Improving Process Performance Across Multiple Sites with a PI System Infrastructure

Transcription

1 Improving Process Performance Across Multiple Sites with a PI System Infrastructure Presented by Peter Lundqvist, Mathias Holmgård

2 Peter Lundqvist Principal Engineer DuPont Industrial Biosciences 2

3 Mathias Holmgård Automation Engineer DuPont Industrial Biosciences 3

4 Contents of todays talk Show an application built in Excel on a central server concept. The benefits with this application is mainly time savings. Analysis of global run data from multiple sites can now be made in minutes instead of days. 4

5 Global Science Company with a Broad Portfolio 5

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7 Manufacturing set-up Plant A Plant B Plant C Plant D Plant E Plant F Plant G Pilot scale - Different colors illustrates different platforms (approximated) - Number of dots illustrates on a relative basis number of runs (not based on actuals) = engineers 7

8 Reasons for a central PI Server WAN traffic site-to-site slow Unrealistic to pull the data from each sites PI Server PI Batch performance an issue Easiest way to fix was installing a Central PI Server pulling the needed data from the sites 8

9 Architecture of the Central PI Server solution One PI to PI Interface on the Central PI Server One instance per Production Site pulling data Data is converted to SI units on the local PI Server before transfer PI Server 2014 in use PI Asset Framework (PI AF) for configuration PI Batch for batches 9

10 Structure of Excel tool Start Time Process Order PI Batch End Time PI DataLink Aliases Measurements Excel Trends 10

11 Time *-350d * Time incr. 00:06:00 360,00 360s File version : 2014_02_26, PLu Unit *MF* 2 PI server gcorpp01 BAC Phase to plot Fermentation 2 Process Fermentation Batch Batch id Product Unit Product Color Transp. Line weight Trend Alias Unit Y-min Y-max Output Batch 1 - * 0 2 Trend 1 OTR mmol/kg/h SU Batch 2 - * 0 2 Trend 2 CTR mmol/kg/h SU Batch 3 - * 0 2 Trend 3 Carbon-source 1 Feed Mass Flow (as is) kg/h 52 0 auto 2450 SU Batch 4 - * 0 2 Trend 4 DO2-2 (%) % 71 0 auto 2534 SU Batch 5 - * 0 2 Trend 5 Active ph ph 2 6,7 7,8 713 SU Batch 6 - * 0 2 Trend 6 ph-1 ph 120 6,7 7, SU Batch 7 - * 0 2 Trend 7 Ammonia Feed Mass Flow (as is) kg/h 23 0 auto 636 SU Batch 8 - * 0 2 Trend 8 Ammonia Feed Totalizer (as is) kg 26 0 auto 1238 SU Batch 9 - * 0 2 Trend 9 Mixing Electrical Energy / Broth Mass kw/kg auto 669 SU Batch 10 - * 0 2 Trend 10 Airflow (Nm3/h) Nm3/h SU Batch 11 - * 0 2 Trend 11 Over Pressure bar ,5 534 SU Batch 12 - * 0 2 Trend 12 kla-1 1/h SU Batch 13 - * 0 2 Trend 13 Total CTR mol/h SU Batch 14 - * 0 2 Trend 14 Total OTR mol/h auto 727 SU Batch 15 - * 0 2 Trend 15 VVM 1/min auto 534 SU Batch 16 - * 0 2 Trend 16 Offgas %CO2 % auto 668 SU Batch 17 - * 0 2 Trend 17 Offgas %O2 % auto 2570 SU Batch 18 - * 0 2 Trend 18 Temperature Fermentation C auto 660 SU Batch 19 - * 0 2 Trend 19 Broth Mass kg 40 0 auto 2427 SU Batch 20 - * 0 2 Trend 20 DCO2-1 - at probe level (mmol/kg) mmol/kg 66 0 auto 534 SU Trend 21 Test 1 Unit 1 0 auto Update graph lines 0 = filled Trend 22 Test 2 Unit 2 0 auto 0,5 = semi-transparent Trend 23 Test 3 Unit 3 0 auto 1 = transparent Trend 24 Test 4 Unit 4 0 auto Scale X-axis Trend 25 Test 5 Unit 5 0 auto 1 = thin 2 = default X-min X-max Scale Y-axis 3 = thick 0 40 Recalc All Recalc Data Zoom 85 Get Raw Materials Recalc Batches RecalcUnit Data Zoom Graphs Get Batch Output Recalc Graphs Recalc Calculations Clear data RecalcFind Batches 11

12 Time *-350d * Time incr. 00:06:00 360,00 360s File version : 2014_02_26, PLu Unit *MF* 2 PI server gcorpp01 BAC Phase to plot Fermentation 2 Process Fermentation Batch Batch id Product Unit Product Color Transp. Line weight Trend Alias Unit Y-min Y-max Output Batch 1 - * 0 2 Trend 1 OTR mmol/kg/h SU Batch 2 Same - * front end 0 2 Trend 2 CTR mmol/kg/h SU Batch 3 - * 0 2 Trend 3 Carbon-source 1 Feed Mass Flow (as is) kg/h 52 0 auto 2450 SU Batch 4 for multiple - * process 0 2 Trend 4 DO2-2 (%) % 71 0 auto 2534 SU Batch 5 - * 0 2 Trend 5 Active ph Automatic ph 2 scaling 6,7 7,8 713 SU Batch 6 - * 0 2 Trend 6 ph-1 ph 120 6,7 7, SU areas Batch 7 - * 0 2 Trend 7 Ammonia Feed Mass Flow (as is) of y-axis kg/h of 23 trends 0 auto 636 SU Batch 8 - * 0 2 Trend 8 Ammonia Feed Totalizer (as is) kg 26 0 auto 1238 SU Batch 9 - * 0 2 Trend 9 Mixing Electrical Energy / Broth Mass based kw/kg on 107 platform 0 auto 669 SU Batch 10 - * 0 2 Trend 10 Airflow (Nm3/h) Nm3/h SU Batch 11 - * 0 2 Trend 11 Over Pressure bar ,5 534 SU Batch 12 - * 0 2 Trend 12 kla-1 1/h SU Batch 13 - * 0 2 Trend 13 Total CTR mol/h SU Batch 14 - * Easy customization of0 2 Trend 14 Total OTR mol/h Interaction auto with 727 SU Batch 15 - * 0 2 Trend 15 VVM 1/min auto 534 SU Batch 16 trend - * colors, line weights 0 2 Trend 16 Offgas %CO2 % SAP to auto get batch 668 SU Batch 17 - * 0 2 Trend 17 Offgas %O2 % auto 2570 SU Batch 18 - * 0 2 Trend 18 Temperature Fermentation C auto 660 SU Batch 19 - * and transparencies 0 2 Trend 19 Broth Mass kg 40 0outputs auto 2427 SU Batch 20 - * 0 2 Trend 20 DCO2-1 - at probe level (mmol/kg) mmol/kg 66 0 auto 534 SU Trend 21 Test 1 Unit 1 0 auto 0 = filled Trend 22 Test 2 Unit 2 0 auto Update graph lines 0,5 = semi-transparent Trend 23 Test 3 Unit 3 0 auto 1 = transparent Trend 24 Test 4 Unit 4 0 auto Trend 25 Test 5 Automatic Unit 5 0 scaling auto Scale X-axis 1 = thin Scale Y-axis Get Raw Materials Get Batch Output Clear data Interaction with SAP to get batch raw-materials 2 = default X-min X-max 3 = thick 0 40 Recalc All Recalc Batches Recalc Graphs RecalcFind Batches Recalc Data RecalcUnit Data Recalc Calculations of x-axis on trends Zoom 85 Fast Zoom zooming Graphs of graphs when switching computer 12

13 Time *-350d * Time incr. 00:06:00 360,00 360s File version : 2014_02_26, PLu Unit *MF* 2 PI server gcorpp01 BAC Phase to plot Fermentation 2 Process Fermentation Batch Batch id Product Unit Product Color Transp. Line weight Trend Alias Unit Y-min Y-max Output Batch * 0 2 Trend 1 OTR mmol/kg/h SU Batch * 0 2 Trend 2 CTR mmol/kg/h SU Batch * 0 2 Trend 3 Carbon-source 1 Feed Mass Flow (as is) kg/h 52 0 auto 2450 SU Batch * 0 2 Trend 4 DO2-2 (%) % 71 0 auto 2534 SU Batch * 0 2 Trend 5 Active ph ph 2 6,7 7,8 713 SU Batch * 0 2 Trend 6 ph-1 ph 120 6,7 7, SU Batch * 0 2 Trend 7 Ammonia Feed Mass Flow (as is) kg/h 23 0 auto 636 SU Batch * 0 2 Trend 8 Ammonia Feed Totalizer (as is) kg 26 0 auto 1238 SU Batch * 0 2 Trend 9 Mixing Electrical Energy / Broth Mass kw/kg auto 669 SU Batch * 0 2 Trend 10 Airflow (Nm3/h) Nm3/h SU Batch * 0 2 Trend 11 Over Pressure bar ,5 534 SU Batch * 0 2 Trend 12 kla-1 1/h SU Batch * 0 2 Trend 13 Total CTR mol/h SU Batch * 0 2 Trend 14 Total OTR mol/h auto 727 SU Batch * 0 2 Trend 15 VVM 1/min auto 534 SU Batch * 0 2 Trend 16 Offgas %CO2 % auto 668 SU Batch * 0 2 Trend 17 Offgas %O2 % auto 2570 SU Batch * 0 2 Trend 18 Temperature Fermentation C auto 660 SU Batch * 0 2 Trend 19 Broth Mass kg 40 0 auto 2427 SU Batch * 0 2 Trend 20 DCO2-1 - at probe level (mmol/kg) mmol/kg 66 0 auto 534 SU Trend 21 Test 1 Unit 1 0 auto Update graph lines 0 = filled Trend 22 Test 2 Unit 2 0 auto 0,5 = semi-transparent Trend 23 Test 3 Unit 3 0 auto 1 = transparent Trend 24 Test 4 Unit 4 0 auto Scale X-axis Trend 25 Test 5 Unit 5 0 auto 1 = thin 2 = default X-min X-max Scale Y-axis 3 = thick 0 40 Recalc All Recalc Data Zoom 85 Get Raw Materials Recalc Batches RecalcUnit Data Zoom Graphs Get Batch Output Recalc Graphs Recalc Calculations Clear data RecalcFind Batches 13

14 Time *-350d * Time incr. 00:06:00 360,00 360s File version : 2014_02_26, PLu Unit *MF* 2 PI server gcorpp01 BAC Phase to plot Fermentation 2 Process Fermentation Batch Batch id Product Unit Product Color Transp. Line weight Trend Alias Unit Y-min Y-max Output Batch * CEDA_MF_R261 C Trend 1 OTR mmol/kg/h SU Batch * CEDA_MF_R262 C Trend 2 CTR mmol/kg/h SU Batch * CEDA_MF_R263 C Trend 3 Carbon-source 1 Feed Mass Flow (as is) kg/h 52 0 auto 2450 SU Batch * CEDA_MF_R264 C Trend 4 DO2-2 (%) % 71 0 auto 2534 SU Batch * CEDA_MF_R261 C Trend 5 Active ph ph 2 6,7 7,8 713 SU Batch * CEDA_MF_R262 C Trend 6 ph-1 ph 120 6,7 7, SU Batch * CEDA_MF_R264 C Trend 7 Ammonia Feed Mass Flow (as is) kg/h 23 0 auto 636 SU Batch * CEDA_MF_R261 C Trend 8 Ammonia Feed Totalizer (as is) kg 26 0 auto 1238 SU Batch * CEDA_MF_R262 C Trend 9 Mixing Electrical Energy / Broth Mass kw/kg auto 669 SU Batch * CEDA_MF_R263 C Trend 10 Airflow (Nm3/h) Nm3/h SU Batch * CEDA_MF_R261 C Trend 11 Over Pressure bar ,5 534 SU Batch * CEDA_MF_R262 C Trend 12 kla-1 1/h SU Batch * CEDA_MF_R263 C Trend 13 Total CTR mol/h SU Batch * CEDA_MF_R264 C Trend 14 Total OTR mol/h auto 727 SU Batch * CEDA_MF_R261 C Trend 15 VVM 1/min auto 534 SU Batch * CEDA_MF_R262 C Trend 16 Offgas %CO2 % auto 668 SU Batch * CEDA_MF_R263 C Trend 17 Offgas %O2 % auto 2570 SU Batch * CEDA_MF_R264 C Trend 18 Temperature Fermentation C auto 660 SU Batch * CEDA_MF_R261 C Trend 19 Broth Mass kg 40 0 auto 2427 SU Batch * CEDA_MF_R262 C Trend 20 DCO2-1 - at probe level (mmol/kg) mmol/kg 66 0 auto 534 SU Trend 21 Test 1 Unit 1 0 auto Update graph lines 0 = filled Trend 22 Test 2 Unit 2 0 auto 0,5 = semi-transparent Trend 23 Test 3 Unit 3 0 auto 1 = transparent Trend 24 Test 4 Unit 4 0 auto Scale X-axis Trend 25 Test 5 Unit 5 0 auto 1 = thin 2 = default X-min X-max Scale Y-axis 3 = thick 0 40 Recalc All Recalc Data Zoom 85 Get Raw Materials Recalc Batches RecalcUnit Data Zoom Graphs Get Batch Output Recalc Graphs Recalc Calculations Clear data RecalcFind Batches 14

15 Time *-350d * Time incr. 00:06:00 360,00 360s File version : 2014_02_26, PLu Unit *MF* 2 PI server gcorpp01 BAC Phase to plot Fermentation 2 Process Fermentation Batch Batch id Product Unit Product Color Transp. Line weight Trend Alias Unit Y-min Y-max Output Batch * CEDA_MF_R261 C Trend 1 OTR mmol/kg/h SU Batch * CEDA_MF_R262 C Trend 2 CTR mmol/kg/h SU Batch * CEDA_MF_R263 C Trend 3 Carbon-source 1 Feed Mass Flow (as is) kg/h 52 0 auto 2450 SU Batch * CEDA_MF_R264 C Trend 4 DO2-2 (%) % 71 0 auto 2534 SU Batch * CEDA_MF_R261 C Trend 5 Active ph ph 2 6,7 7,8 713 SU Batch * CEDA_MF_R262 C Trend 6 ph-1 ph 120 6,7 7, SU Batch * CEDA_MF_R264 C Trend 7 Ammonia Feed Mass Flow (as is) kg/h 23 0 auto 636 SU Batch * CEDA_MF_R261 C Trend 8 Ammonia Feed Totalizer (as is) kg 26 0 auto 1238 SU Batch * CEDA_MF_R262 C Trend 9 Mixing Electrical Energy / Broth Mass kw/kg auto 669 SU Batch * CEDA_MF_R263 C Trend 10 Airflow (Nm3/h) Nm3/h SU Batch * CEDA_MF_R261 C Trend 11 Over Pressure bar ,5 534 SU Batch * CEDA_MF_R262 C Trend 12 kla-1 1/h SU Batch * CEDA_MF_R263 C Trend 13 Total CTR mol/h SU Batch * CEDA_MF_R264 C Trend 14 Total OTR mol/h auto 727 SU Batch * CEDA_MF_R261 C Trend 15 VVM 1/min auto 534 SU Batch * CEDA_MF_R262 C Trend 16 Offgas %CO2 % auto 668 SU Batch * CEDA_MF_R263 C Trend 17 Offgas %O2 % auto 2570 SU Batch * CEDA_MF_R264 C Trend 18 Temperature Fermentation C auto 660 SU Batch * CEDA_MF_R261 C Trend 19 Broth Mass kg 40 0 auto 2427 SU Batch * CEDA_MF_R262 C Trend 20 DCO2-1 - at probe level (mmol/kg) mmol/kg 66 0 auto 534 SU Trend 21 Test 1 Unit 1 0 auto Update graph lines 0 = filled Trend 22 Test 2 Unit 2 0 auto 0,5 = semi-transparent Trend 23 Test 3 Unit 3 0 auto 1 = transparent Trend 24 Test 4 Unit 4 0 auto Scale X-axis Trend 25 Test 5 Unit 5 0 auto 1 = thin 2 = default X-min X-max Scale Y-axis 3 = thick 0 40 Recalc All Recalc Data Zoom 85 Get Raw Materials Recalc Batches RecalcUnit Data Zoom Graphs Get Batch Output Recalc Graphs Recalc Calculations Clear data RecalcFind Batches 15

16 kg % mmol/kg/h ph 400 OTR 7,8 Active ph 350 7, , , ,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 7 6,8 6,6 6,4 6,2 6 0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 4500 Ammonia Feed Totalizer (as is) 9 Offgas %CO ,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 0 0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 16

17 Batch Batch id Product Unit Product Color Transp. Line weight Batch * CEDA_MF_R261 C Batch * CEDA_MF_R262 C Batch * CEDA_MF_R263 C Batch * CEDA_MF_R264 C Batch * CEDA_MF_R261 C Batch * CEDA_MF_R262 C Batch * CEDA_MF_R264 C Batch * CEDA_MF_R261 C Batch * CEDA_MF_R262 C Batch * CEDA_MF_R263 C Batch * CEDA_MF_R261 C Batch * CEDA_MF_R262 C Batch * CEDA_MF_R263 C Batch * CEDA_MF_R264 C Batch * CEDA_MF_R261 C Batch * CEDA_MF_R262 C Batch * CEDA_MF_R263 C Batch * CEDA_MF_R264 C Batch * CEDA_MF_R261 C Batch * CEDA_MF_R262 C

18 kg % mmol/kg/h ph 400 OTR 7,8 Active ph 350 7, , , ,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 7 6,8 6,6 6,4 6,2 6 0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 4500 Ammonia Feed Totalizer (as is) 9 Offgas %CO ,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 0 0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 Elapsed Time (h) 18

19 Future plans For Central Server concept More Process Areas Training/Debugging PI Event Frames In DuPont IB PI Connected Services PI Coresight PI AF and PI Event Frames 19

20 Questions Please wait for the microphone before asking your questions State your name & company 20

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