412: Integrating SAP ® Software into DeltaV Philippe Moro, IT Manager Lubrizol France - Rouen,...
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Transcript of 412: Integrating SAP ® Software into DeltaV Philippe Moro, IT Manager Lubrizol France - Rouen,...
412: Integrating SAP® Software into DeltaV
412: Integrating SAP® Software into DeltaV
Philippe Moro, IT Manager
Lubrizol France - Rouen, France
Christopher Worek, Senior Principal Engineer
Emerson
2
PresentersPresenters
Philippe Moro
Christopher Worek
3
IntroductionIntroduction
Integrating SAP® software into DeltaV for an application of the multivariate statistical analysis of online batch processing
Part 1 - Philippe– Introduction, architecture– Security, integration workflow and data structure
Part 2 - Chris– DeltaV integration and the usage of SAP software data
Part 3 – Philippe and Chris– Teamwork, lessons learned, benefits of this project– Wrap up summary and Q&A
4
Part 1
Introduction, ArchitectureSecurity, Integration Workflow and Data Structure
Part 1
Introduction, ArchitectureSecurity, Integration Workflow and Data Structure
Philippe Moro
5
IntroductionIntroduction
This presentation describes how we have integrated– SAP® software lab results data with DeltaV continuous
historian data
In order to allow DeltaV modules – to make multivariate analysis online
This integration allows us to improve our process– With this solution, our target is to detect any batch that is
close to being outside of its good batch profile and to get the contribution of the variables to the variability in order to adjust the right parameters immediately.
6
IntroductionIntroduction
This presentation describes the service-oriented architecture of a beta solution we have built with Emerson in the context of our alliance
Topics we will cover are– The physical and logical architecture– The lab data model in SAP® software– The lab data model in DeltaV– The integration in a secure mode– How this workflow leverages the usage of Web services using the
Microsoft .net framework• In the SAP software side• In the Emerson side
– The key steps of the project in the context of our alliance with Emerson
– The business results achieved
7
The ProblemThe Problem
External SAP® software data impacts production system– We improve control by having lab data integrated online
Need a way to get SAP software data into DeltaV No modification to existing DeltaV production system
– It is a beta solution connected to a production system
Minimal impact to existing DeltaV production system– This unit is new and running 24/7– Improvement is needed on this unit
8
The Problem (Slightly Restated)The Problem (Slightly Restated)
Lab data captured on systems outside the control of DeltaV system
Lab data entered asynchronously to the execution of a batch
Lab data may be entered anytime during the execution of a batch (including after the batch has completed).
Lab data serves two purposes1. Online (active) data used in online analytics
2. Off-line (past) data used for data analytics model generation
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Online/Off-Line AnalyticsOnline/Off-Line AnalyticsLab data serves two purposes
1. Online (active) data used in online analytics
2. Off-line (past) data used for data analytics model generation
10
The SolutionThe Solution
Install DeltaV.PAT beta station as a stand-alone system (Windows Workgroup) running DeltaV
Connect DeltaV.PAT station to plant LAN (with minimum privileges)
Web service installed on DeltaV.PAT to accept SAP® software data
Custom.net code to call standard SAP software Web services
11
The Architecture of this Solution: PhysicalThe Architecture of this Solution: PhysicalIIS .net Web services
SAP QM Bapis
Firewall
Batch exec & campaign mgr
Continuous historianbatch historian
PRO+Operator interface
Truck unload and batch information
Control network
Lubrizol domain
Analytics
Embedded analysis &
diagnostic apps.
Beta stationfor multivariate
analysis
Laboratory tests results
SAP SQL
OPC mirror on Emerson continuous historian
12
The Architecture of This Solution: LogicalThe Architecture of This Solution: Logical
SAP labanalysis
Lubrizol Windows service
Lubrizol Windows service
Lubrizol Web Service
Emerson integration utilitylab and process control data
Lubrizol Windows Service
Lubrizol Web service
SQL 2005SAP Web service
Firewall
Batch Historian
Lubrizol domain
DeltaV domain
Embedded analysis &
diagnostic apps.
Beta stationfor multivariate
analysis
Continuous historian
Truck unload and batch information
Laboratory tests results-Initial components-In process -Final
Online multivariate analysis
OPC mirror on Emerson continuous historian
External component
Emerson component
Lubrizol component
SQL ExpressDelta V 8.3
Delta V 9.3
Continuous historian
13
The Software ComponentsThe Software ComponentsSAP® software is used for the lab data entry QE01, QE02, QE03 QE11,QE12SAP® software is used for the lab data entry QE01, QE02, QE03 QE11,QE12
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The Software ComponentsThe Software Components
SAP® Software Web services and Microsoft.net frameworkSAP® Software Web services and Microsoft.net framework
All the .net programs are written with Microsoft Visual Studio.net 2005
In these services, the dialog with the SAP software bapis uses the wsdl files generated by SAP software when adding visual studio
Web references to the SAP software Web services, which calls the SAP software BAPIS
Lubrizol Windows service SQL 2005SAP software Web services
SAP labanalysis
15
The Software ComponentsThe Software Components
SAP® Software ECC 5 Standard BapisSAP® Software ECC 5 Standard Bapis
BAPI_INSPLOT_GETLIST
BAPI_INSPOPER_GETLIST BAPI_INSPOPER_GETCHAR BAPI_INSPOPER_GETDETAIL
BAPI_INSPLOT_GETDETAIL
The dialog between .net programs and SAP software is based on the usage of the following standard SAP software business application interfaces.
Get the inspection lot list
for each inspection lot list
Get the operations associatedGet the lab test descriptionsGet the result for each inspection point or each single pointGet the storage location for eachinspection lot
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The Software ComponentsThe Software Components
ws = New SapZInspLotListPRD.ZInspLotListService
sapReturn = ws.InspectionLotGetList(Batch, CreatDat, Customer, DelivItem, DelivNumb, InspLotList, _ Manufacturer, MatDoc, MatDocItm, Material, MaxRows, MaxRowsSpecified, Order, Plant, PoItem, _ PoNumber, RsOrder, SelectionId, StatusCreated, StatusReleased, StatusUD, Vendor, Version)
Microsoft .net reference to the SAP® software Web serviceMicrosoft .net reference to the SAP® software Web service
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The Software ComponentsThe Software ComponentsLubrizol Windows service
SQL 2005
In processinspection lot
In processinspection lot
Finalinspection lot
Finalinspection lot
Inspection Point
Inspection Point
Inspection Point
Inspection Point
Inspection point
Inspection point Test
Results
Test ResultsTest
results
Test results
Test resultsforin processanalysis
Test resultsforin processanalysis
Inspection Point
Inspection Point
Inspection Point
Inspection Point
Inspection point
Inspection point Test
Results
Test ResultsTest
Results
Test ResultsTest
results
Test results
Test resultsfortruck unloadanalysis
Test resultsfortruck unloadanalysis
Lubrizol Web service
Lubrizol Windows service
Batch historian
SAP labanalysis
18
The Software ComponentsThe Software Components
SQL 2005
Test resultsforin processanalysis
Test resultsforin processanalysis
Test resultsfortruck unloadanalysis
Test resultsfortruck unloadanalysis
Lubrizol Web service
Lubrizol Windows service
Batch Historian
19
Security ConsiderationsSecurity Considerations
Using Web services allows controlled penetration of existing firewalls
Firewall
Lubrizol domain
DeltaV domain
Web service
Web service
SAP® software
20
Security at 3 LevelsSecurity at 3 Levels
Firewall
Windows® operating system service
Microsoft Internet information service server Lubrizol Web service
XML
1
2
3
Firewall IIS configuration Xml messageFirewall IIS configuration Xml message
Windows® operating system service
Microsoft Internet information service server Web service 2
Lubrizol domain
Delta V domain
21
Firewall SecurityFirewall Security
• Stations are defined by Ip network groups
« Outside » = Lubrizol domain
« Inside » = DeltaV domain
• Rules to control the traffic are defined between groups1
22
Firewall SecurityFirewall Security
1
TCP port authorized is defined for each rule
23
IIS SecurityIIS Security
TCP port authorized is defined for each Web site
Web services authorized are defined with the IIS Manager
2
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XML SecurityXML Security<?xml version="1.0" encoding="UTF-8"?><Lubrizol Security>..</Lubrizol Security ><LabData version="1.0"> <Plant></Plant> <ProcessOrder></ProcessOrder> <SampleDatePicking></SampleDatePicking> <AnalysisProcessStep></AnalysisProcessStep> <Results> <Result InspCharDescr= ‘’ ’’>
<Material></Material><Tank></Tank>..<Status>1</Status>
</Result> <Result InspCharDescr= ‘’ ’’>
<Material></Material><Tank></Tank>..<Status>1</Status>
</Result> </Results></LabData>
• Easy to add/delete security information in the xml file
• Easy to encrypt/decrypt
3
25
Web service developed to writeSAP® software lab data on the DeltaV sql tablesWeb service developed to writeSAP® software lab data on the DeltaV sql tables
Lubrizol Web service
Firewall
SQL Express
The Software ComponentsThe Software Components
26
The Software ComponentsThe Software Components
Test resultsforin processanalysis
Test resultsforin processanalysis
Test resultsfortruck unloadanalysis
Test resultsfortruck unloadanalysis
Lubrizol Web service SQL Express
Batchlabparameters
Batchlabparameters
27
Lubrizol Web service
SQL Express
The Software ComponentsThe Software Components
Test resultsforin processanalysis
Test resultsforin processanalysis
Test resultsfortruck unloadaalysis
Test resultsfortruck unloadaalysis
Emerson integration utilitylab and process control data
Embedded analysis &
diagnostic apps.
Beta stationfor multivariate
analysis Continuous historian
Batchlabparameters
Batchlabparameters
28
Part 2
DeltaV Integration and the Usage of SAP® Software Data
Part 2
DeltaV Integration and the Usage of SAP® Software Data
Chris Worek
29
SAP® Software Integration – PrerequisitesSAP® Software Integration – Prerequisites
1. As part of the Lubrizol <> Emerson alliance Lubrizol agrees to discuss product workflow and share
production data Emerson agrees to provide equipment and share technical
designs
2. Web service signature (XML) agreed upon for pushing SAP software data down to DeltaV domain
3. SQL tables agreed upon to hold SAP software data for processing
30
SAP® Software Integration SAP® Software Integration
SQL server tables created to mirror SAP software data– Truck data tables– Lab data tables
SQL server tables used to stage SAP software data coming from SAP software
Beta station service processes SAP software data and– Writes active SAP software data to online DeltaV modules– Writes past SAP software data to DeltaV continuous
historian Online DeltaV results available via Web service
31
SAP® Software Integration – S/W ArchitectureSAP® Software Integration – S/W Architecture
LubrizolGateway
WebService
PatOnlineApplication
Model
DVCH
DeltaV9.3
ModuleX, Y
inputs
LabData
XM
L m
odel
SQL
Truck, Lab
Analysis D
ata
WebService
Sta
ge S
umm
ary
Dat
a
Model
updates
Offline Beta StationOr
Other Offline Applications
LabDataUtility
Stage Summary
Utility
DeltaV.PAT Beta Station
Lab Data Entry
StageSummary
InitialC
onditions
SAPSystem
DeltaVProduction
Truck Data Entry
OP
CM
irror
Truck Data
Lab Data
DataFlowBy request
32
SAP® Software Integration Data FlowSAP® Software Integration Data Flow
1. New data entered into SAP software
2. Custom Lubrizol Gateway application detects new records
3. Gateway application calls Web service and passes XML representation of SAP software data
4. Web service parses XML and populates SQL database
5. Web service alerts LabData Utility that new data is available
6. LabData Utility queries SQL for new records
7. New records parsed and written to DeltaV (SQL tables contain logic that links lab tests/truck data with DeltaV tags)
SAP software data now available for online processing or off-line model generation
33
Application FlowApplication Flow
PRO+
DeltaV Domain
Application Station
H1
Operator Station
DeltaV.PATBeta Station
(2)OPC
MIRROR
(1) RUN
BATCH
Lubrizol Domain
(3)LAB Data From SAP
(5)End of Stage
ResultsTo
Enterprise
SAP
(4)Online
Analysis
Firewall
34
Additional DetailsAdditional Details
Using standard interfaces (OPC Mirror, Web services) allows communication between Lubrizol production system (DeltaV 8.3) and DeltaV.PAT station (DeltaV 9.3)
Minimal impact to production system – OPC Mirror server outside production system transfers data
from production system to DeltaV.PAT beta station– Only impact to production system is OPC Read
DeltaV.PAT beta station is a stand-alone system with minimal impact to existing production system
35
Using SAP® Software DataUsing SAP® Software Data
DeltaV continuous historian DVCH provides a mechanism to post date the lab data.
SAP software data captured in the context of a batch is written to DeltaV modules. These DeltaV modules are automatically historized into DVCH.
SAP software data captured outside the context of a batch is written directly to DVCH. – If lab data is received after the end of a batch it is post dated
at the right time in the past in the continuous historian flow.
36
DvCH Data Extraction DvCH Data Extraction Select Data PointsSelect Data PointsDvCH Data Extraction DvCH Data Extraction Select Data PointsSelect Data Points
Select points from the list of available tagsSelect points from the list of available tags
Use > and < buttons to move tags between listsUse > and < buttons to move tags between lists
Save – persists selected tags to diskSave – persists selected tags to disk
Load – verify saved tags and fill selected listLoad – verify saved tags and fill selected list
Reset – clears selected list and starts overReset – clears selected list and starts over
37
DvCH Data Extraction DvCH Data Extraction Select TimespanSelect TimespanDvCH Data Extraction DvCH Data Extraction Select TimespanSelect Timespan
Specify start and end times for dataSpecify start and end times for data
Specify UTC or local time note DvCH points use UTCSpecify UTC or local time note DvCH points use UTC
Choose “Raw” when examining single pointsChoose “Raw” when examining single points
Choose “Interpolated” to align multiple pointsChoose “Interpolated” to align multiple points
38
DvCH Data Extraction DvCH Data Extraction Select Output fileSelect Output fileDvCH Data Extraction DvCH Data Extraction Select Output fileSelect Output file
Enter a valid DOS filename – file does not have to exist
Enter a valid DOS filename – file does not have to exist
Use comma or tab delimited output formatUse comma or tab delimited output format
Row numbers – integer count on each line output Row numbers – integer count on each line output
Duration – incremental timespan from start timeDuration – incremental timespan from start time
BAD status – values with status other than GOOD are either written or omitted
BAD status – values with status other than GOOD are either written or omitted
39
Business Results AchievedBusiness Results Achieved
Field tests with DeltaV.PAT analytics station currently in place at Lubrizol (Rouen, France).
End result is that SAP® software data for the process can be querried from DVCH and appears as just another tag.
With this project we leverage– Lubrizol service-oriented architecture for the SAP software
integration– Emerson service-oriented architecture for the DeltaV
integration– Our experience in batch analytics– The Lubrizol/Emerson alliance teamwork
40
Part 3
Teamwork, Lessons Learned, Benefits of this Project
Part 3
Teamwork, Lessons Learned, Benefits of this Project
Philippe Moro
41
The Project ManagementThe Project Management
OMS Steering Team
Priorities and directionIdentify focus group activities
Metrics developmentCoordination/communication
Global Organization and Alliance – Lubrizol and EmersonGlobal Organization and Alliance – Lubrizol and Emerson
OMS Executive Team
Alliance Sponsor
Standardization Team
Define global standardsDefine mechanism to document
and share standards
Business Opportunities Team
Priorities and directionIdentify focus group activities
Metrics developmentCoordination/communication
Technology Team
Manual batchLoop tuning for controllers
Advanced controlAsset management
DPCS Migration Team
Migration guidelineMigration strategy
TimetableMonitor progress
Integration/Architecture Team
Define integration strategyArchitecture of components
Support implementation
42
Global Organization and Alliance – Lubrizol and EmersonGlobal Organization and Alliance – Lubrizol and Emerson
Operation Engineer Team
Process designFunctional specificationsBatch model definition
Tests validation
DPCS Team
DeltaV configurationDeltaV programming
Control network
IS Team
Global architectureComponent development
Data securityGlobal network
Integration/Architecture Team
Define integration strategyarchitecture of components
Support implementation
Operation Engineer Team
Process DesignFunctional specificationsBatch Model definition
Tests Validation
DPCS Team
DeltaV ConfigurationDeltaV Programming
Control network
IS Team
Global architecturecomponent development
Data securityGlobal Network
Operation Engineer Team
Process DesignFunctional specificationsBatch Model definition
Tests Validation
DPCS Team
DeltaV ConfigurationDeltaV Programming
Control network
IS Team
Global architecturecomponent development
Data securityGlobal Network
Operation Engineer Team
Process designFunctional specificationsBatch model definition
Tests validation
DPCS Team
DeltaV configurationDeltaV programming
Control network
IS Team
Global architectureComponent development
Data securityGlobal network
Core Team Core Team
Site Teams Site Teams
Projects
The Project ManagementThe Project Management
43
Lessons LearnedLessons Learned Document and periodically review the workflow
– To share the same understanding– To synchronize sub teams
Control and periodically review SAP® software lab data– They are often captured for ERP needs– You need them very integrated to the batch activity– You need them for statistical analysis
This is a framework of components– Test the code as soon as possible, even part of it– It helps you to validate your design
You will modify some operation processes– Make sure people have the right information, the right training– You want them to capture the right data at the right time
The Project ManagementThe Project Management
44
Moving plants to more:
– Instrumentation
– Process control
– Automation
– Batch control
Increased production reliability
Reduced process variation
More data availability; dealing with multivariate relationships
Ability to analyze the data (off-line, online)
Implications to Operations Implications to Operations
45
Importance to OperationsImportance to Operations
Batch end point characterization Product quality prediction/improvement Abnormal situation characterization/prevention Soft sensors Characterizing process relationships Process variation, impacts and reduction Improve process control Target areas needing better control Improve economics Improve product quality
46
Thank You
Q & A
Thank You
Q & A
Vision without action is merely a dream.
Action without vision just passes the time.
Vision with action can change the world.
- Joel Barker, Futurist
SAP is a registered trademark of SAP AG in Germany and in several other countries.
Windows is a registered trademark of Microsoft Corporation in the United States and other countries.
47
Where to Get More InformationWhere to Get More Information
Emerson Exchange 2008– Session ID: 364 - Process Analytics In Depth– Session ID: 366 - The Application of Data Analytics in Batch
Operations– Session ID: 367 - Tools for Online Analytics
48
About the PresentersAbout the Presenters
Philippe Moro - IS Manager, Lubrizol France
Philippe is an Information System Manager at Lubrizol’s Rouen, France plant. After working 7 years in the medical area, Philippe joined the chemical industry. He has 21 years of experience in this area working with various information systems. He is a team leader in a the global Lubrizol Operation Management Systems organization. During the last 5 years, his team focused on the architecture of an integration solution between the Lubrizol ERP system and control systems.
49
About the PresentersAbout the Presenters
Christopher Worek, Senior Principal Engineer, Emerson Process Management [email protected] has worked in the process control industry since 1989, when he joined Texas Instruments Industrial Controls division in Johnson City, Tennessee, as a software engineer for the TI 305, 405 and 505 lines of controllers. He also spent 6 years working with Telemechanique/Group Schneider on software for the TSX line of controllers. Chris joined Emerson Process Management in 1999, and is a member of the Future Architecture Team. Chris has been awarded patents for his work at Emerson on messenger, history analysis and other projects.