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Pioneers of Digital Transformation
Adani Ports is the largest private port operator in India, handling the majority of the country's international trade. Economic growth is driving an expected increase in demand for port services. Adani Ports is planning ahead for this growth by investing in both new port construction and port automation, to ensure that all facilities achieve peak performance levels. The PI System is the backbone of these initiatives, providing the data collection, analysis and reporting tools that have helped Adani Ports achieve ongoing performance improvements and wider profit margins at ports old and new.
Founded in 1977 by Dr. Paul MacCready, AeroVironment is a pioneer in creating human-powered vehicles. Their portfolio of successes includes the first vehicle to cross the 23-mile wide English Channel, the first solar-powered vehicle, and, since 1985, UAVs (also known as drones). The company originally developed drones for the military and Department of Defense, but the value of the visual data collected by drones has created demand in the commercial sector. Now, with help of the OSIsoft PI System, AeroVironment is finding new applications for drone data.
One of the world's most important energy producing companies, AES generates and distributes electricity in 17 countries, employing around 21,000 people around the globe and serving over 10 million customers. In Brazil, the group's operations are divided into five different companies: AES Eletropaulo, AES Ergos, AES Sul, AES Uruguaiana, and AES Tietê. At the 2016 LATAM Regional Conference, Carlos Macedo, operations engineer at AES Tietê, describes the company's operations and how the PI System was used to streamline decision-making, minimizing risks and optimizing the operation of power plants at the AES Tietê division.
Ansaldo Energia is a 160-year old company headquartered in Genoa, Italy and a leading producer of thermoelectric power generation plants with a primary focus around plant engineering, manufacturing, and service. The company has over 100 power plants and 300 gas turbines around the world and provides remote monitoring services for 19 customers in 13 countries. At the 2016 OSIsoft EMEA Users Conference, Sandro Gollini, a Diagnostic System Engineer at Ansaldo Energia, and Giuseppe di Bartolo, owner of TQService, discussed how Ansaldo Energia is leveraging the PI System for remote asset monitoring to decrease downtime, reduce maintenance costs, and improve service for customers.
Arizona Public Service (APS) is also one of the leading solar utilities in the country with over 170 MW of solar capacity and 40MW slated to come online in the near future. APS' talk addressed both the value of the PI System and their Enterprise Agreement (EA). Katie Hoepfl discussed how Arizona Public Service uses the PI System to manage asset health with only six field technicians. Kurt Pager discussed how their innovative residential solar program is enabled by a collaboration with the Electric Power Research Institute (EPRI) and the University of Arizona.
Michel Plourde, Director of Systems, describes how ArcelorMittal - Mine Canada created an Enterprise Information Hub to make their supply chain more responsive to real-time production conditions and transform their business from a pure push operation to a client-driven, pull business.
With annual achievable production capacity of approximately 114 million tons of crude steel, and some 210,000 employees across 60 countries, ArcelorMittal is the world's leading steel and mining company. ArcelorMittal Long Products (AMLP) Canada specializes in the manufacture of semi-finished products such as billets, slabs, bars and rod. Jean-Yves St. Onge of AMLP and Alexandre Côté of ATS Process Automation Systems described how AMLP updated legacy VAX-VMS systems to empower their people and improve quality.
Faced with a downturn in gold prices and rising exploration costs, Barrick Gold,like others in the industry, was under pressure to reduce operational costs. Barrick believed the best way to do that was to improve its utilization of operations and business data. A team inside Barrick believed that by signing an Enterprise agreement (EA) with OSIsoft and better leveraging their existing PI System™, the company could improve utilization of corporate data and dramatically reduce operational costs. But signing an EA would require a large, unbudgeted, capital expenditure at a time when the company was focused on cutting costs.
In 2015, Barrick Gold produced approximately 6.12 million ounces of ore with more than 75% production coming from the Americas region. Their Goldstrike mine is the most prolific gold-mining district in the Western Hemisphere and includes the Betze-Post open-pit mine, a truck and shovel operation, and the Meikle and Rodeo underground mines. Ted Olsen-Tank described how the PI System enabled Barrick Gold to operate more efficiently while complying with strict environmental regulations.
Bharat Light & Power (BLP) owns and operates 200 megawatts of renewable energy projects in India. To manage these assets, BLP developed the proprietary Orion platform, built on top of the OSIsoft PI System. Balakrishnan G. Iyer, Chief Development Officer, discussed BLP's new managed services operation, which enables other renewable energy companies to tap into the real-time data and predictive intelligence.
As a global building materials company, CEMEX has a presence in more than 50 countries throughout the world and yearly sales exceeding $15 billion. As one of the leading manufacturers of cement and ready-mix congregate and aggregates in the world, CEMEX's cement operations stretch across 70 sites in 21 countries. In his presentation, Mr. Rodrigo Quintero, Operations Model and Planning Manager described CEMEX's 20-year journey to achieve visibility across all 70 plants, adding context to data for reporting and analysis and finally integrating and analyzing operational data at scale to generate overall enterprise intelligence.
Headquartered in Monterey, Mexico, CEMEX is a global manufacturer of building materials including cement, ready-mix concrete, and aggregates. As part of its commitment to becoming the most efficient and innovative building materials company in the world, CEMEX continually evaluates and evolves its systems and processes. One example of this commitment to evolution is CEMEX's use of the PI System™.
In his presentation, Raúl Cubillo, Operations Manager for CENACE, the technical and commercial administrator of Ecuador's wholesale electricity market, described how CENACE is applying Real-Time Situational Awareness concepts and techniques - through configuration models and visualization - to give operators contextualized information for decision-making.
Clearwater Paper is the largest provider of private label tissue to retail grocery chains in the United States and a manufacturer of bleached paperboard. With seven manufacturing sites, over 10 paper machines, over 50 tissue converting lines, and pulp mills, recovery, and power boilers, real-time operational intelligence is critical to the company's success. A PI System user for over 20 years, Clearwater Paper relies heavily on system insights, but it was a challenge to manually create targets and KPIs for every PI Tag. With the help of Envoy Development, they were able to put the right metrics in place to understand deviations and take appropriate action to keep production on track.
Columbia Pipeline Group (CPG), a leading natural gas supplier, delivers natural gas to the Northeastern United States via a cross-country pipeline. Ensuring that its infrastructure is able to serve the energy needs of its customers is a key priority. When reliability issues came into focus in 2010, CPG expanded its use of the OSIsoft PI System. By improving operational performance, the company saved millions of dollars in avoided costs and increased customer satisfaction.
Challenges rarely come from just one direction. Like many businesses Covestro, a worldwide leader in polymer production, has been beset by industry, regional, infrastructure, and operational challenges. Despite these, Dr. Felix Hanisch, Covestro's Head of Process Control Technology, showed attendees at the 2016 EMEA Users Conference how the PI System can help chemical process companies realize huge cost savings and produce significant environmental benefits.
Deschutes Brewery, is the seventh largest craft brewery in the United States. At OSIsoft's 2016 Users Conferences in San Francisco and Berlin, Brian Faivre (Brewmaster of Operations) and Tim Alexander (Assistant Brewmaster) explained how the PI System has helped Deschutes: reduce production time by up to 72 hours for each batch, maximize capacity and postpone $8 million in capital upgrades, and understand the brewing personality of each of its beers through machine learning.
After a PI System pilot project in 1999 helped one of Detroit Edison's power plants save $180,000 in just six months, DTE Energy rolled out the PI System to each of its 7 major power plants. With the PI System in place company-wide, DTE Energy launched a fleet optimization program in 2006 that has saved the company millions of dollars annually.
DTE Energy Co. is a diversified energy company involved in the development and management of energy-related businesses and services. This story describes how DTE combined sensors, Esri ArcGIS and the PI System to reduce customer outage minutes across their distribution system.
eBay Inc. uses the PI System to prioritize and monetize its data center operations, improve their Power Usage Effectiveness (PUE) and growing their technical infrastructure.
At data centers in Utah and Arizona, e-commerce giant eBay has developed a data storage solution to ensure that data critical to their commercial operation is always available. However, with eBay's data growing exponentially, these data centers must scale as quickly as the data does. To meet eBay's requirements for data center scalability and data availability, eBay has partnered with Dell Data Center Solutions (DCS), the #1 OEM hyperscale server provider, and OSIsoft. In a presentation at OSIsoft's 2015 Users Conference, Dwayne Kalma, the Data Center and Network Software Engineer for eBay, and Tyler Duncan, the Principal Thermal and Controls Engineer for Dell, explained how “the combined partnership of eBay, Dell, and OSIsoft's EA team has given us the tools needed to revolutionize the industry for Modular Data Center deployments, incorporating specialty system knowledge from each group, which altogether lead us to a more efficient, scalable, rapidly deployable integration".
How can a residential electric vehicle [EV] charger improve grid reliability, reduce emissions and support clean energy? At OSIsoft's 2015 Users Conference, Dr. Valery Miftakhov presented how eMotorWerks uses the PI System to enable “true vehicle to grid integration” through their JuiceBox Smart[Grid] Charging System. By shifting when and how much electricity the JuiceBox network draws from the grid, the Smart[Grid] System tailors EV charging parameters according to grid conditions to “maximize electric vehicle [EV] charging speed and efficiency while reducing costs.” Using the PI System, eMotorWerks has created a shared data ecosystem “to deliver superior charging performance while providing valuable services to improve grid stability and enable growth of renewable [power] generation.”
Turkey's booming electric power industry has meant a need for efficient, rapid growth. ENKA, a leading construction firm, won a bid to construct three new power plants in the early 2000s. By using the OSIsoft PI System™, ENKA has been able to seamlessly deliver energy to the booming Turkish economy, controlling costs and virtually eliminating downtime.
To better serve its 2.5 million consumers and over 600 large industrial customers, Evides Waterbedrijf created a software platform called GAMEs that leverages the OSIsoft PI System, Esri® ArcGIS®, and TaKaDu to give its employees the power to isolate pipe bursts, monitor water flows, enhance situational awareness, and improve responsiveness across Evides' extended service territory. Jan Urbanus described the program at the 2016 OSIsoft EMEA Users Conference in Berlin and outlined next steps.
Exelon Corporation is the largest owner and operator of nuclear plants in the United States. With 23 reactors at 14 facilities in Illinois, Maryland, Nebraska, New Jersey, New York, and Pennsylvania, Exelon produces nearly 34,000 megawatts and powers millions of homes. Exelon believes the safety of the community and its workers is its highest priority, and that good maintenance ensures safety.
With a network combining about 14,000 km of transmission lines and more than 100 substations, Fingrid Oyj, the electricity transmission operator in Finland, needed to find new ways to optimize network reliability while minimizing maintenance and investment costs. “Part of that task can be achieved by identifying the weakest-performing assets and hidden defects in components at an early stage,” explained Fingrid planning engineer Kimmo Nepola while speaking at the 2013 OSIsoft Users Conference. “That allows us to not only avoid failures, but also to optimize the timing of new investments and maintenance.”
Manufacturers worldwide are launching strategies to integrate digital intelligence into industrial equipment to improve uptime, prevent accidents and help the bottom line. Worldwide, process industries lose $20 billion dollars due to unplanned downtime and faulty maintenance practices and approximately 80% of these losses could be stopped with early, accessible information.
A member of the Roche Group, Genentech is a leading biotechnology company that discovers, develops, manufactures and commercializes medicines to treat patients with serious or life-threatening medical conditions. Although Genentech has been a PI System user for over 15 years, they were initially hesitant to embrace Event Frames as a new batch technology until they assessed the cost, value and functionality.
Water loss is nearly always the result of a leaky pipe somewhere in the system. The challenge is to find the location of the leak, and to do so quickly with minimum staff time, before significant water is wasted. Halifax Water used its already installed PI System to support water leakage reduction by 40 million litres per day, saving more than C$600,000 on an annual basis.
For over 50 years, the IBM Burlington facility has been producing semiconductors in Burlington, Vermont. Committed to continuously evolving their operations to save money and improve efficiency, IBM Burlington installed the PI System in the 1990s to help improve organizational communication. Since then, IBM Burlington has leverage the PI System to have achieve dramatic results from increasing manufacturing capability to reducing water usage by 27% to saving millions in yearly expenses.
Since 1972, Itochu Techno-Solutions Corporation has been an independent systems integrator and service provider serving a broad range of industries in Japan. At the OSIsoft's 2015 Users Conference, Mr. Hisashi Fukuda, General Manager of Itochu Techno-Solutions Corporation, presented how OSIsoft's PI System has enabled Itochu to use data-driven approaches to deliver services across Japan's dynamic energy market. Furthermore, OSIsoft's Connected Services has enabled Itochu to transform their business model by connecting customers on both ends of the energy supply-demand market using their unique cloud-based service.
Founded in 1997, JiangSu Nuclear Corporation, Ltd ("Jiangsu Nuclear") is responsible for the construction, commercial operation, and management of the Tianwan nuclear power station. Currently, the 2 nuclear generator units from phase 1 are in commercial operation, construction of units No.3 and No.4 from phase 2 is in progress, and construction of units No.5 and No.6 from phase 3 has commenced. Yang Qiang, Senior Engineer from Jiangsu Nuclear introduced how they use the PI System is used to manage data and achieve business intelligence in a large nuclear power plant at the 2016 OSIsoft China Users Conference.
The Kellogg Company's food products are a staple in kitchens in over 180 countries. With over $14 billion in annual sales, Kellogg's produces many household names, such as Keebler, Pop Tarts, and Eggo Waffles. In 2005, Kellogg's embarked on a project to reduce its energy footprint while improving their bottom line. By leveraging their previously installed PI System, Kellogg used operational data to reduce energy consumption in its Battle Creek plant.
Headquartered in Budapest, Hungary, the MOL Group is a leading Central and Eastern European oil and gas company. Over its 75-year history, the MOL Group has expanded to employ over 30,000 people across its facilities in over 40 countries. In the last 18 years, OSIsoft's PI System has played an increasingly important role in the company's rapid development. At OSIsoft's recent 2015 EMEA Users Conference, Tibor Komroczki, Head of Process Information and Automation, spoke about the evolution of the company's use of the PI System and, in particular, the crucial function the PI System's unified data infrastructure and Asset Framework (AF) have played in standardizing downstream activities across multiple sites.
With a strong commitment to the preservation of earth's natural resources, Outotec builds sustainable facilities and process management solutions for minerals and metal processing, water treatment, and energy production from biomass and waste. Recently, Outotec developed a new digital services platform that links operational data from customer sites with Outotec subject matter experts to deliver aftermarket services and lifecycle solutions. Kerry Sullivan, Outotec's MES Manager for the Mineral Processing Business, spoke about how OSIsoft enabled his company "to provide remote services in order to help people optimize the performance of [their] sites.”
PETRONAS CARIGALI is the upstream arm of Malaysia's state-owned, fully integrated oil and gas company. It is responsible for exploration and production, with 190 offshore platforms and a total yield of more than 2 million barrels of oil each day. As the offshore business continues to grow, PETRONAS needed better tools to manage its fleet. It selected the OSIsoft PI System™.
As the national oil company of South Africa, PetroSA's business spans the entire petroleum value chain. The company refines diesel, gasoline, kerosene, and specialty products as well as more than 1 Tcf of natural gas. Although PetroSA has used the PI System for over 20 years, it recently re-evaluated its role while centralizing and standardizing a diverse range of operational and business functions. PetroSA's Senior Business Architect Rubin Boer discussed the impact of evolving the PI System from historian to real-time operational repository had on overall performance of PetroSA's operational and business processes.
PJM Interconnection is responsible for maintaining grid reliability and running energy markets across 13 states and the Washington DC area. As one of the largest transmission operators in the country, they serve 61 million people and manage a peak load of 163,000 megawatts. To improve its operators' situational awareness, PJM recently developed the Dispatch Interactive Map Application (DIMA), which brings together real-time grid, weather and spatial data using ESRI ArcGIS and the OSIsoft® PI System. Erich Cline, Software Architect, Integral GIS; Frank DiCicco, GIS Lead; and Ed Kovler, Solutions Architect presented a demonstration of DIMA at the 2015 OSIsoft Users Conference in San Francisco.
PowerStream, the second largest municipally owned distribution company in Ontario, Canada, has been leveraging the PI System since 2012 to improve the operation and management of its Operations division. Starting its use of the PI System with 5,000 tags as part of its maintenance management system integration, PowerStream now employs over 30,000 tags in what the organization calls a "prioritized condition-based model" to make valuable information available to all stakeholders and make operational decisions in real time.
Qatar Power is an Independent a in the Ras Laffan Industrial City in the Gulf State of Qatar. Since implementing the PI System, it has been named Power and Water Utility of the Year within the Gulf Cooperation Council in 2012, 2013, and 2014, and, in 2014, was the first Middle Eastern company to receive a Commended Electricity Industry Sector Award. In his presentation, Parshu Borkar, Senior Engineer - Commercial and Performance, explained how his company has leveraged the PI System to optimize O&M, reduce resource consumption, and improve worker safety.
Quarcum Technologies is a Brazilian technology company that, among other activities, makes equipment for remote machine monitoring and data analysis. In partnership with OSIsoft, Quarcum has developed a new service that delivers its full infrastructure - for a monthly fee - so customers can access meaningful information in an easy-to-view online interface without needing to investment in hardware or operating systems. In his presentation, Luigino Rigitano, Quarcum's business director, described how the platform operates and presented two customer stories that demonstrate its success.
Sappi Fine Paper of North America is headquartered in Boston, Massachusetts and is the preeminent producer of coated fine paper in North America. The company has long made sustainability a key component of its business strategy, increasing profits by improving operational efficiencies and reducing waste. The result: winning new customers by producing some of the industry's most environmentally preferable papers.
Sinopec Argentina E&P is an oil and gas company in the San Jorge Gulf of Southern Argentina. It has about eight thousand wells in eight areas; in Mendoza, Chubut, and Santa Cruz and a head office in Buenos Aires. In his presentation, Adrián Pavesi, head of the automation team, described the company's first steps with the PI System and their later Enterprise Agreement where the PI System was deployed in all of the company's fields. Two years ago Sinopec began working with OSIsoft and the PI System. The presentation aims to demonstrate two realities. The first is “a mall-scale pilot project that served to leverage the tool (PI System),” and the second is “how we are working with the Enterprise Agreement that we signed, starting with the benefits we were able to obtain from the first deployment,” said Mr. Pavesi.
The PI System gathers data from multiple systems and serves as a universal translator that synchronizes data center operations to boost efficiency, improve planning, and reduce IT and facility costs. With this information data centers can comply with increased government pressure to improve efficiency and reduce environment impact and meet the goals outlined in Executive Orders such as Executive Order 13423 and Executive Order 13514.
SunCoke Energy operates six sites in the US and Brazil for the conversion of metallurgical coal into metallurgical coke used in the manufacture of steel. At the 2015 OSIsoft Users Conference in San Francisco, Stephen Reynolds, Manager of Continuous Improvement for SunCoke Energy, described how the company has used the PI System to develop and implement fleet-wide operational intelligence, improve performance, and profitability.
Syncrude is one of the largest operators in Canada's growing oil sands industry. In Northeast Alberta, Syncrude operates two large-scale surface mines using truck and shovel techniques. Kyle Gogolinski, Process Control and Automation leader at Syncrude and Peter Wright, Head of the Industrial Information team at Dexcent, introduced Syncrude's Mobile Equipment Events Synthesis solution for analysis and reporting of mechanical events and discussed its impacts on mobile equipment uptime, safety and operating costs.
How can genetic biotechnology, an ethanol plant and operational data benefit an entire community? Syngenta is a global company with more than 29,000 employees in 90 countries and revenues of over $14 billion USD. By delivering seeds, seed care, and lawn and garden products, its mission is to bring plant potential to life, supporting a sustainable transformation in farming productivity and communities.
The OSIsoft PI System is at the center of Thames Water's “intelligence Hub” (iHub), which merges disparate data sources to drive operational performance. Thames Water can now garner critical insights from its network of water delivery and sewage waste removal systems that span the greater London area. During the 2016 OSIsoft EMEA Users Conference in Berlin, Simon Coombs, a consultant who has spent over 30 years specializing in IT/OT convergence for utilities companies, and Nick Burkinshaw, a 20 year IT veteran at Thames Water, detailed how Thames Water successfully converged IT and OT systems with the OSIsoft PI System.
Tyson Foods processes meats and prepared foods. From breakfast sandwiches to delicious corn dogs, Tyson processes 68,000,000 pounds of meat per week. “Up until four years ago, we had zero visibility into plant operations data, so decisions were being made without data to back it up,” said Jonathan Reichart, Senior Engineer, during the 2016 OSIsoft Users Conference. With the need for operational visibility, Tyson turned to the Factory Talk Historian which is powered by the OSIsoft PI System™ to make informed, data-driven decisions.
The University of California at San Diego (UCSD) has a long history of self-reliance when it comes to energy. By embracing clean energy technologies in its operations and by collecting data to build an ambitious long-term sustainability plan, UCSD offers a glimpse into the future. Today, the campus produces 92% of its own energy. It's striving to go further with a combination of new clean energy resources, additional on-site generation and storage, and innovative demand-reduction strategies.
Headquartered in Mukilteo, Wash., UniEnergy Technologies (UET) is a young company that manufactures and installs large-scale energy storage solutions for utility, commercial, and microgrid applications. Their core technology is a vanadium flow battery. In a talk at the 2015 OSIsoft Users Conference, Becca Gillespie, Application Manager at UniEnergy Technologies, described how UET uses OSIsoft's Connected Services to offer capacity guarantees for their technology.
The University of Iowa is one of the nation's top public research universities with over 30,000 students, cutting-edge research facilities, a 705-bed hospital complex, and an ongoing commitment to sustainability. The University originally implemented the OSIsoft PI System in 2004 to help manage its on campus power plant. When an aggressive 10-year sustainability program was announced in 2010, the University decided to leverage its existing PI System infrastructure to help it reach its new sustainability goals.
Representing over 50 percent of energy production in Sweden, hydro power is the backbone of Sweden's energy system. With about 520 employees Vattenfall Hydro Power is the third largest hydro power provider in Europe. The utility manages 55 large-scale power plants and about 50 smaller-scale plants in Sweden and Finland with an annual production of 30-35 TWh and a capacity of about 8.300 MW. “We've been operating hydropower units for over 100 years,” noted Maintenance Development Engineer Magnus Holmbom in a presentation at OSIsoft's 2015 EMEA Users Conference.
Xcel Energy provides power for 3 million electric customers and 1.9 million natural gas customers across eight states. According to the American Wind Energy Association (AWEA), it has been America's leading provider of wind-generated power for the past 11 years, and the company holds a world record for electricity generated from wind power. At OSIsoft's 2015 Regional Seminar in Denver, Kasen Huwa, Senior Business Manager at Xcel Energy, explained how his company's Enterprise Agreement with OSIsoft has ensured “all of our data is secure,” enabled “a point count increase,” and empowered a data initiative to reduce error in wind forecasting and increase savings.
To ensure its ability to deliver clean, reliable, water to households and businesses, Yorkshire Water depends on having access to a large pool of data. When the company's telemetry infrastructure could no longer keep up with its need for data, Yorkshire Water turned to the PI System™ for faster, more scalable, data management and achieved more than £1 million in annual savings through reduced energy use, improved leak detection and better chemical management.