industrial analytics transforms cp kelco to embrace the future · 1. af analytics to calculate...
TRANSCRIPT
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Industrial Analytics Transforms CP Kelco
to Embrace the Future Norman W. Ridgley
Sr. Manager Operational Excellence
For CP Kelco, a Huber Company
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Headquarter in Atlanta, Georgia
• Global leader in the manufacturing of specialty hydrocolloids with offices and manufacturing sites across the global
• 2,200 employees worldwide
• Have six global manufacturing sites
• Products are derived from raw materials found in nature
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• All products are batch fermentation based
• Produced from bacteria found in nature • Examples:
• Xanthan Gum is derived from bacteria found on cabbages leaves
• Gellan gum is from the Lily pad varieties found on ponds/lakes
• Main uses include food, personal and oral care, beverage, pharmaceutical, industrial applications, and oilfield
• Examples
• Salad dressing is thick in the bottle for suspension, but flows when poured
• Long term suspension for specialty drinks
Biogums: Xanthan Gum, Gellan Gum, and Diutan
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Continuous batch process
• Pectin • Extracted from citrus peels (orange, lemon, etc.) or sugar beet pulp
• Gelling, thickening, and stabilizing in a variety of food applications • Example: Jam and jellies
• Carrageen • Extracted from red seaweed
• Gelling, thickening, and stabilizing for food, household and personal care industrials
• Example: Marinating of meat and poultry
Food Gums: Pectin and Carrageen
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Common to These Six Sites -OSIsoft PI System-
Großenbrode, Germany Pectin
Limeira, Brazil Pectin
Lille Skensved, Denmark Pectin, Carrageenan & Refined LBG
Okmulgee, Oklahoma, USA Xanthan Gum, Gellan Gum
Matão, Brazil Citrus Peel Processing
San Diego, California, USA Xantham Gum, Gellan Gum
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
This Is Where We Started Not Getting Full Value from Our Data
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Theme was “Visualizing Your Data”
• All six PI using plant sites sent representatives • Included representatives from our corporate IT and OSIsoft
• The week was broken into four major parts • Where we are (baseline)
• What is possible
• What do we want to become
• Action plan to get there
• End of the week we had a five year plan and a process data users group
April 2017 Process Data Users Conference At Company Headquarters
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Use OSIsoft Asset Frame (AF) to facilitate process analysis through analytics, events, and notifications
• Create data relationships at the process and batch level
• Identify tools for visualizing, trending, and analysis
• Analyze based on exceptions to drive Simplicity
• Promote organic growth across sites sharing successes
• In addition • Train Process Engineers to maximize utilization of data
• Define Big Data Analytic Tools for further insights into the data
How We Plan To Capture Value
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Base PI System
- AF & Notifications
Configuration - Training - Standards - Data Merge
Stage 1 - KPI Tracking - Deviations - E-Mail Alerts
Stage 2 - Batch Tracking - CBM - Analysis - OEE Equip
Stage 3 - Big Data - AI & Process Control
5- Year Process Data Progression Focus
18 months
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Okmulgee: Test integration of OSIsoft PI AF system, plant SQL databases, and data analytics tools
• Develop batch tracking using AF
• Microsoft’s Power BI for big data visualization
• TrendMiner for process data analytics to support the AF build and analysis of raw PI data
• Skensved: Develop AF events for batch tracking within a pectin and carrageen processing plants
Pilot Sites: Okmulgee and Skensved
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• Built in 1977 as an all Xanthan Gum fermentation plant
• Site has had two major expansions
• Today produces numerous deviations of Xanthan Gum and other commercial gum types
• There are approximately 170 employees
• Using OSI PI System since 1998
The Okmulgee Site
Okmulgee, Oklahoma, USA Xanthan Gum, Gellan Gum
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Fermentation Has Two Major Processes
Unit Op 2
Unit Op 1
Unit Op X….
Today’s Topic
Unit Operations
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
1. AF analytics to calculate fermentor phases into a PI tag for each tank (key component)
2. TrendMiner validated AF calculation of phases
3. Review potential KPIs using TrendMiner
4. Key KPIs are tracked by AF events for each batch
5. AF analytics capture statistics at the end of each batch into PI tags
6. Batch summary data captured in AF event including those created using AF analytics (step 5 above)
7. Power BI used PIOLEDB to extract event data and merge with plant SQL databases for “big data” analysis
Okmulgee Strategy & Action Plan
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Tracking Individual Tank Performance
• PI Event Data • SAP Data • Local Data
Power BI Data Model • Shape data • Create relationships
• Create visuals • Analyze • Compare batch trends using TrendMiner
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Configuration Step
1. Power BI was used to identify best performing batches (yield, quality, kg/hr rate, etc.)
2. In TrendMiner created overlays of the best 3-4 batches for a tank
3. Converted to a finger print in TrendMiner as show on the right
• Creates acceptable range of operation by PI tag
TrendMiner Finger Print Creation
TrendMiner Finger Print for Batch Deviation – Set Up
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Analysis Step
1. Using Power BI visuals again, picked low performing batches needing further analysis
2. In TrendMiner used search filter to trend low performing batch
3. Compared low performing batch to the finger print created early
4. In this case it was a startup issue causing the control logic to deviate on the low performing batches
5. Installed event and notification monitoring
TrendMiner Finger Print Creation
TrendMiner Finger Print for Batch Deviation – Analysis
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• Used layers in TrendMiner to compare batch runs
• Discovered deviations in the batch process control that only lasted for a few minutes
• Consistent across all batches
• After review was able to see issue with batch process control logic
• Logic will be updated to remove deviations
Using Layers in TrendMiner to Compare Batches TrendMiner Overlay Example
Batch Clock Relative
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• Failure alarm issue with the fermentor tanks
• Failure descriptions from the control system was limited
• Using TrendMiner and AF batch markers to summarize valve operations and download the data to Excel
• Using pivots exposed high frequency of specific valve failures or tank
• Data is being used for reliability improvements
Productivity Improvement
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• Created event severity levels based on key process variables
• Used TrendMiner to validate AF calculations and stats
• Collected associated process data within the events to better understand root cause
• Supporting process variables of the event
• Now starting to use it for some batch operation monitoring with “start triggers” marking the different operational statuses
Linking Tag Deviations To Batch Productivity and Quality
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Reducing Deviation Improved Okmulgee OEE Using OSIsoft AF/EF, TrendMiner, and Microsoft’s Power BI the site was able to identify and either reduce or eliminate process deviations. Reduction in deviations supported the overall process improvement objective of over $1MM annual savings.
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Was a key support tool in identify deviations within our process
• Validate if the deviation was repeating and the degree of impact
• If yes then we spent resources to develop an AF model for reporting into Power BI
• Used TrendMiner to validate the AF models were working properly
• Finger printing and overlays were key to determine operational deviations in the batch control system
• Used to support capital engineering projects to confirm operational issues
• Resulted in a project to upgrade during shutdown of this year
Summary
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RESULTS CHALLENGE SOLUTION
COMPANY and GOAL
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Industrial Analytics Transforms CP Kelco to Embrace the Future We wanted to advance our use of process data across sites by leveraging OSIsoft AF and creation of a visualize analysis tools. Our pilot at the Okmulgee site tested the benefits of using AF, TrendMiner, and Microsoft’s Power BI to construct data models for visualization of process data.
To advance the use of plant data to improve throughput, quality and operating cost.
In April 2017 Process data conference was held at company headquarters
Pilot program at Okmulgee used AF, Power BI, and TrendMiner in an effort to improve OEE.
• Agreed to expand site data infrastructure
using OSIsoft AF and standardize on
configuration
• Growth was to be organic using
engineers at each plant site
• Agreed to pilot TrendMiner and
Microsoft’s Power BI
• All six plant sites were using the same
basic data infrastructure based on
OSIsoft data historian and Process Book
for the past +15 yrs
• How to advance data analysis using new
tools and merge with other data sources.
The Big Data challenge
• Okmulgee site OEE numbers have
improved as process deviations were
reduced. Potential $1MM per year
savings
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#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Enhance integration with TrendMiner and Power BI
• Expand the number of TrendMiner Users
• Begin to branch out AF/EF to remaining processes
• Track batches in the recovery process within each unit operations
• Use TrendMiner to develop key KPIs and limits with each unit op
• Configure AF event deviations
• Expand AF into Utilities area • TrendMiner developing KPIs and operating alerts
• Develop AF tracking of major KPIs and events
Next Steps
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
• Norman W. Ridgley
• Sr. Manager, Operational Excellence
• CPKelco, a Huber Company
Industrial Analytics Transforms CP Kelco to Face the Future
Norm’s
Trust in god, everyone else has to have data
If you torture the numbers enough you can get them to say anything
Share - Knowing it all still means nothing if tribe knows nothing
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Questions
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Thank You
Merci
Grazie