were developed and integrated within the Process Book environment
Liquor tests
Lime kilns production rate calculations
Operation Log Book
Document Browser (access to reports, ISO and reference documents, …)

32. Training ~ 5 weeks of training by Walsh and Cogexel:
La Tuque trainers (operation)
Users (PB, DL, Manual Entries) - use of applications only
PI System Administrators

33. Projected Work for This Year
New PI Server for Profiles
Communication link with MAJIQ Replix server (quality and finished product data)
Expansion of PI-Batch for complete grades monitoring

34. Benefits Mill users empowerment was immediate
Improved personnel productivity
Process Diagnostics: improved reaction, reduced duration of problems
Improved tracking of equipment downtime
Although not essential for production PI has become a critical tool for all users

35. Questions ?