Deployment of
the PDH
Infrastructure at
Verallia
Presented by Pedro Baptista, Project Manager
Vincent Turck, Industrial IT Director
© Copyri g h t 2013 OSIso f t , LLC.
A worldwide leader attentive to its
customers
2 leading international glass
nd
manufacturer in 2012
–
3.8 billion in sales
– Approximately 25 billion bottles
and jars produced in 2012
– Industrial presence in 14 countries,
with 58 sites (46 glassmaking
production sites), 10 technical
centers and 94 furnaces
– More than 14,000 employees
around the world
– Commercial presence in 46 countries
with over 10,000 customers
– 13 innovation awards in 2012
© Copyri g h t 2013 OSIso f t , LLC.
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2012 Sales:
3.8 billion Euros
By Geographical Area
By End Market
Beer
Still wines
21%
29%
Other
(including
tableware and
decoration)
United
States
33%
South
America
Western
Europe
8%
4%
Other bottles
Sparkling
wines
9%
Food
18%
Spirits
9%
56%
Eastern
Europe
3%
In millions €
2012
2011
10%
Sales (*)
3,792
3,628
Operating Income (*)
414
448
EBITDA (*)
656
685
Capital Expenditure (*)
285
272
© Copyri g h t 2013 OSIso f t , LLC.
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A worldwide industrial and commercial presence, aligned
with the markets (*)
Industrial presence in 13 countries
Commercial presence in 45 countries
44 industrial sites
(*) excluding Verallia North America
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PDH Project : Process Data Historian
PDH is an Infrastructure to collect, store and publish raw data
directly from the field. PDH uses the PI System from OSIsoft.
PDH is a global system and PI Server & PI AF Server are
installed in a central Datacenter.
Business Applications will be developed on top of this PDH
Infrastructure.
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PDH : Data Flow
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PDH : Central Architecture
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PDH Pilot : Compressor & IS Air Application
•
Objectives
–
–
•
Control the Compressed Air production and consumption.
Analyze data to find the optimize process.
Benefits  Reduce Cost
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PDH Pilot : Compressor & IS Air Application Scope
– 39 Sensors to measure flow, pressure, temperature
•
•
•
•
All compressors
Furnace
Cold End
2 Machines (2x Tandem)
– Every half machine equipped separately
– Measurement devices for Power.
– Measurement devices for Hydrometric point
© Copyri g h t 2013 OSIso f t , LLC.
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Architecture of PDH compressed air solution
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Compressed Air deployment : Feedbacks
 Some IS machines consume three times more air
than others.
 Some systems consume more air than theorical
model.
 Compressor Control Command was setup with
wrong parameters.
 Operators were not following industrial rules and
were wasting air during job changes.
© Copyri g h t 2013 OSIso f t , LLC.
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PDH : choosing our optimal clients tools V1
Data are accessible via PI AF only in order to use “Element Relative
Display”
One Single PI ProcessBook for Operators.
 Heavy VB development in PI ProcessBook (mainly to switch from
one plant to another) : Slow response time.
 One Single PI ProcessBook not relevant for our central
architecture.
One Excel PI DataLink file for client reporting
 Excel is slow mainly due to PI AF browsing.
© Copyri g h t 2013 OSIso f t , LLC.
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PDH : choosing our optimal clients tools V1



Common element
structure for all
countries & plants.
Standard Attributes
Naming
Last Level is
specific to each
plant
© Copyri g h t 2013 OSIso f t , LLC.
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PDH : choosing our optimal clients tools V1
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PDH : choosing our optimal clients tools V1
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PDH : choosing our optimal clients tools V2
Data are accessible via PI AF only in order to use “element relative display”
One PI ProcessBook per Plant for Client Operators
 PI ProcessBook is much faster. Easy to develop.
 Multiple PI ProcessBook files to manage and update.
SAP BusinessObjects with PI OLEDB for reporting
 PI OLEDB difficult to implement. TechSupport was involved to help.
 One common and global reporting tool.
 Merging SAP Data is also possible.
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PDH : choosing our optimal clients tools V2
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PDH : choosing our optimal clients tools V2
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PDH : choosing our optimal clients tools NEXT
Data are accessible via PI AF only in order to use “element relative display”
One home made web application based on PI AF SDK for all operators.





Web Based Application
Fast access to different plant organization
Automatic screen setup mapped on PI AF model structure.
Very Easy to update.
Home made application more difficult to maintain.
SAP BusinessObjects with PI OLEDB for reporting



PI OLEDB difficult to implement.
One common and global reporting tool.
Merging SAP Data is also possible.
© Copyri g h t 2013 OSIso f t , LLC.
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PDH : choosing our optimal clients tools NEXT
© Copyri g h t 2013 OSIso f t , LLC.
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Local
Industrial IT
Local
Project Manager
PI & AF
Server
Administration
Configuration
Standardization
TAG & Structure
Creation
TAG Definition
Standardization
Support
Administration
Configuration
Sector
Local
Applications
Applications
Verallia
Industrial IT
PI
Interface
Server
PDH : Team Roles
Creation
Deploy
Manage
Nothing
Support
Creation
Deploy
Manage
Support
Nothing
Specifications
Testing
Training
Specifications
Testing
Training
Shop floor
operator
Nothing
Nothing
Use
Use
© Copyri g h t 2013 OSIso f t , LLC.
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PDH : Summary, our Client Strategy for now
Local Applications : PI ProcessBook
Specific Reports : PI DataLink
Global Applications : Web Application (home made)
Global Reports : SAP BO
© Copyri g h t 2013 OSIso f t , LLC.
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Contacts
Pedro Baptista
[email protected]
Project Manager
Verallia
Vincent Turck
[email protected]
Industrial IT Director
Verallia
© Copyri g h t 2013 OSIso f t , LLC.
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