OSIsoft PI System
Supporting
Process Decisions
Presented by Seamus McGrath
© Copyri g h t 2013 OSIso f t , LLC.
Novartis:OSIsoft PI System
Supporting Process decisions
Leveraging the capability of OSIsoft PI System to support
process decision making in real-time where no process
control is required
Business Challenge
•
Complex processing of
production data performed
on control system required
offline testing and online
testing which is intrusive
and time consuming
Solution
•
Elevate all of the process
data to the Historian and
deliver the calculations
using BI and testing and
validate without interfering
with Production
Results and Benefits
•
NIR Batch report
•
Faster turnaround of
change
•
Reduced cost of change
•
No process control Execute
logic outside PCS
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• Healthcare
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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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OSIsoft PI System Supporting Process
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
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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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OSIsoft PI System Supporting Process
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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OSIsoft PI System Supporting Process
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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OSIsoft PI System Supporting Process
decisions – implementation approach
• Report can show different conditions for different drying
phases.
Current
Batch/Phase/drying
step
PC/Server
Heartbeat
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OSIsoft PI System Supporting Process
decisions – benefits
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Reduction in the amount of resources spent on sampling (QC)
Reduces delay time between phases and the overall drying time
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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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OSIsoft PI System Supporting Process
decisions – Next Steps
• Quality alarming via the PI System
– No process control
– Key enabler for CPV and EBR
© Copyri g h t 2013 OSIso f t , LLC.
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Seamus McGrath
[email protected]
Head of Automation and IT
Novartis Ringaskiddy Limited
© Copyri g h t 2013 OSIso f t , LLC.
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