Real-Time Performance Management for Today’s Enterprise
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Transcript Real-Time Performance Management for Today’s Enterprise
“IN A BLINK OF AN EYE”
PI & CDM (Clean Development Mechanism)
at Rhodia Brazil
Osisoft Seminary
15/05/2007
Rhodia in Brief
Sales
R&D budget
€ 4,800 million
Paulínia
3% of sales
Plants
EBITDA
69
€ 683 million
Employees worldwide
Ebit
16,000
€ 359 million
Osisoft Seminary
15/05/2007
World Technology Centers
Dudley
Oldbury
Aubervilliers
Dangé
Boston
Cranbury
Freiburg
Lyon
Milan
Kobe
Malvern
Shanghai
Singapore
Paulínia
Santo André
Main Research Centers
Technical Centers
Paulínia
Osisoft Seminary
15/05/2007
Research at Rhodia
R&D budget of approximately 140 M€ - 3% of global turnover
1,050 researchers;
Nearly 150 patent applications every year;
Partnerships with acknowledged Research Centers and Universities:
•
CNRS (France), Santa Barbara and Princeton Universities (USA), Catholic University of Louvain (Belgium), Unicamp (Brazil).
5 leading Research Centers:
In France (Aubervilliers, Lyon),
In the USA (Cranbury), Brazil (Paulínia) and China (Shanghai).
Lyon
Paulínia
Aubervilliers
Bristol
Osisoft Seminary
Paulínia
15/05/2007
Shanghai
Latin America Industrial Sites
Barquisimeto
Valencia
Paulínia
Jacareí
São Bernardo
Santo André (2)
Florencio Varella
Paulínia
Osisoft Seminary
15/05/2007
Strong competitiveness in 90% of its portfolio in Brazil
Areas and
Businesses
%
Portfolio
%
Market
Position in the
Market
43%
1
47%
2
42%
1
Textile Yarns
12%
Industrial Yarns
8%
Engineering Plastics
11%
Phenol and by-products
21%
PHENOL 86%
BISPHENOL 85%
1
Solvents
24%
CETONES 61%
ESTERS 55%
1
Acetow
7%
100%
Silicas
4%
90%
1
Adipic Acid
7%
95%
1
*
*100% in Brazil, 75% in South America
Paulínia
Osisoft Seminary
15/05/2007
1
Rhodia Organization in Latin America
QPAL
Performance
Chemistry
Polyamide and
Polymers
Intermediates
and Solvents
Novecare
Phenol
Engineering Plastics
Silcea
Bisphenol
Organics
Adipic, Sal N and HMD
Industrial Fibers and
Yarns
Leather
Acetow
Acetow
Functions
Purchasing & Procurement
Corporate Communication
Finance
Textile Yarns
Industrial
Bicarbonate
Legal
Solvents and Acetone
Research & Development
Platforms
Human Resources
Government Relationships
Businesses
Paulínia
Osisoft Seminary
Information Systems
15/05/2007
Sustainable Development
At the heart of our identity
A responsible approach for:
Shareholders
Employees
Customers
Suppliers
Environment
One belief
Community
Safety, operational performance and social and environmental responsibilities are
closely linked
Integrate Sustainable Development in the current
management processes
Paulínia
Osisoft Seminary
Engage more deeply the staff
in this initiative
15/05/2007
Sustainable Development
Rhodia, an industry strongly engaged in Sustainable Development, is
enrolled with the “Responsible Care in the Chemical Industry”
program for:
health protection;
environmental protection;
safety improvement.
This involvement translates into:
a global policy of “Responsible Care”;
action plans implemented in every plant;
transparently audited and published results.
Paulínia
Osisoft Seminary
15/05/2007
Once upon a time, on August 2006…
Angela Project
Paulínia
Osisoft Seminary
15/05/2007
Angela ????
Well…
It is all about Kyoto Protocol !!!
Paulínia
Osisoft Seminary
15/05/2007
Kyoto Protocol
• The Protocol was signed during the Forecast Changes
Conference on 1997 and confirmed on Feb 16th, 2005 with
Russia's adhesion as partner;
• Establishes goals of reduction of greenhouse effect caused
by industrialized countries (5,2% of 1990’s emission);
• It does not have additional obligations for developing
countries;
• Creates flexible mechanisms for industrialized countries to
reach their goals regarding Clean Development Mechanism
(CDM), reducing emission on developing countries (those
ones that do not have reduction goals).
Paulínia
Osisoft Seminary
15/05/2007
Kyoto Protocol
Financial Exchanges
Purchase of
Carbon
Credits
Purchase Project
CDM Board
“Clean Development
Mechanism”
Paulínia
Osisoft Seminary
15/05/2007
Kyoto Protocol
GWP – Global Warming Potential
GWP
Time Horizon
Lifetime
(year)
20 years
100 years
500 years
Methane
12
62
23
7
Nitrous Oxide
114
275
296
156
HFC’s
(hydrofluorocarbons)
260
9400
12000
10000
Sulfur Hexafluoride
3200
15100
22200
32400
Gas
Paulínia
Osisoft Seminary
15/05/2007
Angela
Angela Project
Abatement of Nitrous Gas
for Environment of
Latin America
Paulínia
Osisoft Seminary
15/05/2007
Nylon 6.6 – Production´s Route
CUMENE
OXYGEN
ADIPONITRILE
PHENOL
HYDROGEN
CYCLOHEXANOL
HMD
KA OIL
NITRIC ACID
ADIPIC ACID
NITROUS OXIDE
N2O
NYLON SALT
OTHER
APPLICATIONS
NYLON 6.6
Paulínia
Osisoft Seminary
15/05/2007
Rhodia Energy:
Two large scale N2O CDM projects
Reduction of 9 Mt CO2/year
Onsan Project N20
Reduction of 6 Mt CO2/year
Paulínia Project N20
Reduction of N20 from adipic acid plant
Volume: 6 Mt CO2/year
UNFCCC Status: Registered
Start: November 2006
Paulínia
Osisoft Seminary
Reduction of N20 from adipic acid plant
Volume: 9 Mt CO2/year
UNFCCC Status: Registered
Start: September 2006
15/05/2007
PIMS – Purchase Process
• Rhodia’s needs:
– A scalable, robust, auditable and global real time
database for process data, that could store all
information from Rhodia’s chemical plant on a
single server.
Paulínia
Osisoft Seminary
15/05/2007
PIMS – Purchase Process
• Competitors:
– OSIsoft;
– Aspentech;
– GE;
– Yokogawa
Paulínia
• Installed base:
– SDCD Yokogawa;
– PLC GE Fanuc
• Interfaces connection:
– OPC
Osisoft Seminary
15/05/2007
PIMS – Purchase Process
• Topology´s Characteristics :
– Server machine on Rhodia’s Data Center, accessible through network;
– OPC Interfaces machines connected to process network and corporate network
through Firewall;
– Remote access via Rhodia’s VPN (administrators and users);
Paulínia
Osisoft Seminary
15/05/2007
Topology
Server
Users
PI
Network
...
Firewall
Paulínia
OPC Interface
OPC Interface
OPC Interface
OPC Interface
OPC Server
OPC Server
OPC Server
OPC Server
SDCD Centum 3000
PLC´s 9030 GE
Solsys
Future
Osisoft Seminary
15/05/2007
...
Decision Process
• Why did we chose PI?
–
–
–
–
–
–
–
–
–
Paulínia
Real time database x relational database;
Data compression;
High speed when accessing data;
Trackable and reliable data;
Easy to configure and maintain;
User friendly graphical interfaces;
Integration and support performed by PI creators (no intermediaries);
Market Leader.
User application
Osisoft Seminary
15/05/2007
Decision Process
• Initial Structure:
– OSIsoft:
•
•
•
•
5,000 points (prevision: 20,000 points on next 5 years);
Enterprise Server;
OPC Interfaces (EXAOPC and TOPSERVER OPC servers);
07 Combo Pack (DataLink and ProcessBook) concurrent users + 04 individual
users;
• 02 SQC concurrent users;
• 04 training packages (users and administrators).
Paulínia
Osisoft Seminary
15/05/2007
Commissioning Process
•
•
•
•
•
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PI Server and interfaces installation;
Combo Pack and SQC Installation on users’ computers;
Definition of tags to be configured;
Tags configuration;
Development of Reports (based on PI-DataLink);
Configuration of Performance Equation tags;
Users training and on-job support.
Paulínia
Osisoft Seminary
15/05/2007
Reports Development
Occurrences Data
Entrance
Carbon Credits Data
Lab Data Entrance
Paulínia
Osisoft Seminary
15/05/2007
Implementation Team
• Factory
–
–
–
–
Reinaldo Spitzner
Guilherme Silva
João Luiz Costa
Mário Manfrinato
• Project Manager
– Antonio Mazzuco Filho
• PI Administrators
–
–
–
–
–
Ronaldo Sergio Novaes Manzano
Jorge Luiz Catalano
Hamilton Roberto Baldo
Roberto Ruhe
Marcos Santos
• OSIsoft Brazil
– Maria Vitória Agra
– Fábio Glauco dos Santos
Paulínia
Osisoft Seminary
15/05/2007
Performance Indicators
Description
Before PI
After PI
118 Inputs
35 Inputs
2h
15m
10 days
Infinite
Database reliability
Low
Ideal
Data Trackability
None
Total
On-line Integration with other Rhodia´s
Impossible
Total
Pre-audit feasibility to obtain Carbon
Impossible
Habitual
Manual entrances
Operator time (data entrance) / day
History data availability
Paulínia
Osisoft Seminary
15/05/2007
Cronogram
~ 3 weeks
Aug 1st/06 – Decision period before
buying PI
Aug 26th/06 – Decision: PI System
1 week
2 weeks
~ 3 Months
Sept 01st/06 – Purchase
Sept 13th/06 – Training
2 weeks
Sept 29th/06 – System Installation
Oct 1st/06 – PI Commissioning Start
6 weeks
Nov 8th/06 – PI Commissioning End
Paulínia
Osisoft Seminary
15/05/2007
Contacts
Ronaldo Manzano
[email protected]
Hamilton Roberto Baldo
[email protected]
Jorge Catalano
[email protected]
Fábio Glauco dos Santos
[email protected]
Paulínia
Osisoft Seminary
15/05/2007