Sigmafine Brochure Screen

THE PI SYSTEM: SIGMAFINE trust
Expand the power of PI with Sigmafine

for data you can trust
Key Sigmafine benefits: Sigmafine reconciles raw process data, making it consistent and congruous.
Sigmafine validates production information, producing balanced, reliable and
Increased confidence in useful data. Now everyone can share the same information with the confidence
your process data to make better decisions. Sigmafine empowers your personnel with quality
Improved measurement data, saves time, and increases process performance and profits.
system performance
Reduced loss
We use Sigmafine to help

improve the measured data
used in unit monitoring and
unit optimization. We derived
many unanticipated benefits
from implementing this
program. The discipline
required during the
implementation uncovered
several errors that had crept
into our internal material
balances during the years.
Kevin W. Henke
Technical Director
Koch Industries
Decisions you can trust come from data you can trust. Occurrences throughout
the enterprise such as equipment problems, instrument failure, calibration errors,
process losses and human error all create one result inaccurate data. No matter
where the data comes from there are always errors in raw data. To be truly useful,
this data needs to be transformed into a reliable and consistent information base.
Sigmafine is a rigorous, mathematical approach to data reconciliation. It uses all

available measurement data, taking full advantage of the power of measurement
redundancy, to create a common set of dependable data. It is the only tool that
can detect and identify the three most common errors in operation gross error,
random error, and bias error.
THE PI SYSTEM: SIGMAFINE production
After the installation of Sigmafine gives you the confidence of validated data you can trust, enabling you
Sigmafine, the model showed to act quickly and reliably, certain that your data is solid throughout the enterprise.
an incorrect process unit If you cannot trust the data upon which you base your decisions, you are more
lineup. A recycle line was likely to hesitate in making the most profitable business changes or necessary
open that should have been adjustments to your process.
closed. After closing the
recycle we were able to The PI System instantly makes accurate data available to everyone, anywhere
increase hydrotreater within the enterprise. In combination with Sigmafine, the PI System maintains
throughput by 8 percent. precise, reconciled process measurements that can be generated into reports for
This resulted in an energy accountants, engineers, planners, maintenance staff and management at any time.
savings of US$400,000 per Sigmafine reconciles the reporting of yield inventories, variable costs and con-
year and a product profit sumption before sending them to the enterprise resource planning (ERP) system.
increase of US$500,000, for
a total benefit of US$900,000 Turn your production information into a strategic asset
per year.
Have more confidence in your production data. Profit from improved consistency
Planning Manager of the data sent to the ERP systems, increased precision of the data measurements
Refinery, North America used to calibrate planning and control models, and the monitoring of high-value
materials in the process, such as solvents and additives.
Sigmafine can be used for data

unification and monitoring of operating
costs. Whatever youre looking for, the
results displayed through Sigmafine
are current, solid, verified data
you can depend on.
data you can trust
Improve your decision-making
process. Focus on the area and
items identified by PI and Sigmafine
where losses occur and quickly
respond to turn the errors into financial
opportunities. For example, Sigmafine
improved the decision-making process
at a refinery in Texas, resulting in an
annual savings of three million dollars.
Key Sigmafine features:
Object-oriented technology
Flexible data collection
processes
Client/server design
Sigmafine, part of the PI System

from OSIsoft, means reliable
information you can trust.
Sigmafine gives you:
Continuous improvement
Improve measurement system performance. Have the ability to cross-check in plant monitoring and
instruments to determine if performance is within required accuracy and precision diagnosis
parameters. Detect and prioritize instruments such as meters and analyzers that Better maintenance
require periodic maintenance. Sigmafine increases your confidence in the accuracy predictions and prioritization
of key instruments measuring process constraints such as emissions levels and A closed loop between actual
process throughput. and planned data
Better monitoring and
Control losses. Detect bias in measurement of material purchases and product identification of process
sales. Data reconciliation enables you to locate and quantify sources of loss by losses
comparing fiscal and engineering data. Greater margins of certainty
Reduction or elimination of
Precise technical capabilities the effects of random errors
Better error and problem
Sigmafine reconciles raw data and produces clean, balanced and consistent detection
data that is stored in the PI System as the reconciled data. Sigmafines data Faster problem resolution
reconciliation is performed in two steps. The first step uses a gross error Mass balancing
detection expert system to check for data consistency, ranges, and missing data. Component balancing
The second step employs a true least squared formulation solver. This method Data reconciliation
is based on a Kalman filtering algorithm a fast, stable solver. It can analyze Energy balancing
physical, temperature, and pressure measurements, together with properties of the Unmeasured flow calculations
streams in the operations, process unit or production site. The algorithm takes into Flexible data collection
account the calibration tolerance of each variable supplied to the system. process
THE PI SYSTEM: SIGMAFINE trust
We use Sigmafine for This method cross-checks the measurement errors on all meter and gauge
production accounting and readings, according to the tolerance assigned to each measurement. The overall
unit balances. After a recent reconciled, measured value becomes more consistently balanced with all other
turnaround the Sigmafine measurements that took part in the reconciliation calculation.
model showed that a startup
line had been left open. Our Sigmafine can perform an enterprise-wide balance that takes into account all
previous system would not of the available information on measurements for the entire plant. The result is
have noticed this and it would consistent information across the entire manufacturing site and unit-by-unit balance,
have gone undetected. We removing any underlying data conflict.
would probably have lost
about US$175,000 per year Proven technology that pays you back
with our other system.
Sigmafine has a long and successful track record for success in industries around
Manager of Technical Services the world. Take it from those who know. A production accounting manager at a
Gulf Coast Refinery, North America North American refinery says, Before we implemented Sigmafine, our reports were
erratic and showed a lot of swings, and an average monthly oil loss of 0.8%. After
the installation of Sigmafine, we determined that we had an actual loss of 1.5%,
with more controlled daily balances. We have since found the errors and made
corrections. Sigmafine helped us focus on reducing our losses, and helped save
us over US$4,500,000 per year.
Pat McDonald at Imperial Oil says, The plant is processing about 500 million
standard cubic feet per day. Sigmafine identified a bias in the custody transfer
meters. Before we used Sigmafine, 60 percent of our instruments were out of
balance. This has now been reduced to only 9 percent by proper maintenance of
the identified instrumentation. With the correction in the bias and maintenance,
we estimate that Sigmafine has saved us about US$5,000,000 per year.
Save a few million of your own
Investigate Sigmafine as a part of your own PI System and become another

success story. Make better decisions with data you can trust. Contact
[email protected].
www.osisoft.com
777 Davis Street, Suite 250

San Leandro CA 94577 USA
Copyright 2002 OSI Software, Inc. OSIsoft, the OSIsoft logo and the PI System
are trademarks of OSI Software, Inc. All other trademarks are the property of
their respective owners.

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THE PI SYSTEM: SIGMAFINE trust

Expand the power of PI with Sigmafine

We use Sigmafine to help

Sigmafine is a rigorous, mathematical approach to data reconciliation. It uses all

Sigmafine can be used for data

Key Sigmafine features:

Sigmafine, part of the PI System

Save a few million of your own

Investigate Sigmafine as a part of your own PI System and become another

777 Davis Street, Suite 250

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