OSIsoft PI System Supporting Process...

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© Copyr i gh t 2013 OSIso f t , LLC.

OSIsoft PI System

Supporting

Process Decisions

Seamus McGrath


• NIR Batch report

• Faster turnaround of

change

• Reduced cost of change

• No process control Execute

logic outside PCS

Solution Results and Benefits

Novartis:OSIsoft PI System

Supporting Process decisions

Business Challenge

• Complex processing of

production data performed

on control system required

offline testing and online

testing which is intrusive

and time consuming

• Elevate all of the process

data to the Historian and

deliver the calculations

using BI and testing and

validate without interfering

with Production

Leveraging the capability of OSIsoft PI System to support

process decision making in real-time where no process

control is required

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• Healthcare • Pharmaceuticals

• Sandoz

• Vaccines & Diagnostics

• OTC

• Animal Health

• Alcon

– 140,000 Associates across 140 countries

– Pharma/TechOps/ChemOps • API DS manufacturing

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OSIsoft PI System Supporting Process

decisions - background • NIR First Installed in 2008.

• System provides PAT data about the residual solvent (ESTP/CHXA) in the product in the Dryer

• Prior to NIR End Point Tool, IPC samples had to be taken at the end of each Drying Phase, with a delay for testing time.

• NIR provides multiple parameters, with different acceptance criteria for each drying Phase as well as process parameters such as vacuum, temperature and time – a decision on end point requires careful examination of all of the criteria

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decisions - traditional approach • DCS initially considered for giving users Traffic lights, to either

advance the Drying Phase or Manually sample.

• System would be complex to implement on DCS – Difficult to simulate

– Testing in the live plant

– Changes/optimizations causes process interruptions for downloads

– A lot of consumption of DCS tags/space

– Poor graphic capability (legacy PCS)

• We had a resource constraint and there was always a greater priority

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decisions - alternative approach • OSIsoft PI System was then explored as a solution as it

contains all PCS data and NIR data – Premise being it was information only and not process control

– PI System very well embedded in Ringaskiddy and trusted

• PI ActiveView was determined to be the best display solution, used on site since 2003 for web based displays and reports. – NIR Report could be created, validated, released and controlled via

a web content server for the PI System (Novametrics)

• Integrated VBA and PI SDK have the flexibility and power to build a Traffic light display that can reliably show the current state of drying.

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decisions – implementation approach • Watchdog Parameters indicate an error with the NIR or

associated system or drying went over time limits, operator should switch to Manual sampling in this case.

• NIR and Dryer Process Values indicate via traffic light if a good condition is met. Once all conditions are met Operators are prompted to advance phase or sample depending on Drying Phase.

• It also displays the “Trigger Value”, the closest value in the time period to the limit.

• Located on a Control Room PC

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decisions – implementation approach

• Report can show different conditions for different drying

phases.

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Current

Batch/Phase/drying

step

PC/Server

Heartbeat



decisions – benefits • Reduction in the amount of resources spent on sampling (QC)

• Reduces delay time between phases and the overall drying time – Reduced deviations via avoiding over drying

• Allows users to quickly document the NIR Parameters met requirements with authenticated Print function.

• Changes can be made without downloads or alterations to PCS.

• Complex conditions can be handled.

• Report can be opened on any CONNECT PC.

• Lower cost

• Reduced Energy consumption

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decisions – playback

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decisions – Next Steps

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• Quality alarming via the PI System

– No process control

– Key enabler for CPV and EBR


Seamus McGrath

[email protected]

Head of Automation and IT

Novartis Ringaskiddy Limited

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