1. © 2008 OSIsoft, Inc. | Company Confidential OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential OCEANIA TECHNOLOGY SEMINAR 2008 PI at Pan Pac Pulpmill James Bell and Roger Jones

2. 2 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential INTRODUCTION Introduction to Pan Pac Pulpmill Describe use of PI at Pac Pac Electricity Market Interfacing Future values in PI Other Interfaces Redundancy –PI Server –Interfaces

3. 3 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Pan Pac Pulpmill Forest Owner and Forest Product Manufacturer Operational since 1973 100% Japanese owned All pulp sold to Shareholder, Oji Pulp Capacity 260,000T Revenue > 250m Thermo-mechanical process –80MW peak load. Annual usage ~2% NZ power

4. 4 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential PI Background 5000 tag system operational since November 2001 Upgraded to 10,000 tags in 2004 Upgraded to 15,000 tags in 2007 Operating PI Professional Server (HA) with PI-ACE Interfaces –OPC –RDBMS –HTML –PerfMon –SNMP

5. 5 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential PI Background Standardising Control Systems –Started with many ABB AC800 ABB AC410 Allen Bradley PLC network Rosemount RS3 (RNI interface) Bailey –Changing major control systems to DeltaV

6. 6 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential PI Background Standardising Control Systems –Now we have: ABB AC800 ABB AC410 Allen Bradley PLC network Rosemount RS3 (RNI interface) Bailey (interface via DeltaV) DeltaV

7. 7 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential System overview

8. 8 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential PI at Pan Pac - Electricity Electricity is significant to our business –Electricity makes up ~40% of product cost –Annual Power bill $30M to $40M Electricity Data Interfacing –HTML interface –Web services –Comit interface built for Pan Pac

9. 9 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential HTML interface New electricity market load charge system in July 2007 –Regional coincident peak demand (RCPD) –Highest 100 ½ hour peaks for lower North Island –Occur in winter, June to August –Cost >$60,000/MW.pa. Potential cost >$4.5M pa Reduce load in the “100 peaks”, significant savings possible Problem: –Forced on industry with little warning (applied retrospectively) –Web based RCPD load data not available until 24 June 2007 Discovered free website –Possible to estimate RCPD –5 minute update (better than official information)

10. 10 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential HTML interface Solution - HTML interface (Web scraper) Strips text off web Issues –No control of websites –Only HTML Shut plant at right time Saving >$2M in 2007/08

11. 11 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Web Services ACE gets Web Service Data Web Service supplied by EM6 –Scada –RCPD on trial –One minute updates Web Service PI ACE

12. 12 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Comit Interface COMIT –A custom interface by OSIsoft NZ –Two step process WebFetch queries website and returns csv file COMIT interface processes csv and sends data to PI COMIT Interface PI WebFetch

13. 13 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Future Data Electricity Market –Provides forward prices (up to 4h in future) Used for decisions on plant operation –Need to see future data Workaround 1 –ProcessBook VBA

14. 14 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Future Data Workaround 2 –Writing week-ahead interruptible load market offers We send data to PI with timestamps –365d! Custom PB display for operators

15. 15 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Interface to Proprietary Device Particulate Monitor (Air Quality) – proprietary device Problem: no comms to device, manual download required Solution! Serial to wireless Ethernet + PI ACE Using VB.NET, send command, return data Now we can alarm on breach, and monitor with ease

16. 16 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential More options… Cooling Tower Control System –Required Modbus TCP/IP interface, for 9 points! Workaround –Use third party Modbus TCP/IP to OPC Server (cheap!) –Use existing OPC Interface Node to get data into PI Support OSIsoft!

17. 17 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Redundancy We heavily rely on PI PI critical to operations-$1000 decisions often every ½ hour 3 Points of Failure PI Server, PI Interface, OPC Server Interface level failover –OPC Interface level failover to DeltaV OPC Server –It works! We never lose data from DeltaV due to Interface shutdown OPC server level failover –Single DeltaV OPC server was largest risk for data loss –Now dual OPC servers are used, failover is in place and has already prevented data loss from OPC server failure

18. 18 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Redundancy - HA High Availability –Installed PI Server PR1 (HA) –Primary and Secondary PI Servers Good Stuff –Server Maintenance –Seamless failover

19. 19 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Recalculation-can’t overwrite an existing value We use preliminary results before recalc on final values Delivery of fix Oct 2007, we could have used different method but decided to wait for fix …..but still no patch release. Issues with HA’s Buffer sub-system

20. 20 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Issues with HA’s Buffer sub-system Our custom interfaces don’t use Buffer SS = no data to Secondary Server Manual data entry = no data to Secondary Server Fallback to Primary PI Server –HA clients (PB, DL) don’t ‘fallback’ to Primary when it becomes available –With the above missing data this can mean users don’t see all data until reconnection to Primary

21. 21 OCEANIA TECHNOLOGY SEMINAR 2008 © 2008 OSIsoft, Inc. | Company Confidential Looking to the Future PR2 looks like it will resolve most of the issues we have. Future data in PI will be great!