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

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PresentersPresenters

Philippe Moro

Christopher Worek

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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

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Part 1

Introduction, ArchitectureSecurity, Integration Workflow and Data Structure

Part 1

Introduction, ArchitectureSecurity, Integration Workflow and Data Structure

Philippe Moro

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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

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Security ConsiderationsSecurity Considerations

Using Web services allows controlled penetration of existing firewalls

Firewall

Lubrizol domain

DeltaV domain

Web service

Web service

SAP® software

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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

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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

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Firewall SecurityFirewall Security

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TCP port authorized is defined for each rule

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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

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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

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The Software ComponentsThe Software Components

Test resultsforin processanalysis

Test resultsforin processanalysis

Test resultsfortruck unloadanalysis

Test resultsfortruck unloadanalysis

Lubrizol Web service SQL Express

Batchlabparameters

Batchlabparameters

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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

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Part 2

DeltaV Integration and the Usage of SAP® Software Data

Part 2

DeltaV Integration and the Usage of SAP® Software Data

Chris Worek

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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

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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Part 3

Teamwork, Lessons Learned, Benefits of this Project

Part 3

Teamwork, Lessons Learned, Benefits of this Project

Philippe Moro

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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

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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

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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

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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

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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

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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.

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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

philippe.moro@lubrizol.com Chris.Worek@emerson.com

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About the PresentersAbout the Presenters

Philippe Moro - IS Manager, Lubrizol France

philippe.moro@lubrizol.com

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.

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About the PresentersAbout the Presenters

Christopher Worek, Senior Principal Engineer, Emerson Process Management Chris.Worek@emerson.comChris 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.