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GENERIC BATCH REPORTING FOR SIMPLE UNITS

GENERIC BATCH REPORTING FOR SIMPLE UNITS. Marc Souche :Elf Atochem - central engineering group -Lyon -France Advanced Process Control Manager . Summary. Some words on Elf and Elf Atochem Feedback from the diversisty of Pi installation Our main needs for batch units

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GENERIC BATCH REPORTING FOR SIMPLE UNITS

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  1. GENERIC BATCH REPORTING FOR SIMPLE UNITS Marc Souche :Elf Atochem - central engineering group -Lyon -France Advanced Process Control Manager

  2. Summary • Some words on Elf and Elf Atochem • Feedback from the diversisty of Pi installation • Our main needs for batch units • Example of what we want • Different ways to do the job • What we have done • Demo • Wishes for OSI

  3. ELF ELF AQUITAINE AQUITAINE OIL AND GAS REFINING PHARMACEUTICAL CHEMICALS PRODUCTION DISTRIBUTION COMMERCE INTERNATIONAL ELF EXPLORATION ELF ANTAR FRANCE ELF ATOCHEM S.A. SANOFI PRODUCTION ALPHACAN SOCAP Ltd SANOFI WINTHROP ATO FINDLEY S.A. ELF PETROLEUM ELF TRADING S.A. ATOHAAS ELF LUBRIFIANTS NORGE SANOFI DIAGNOSTICS ATOTECH ELF TRADING, Inc. PASTEUR CECA ELF ANTARGAZ ELF TRADING ASIA ELF ATO AGRI SANOFI RECHERCHE GRANDE PAROISSE ETC ... ELF AQUITAINE GAZ SANOFI BEAUTE EAEPF ELF PETROLEUM UK ELF OIL DEUTSCHLAND ELF ATOCHEM ELF PETROLAND NORTH AM. SOMARELF ELF OIL UK ELF CONGO TG SODA ASH, Inc. ELF GABON ELF OIL AFRICA ELF SEREPCA ELF PETR. NIGERIA ETC ... ELF ATO DEUTSCH. ELF EXPL. ANGOLA ELF ATO BELGIUM ELF NEFTEGAZ ELF ATO NEDER ELF PETR. QATAR ELF ATO ESPANA ELF EXPLORATION, Inc ELF ATO PORTUGAL ELF E&P VENEZUELA ELF ATO ITALIA ETC ... ETC ... Elf Organisation

  4. Africa Rest of world Europe (hors France) 1997 REVENUE = $ 43 Bn North America 14% 28% France 16% 42%

  5. CHEMICAL BRANCH : ELF ATOCHEM

  6. PI Installations in Elf ATOCHEM • Range of Processes where PI is installed since 1996 • Really Continous Units • Steamcrackers, Butadiene, Styrene Monomer, • Polyamide Monomer • Hydrogen Peroxide • Chlorine production • Specialties chemicals : Thiochemical, Fluorochemical • Continuous with grade change • Polyethylene • Polypropylene • polystyrene • Batch units • PVC • PVDF (Kynar) • Polyamide (Rilsan- Pebax)

  7. Feedback From End Users PI Usage • Process Book • No problem for all different processes • widely used • Data link • Easy to use for Process and Operating People in Continuous Units • Used for looking into a particular batch in semi continuous units • Not used in batch units • missing functions • time, number of events • batch viex released late

  8. Needs for batch units - Process Development • Final product depends on : • initial conditions (raw material quality, quantities...) • trend of all operating variables (ex : pressure profile) during the batch in all different units where the batch went through • Difficulty to do statistics and to compare • Classical way : key indicators • phases duration's • max pressure • average energy balance • etc • Another way is to do statistics on the trend values • problem of time synchronization between batches • huge amount of data • interpretation • we are working on the subject Validated reports are not in the scope

  9. Needs for Batch units - Process Developpement • Classical way : We need an easy tool doing all this data extraction . • at a product level (PIBATCH for the new PI BATCH PACKAGE) • on different reactors (PIBATCHUNIT) • without programming (as simple as Data - Link) • For ‘simple’ batches • Where batch Id is preserved in every unit

  10. Different ways to do the job • Data link • tricky to calculate phase duration, Value at the begin of a phase etc • not easy to work on alias (parallel reactors) • fixed size problem for Excel arrays • Real Time performance equations or totalizer tags • for phase duration • average over a particular phase • all tricky calculations • Positive : trends (has a meaning if quality does ’t change) • Negative • Cannot recalculate in the past • Lot of work to create and maintain these tags

  11. Differents way to do the job • Calculation in DCS • more rigid but similar problems as previous solution • complicate solution • exist on ‘before PI’ DCS • Feeding an external database • have to configure PI extraction • data duplication • double source of data • second database to be managed : we prefer to have everything in PI • Specific Visual Basic in Excel • works well • difficult to make modifications, to add new parameters • project basis

  12. What we have done • Configurable batch reporting • in Excel • easy to format document • easy to add calculations (e.g. : sum of two phases time, difference of 2 values, paint in read abnormal values...) • no additional software to maintain • for end user usage (Process and operation) • Functionalities • Report for single or multiple batches • usage of current PI batch bases • aliases, batch id, batch query • batch Id is the llink of a product within different units • automatic or manual batch selection • incremental or from zero (arrays expand itself)

  13. Another case Cata : Cata15 Prepo : C15A Main poly : P15 Vacuum : BV15 Prepo : C15B

  14. Demo MASTER SLAVE Preposeq1 Reacseq1 3 PHASES : CHARGE REACTION VIDANGE 3 PHASES : CHARGE REACTION VIDANGE

  15. Configuration Configuration of fonction and destination cell In this case unit name will be C15A or C15B depending which route the batch has taken

  16. Example of Dialog Boxes

  17. Function list Time Functions duration_phase_batch between_step duration_phase duration_digital_batch duration_digital_phase duration_batch Interpolated values value_begin_batch value_end_batch value_begin_phase value_end_phase Count functions nb_change_batch nb_state_batch nb_change_phase nb_state_phase Batch Functions BATCHID STARTTIME ENDTIME PRODUCT UNIT average_batch min_batch max_batch stdev_batch range_batch pctgood_batch total_batch mean_batch Phase functions average_phase min_phase max_phase stdev_phase range_phase pctgood_phase total_phase mean_phase

  18. Exemple of configuration Destination Cell C15* stands for C15A or C15B Depending on which prepo the batch has been made

  19. Batch Report example

  20. Others features • Can easily be used on continuous units with grade change • problem of interrupt due to problems • product sent to scratch silos • Data during this time has to be skipped • two ways to handle the problem • Batch with 2 phases : normal and scratch (averages only on normal) • Multiple batches with same product ID at PI level (batches have to be aggregated)

  21. Roll Out • Already installed • Mass PVC • Polyamide (Nylon) -Rilsan • PVDF (Kynar) • Planned for • PE • PP • other batch units : all of them seems pretty well interested • Presented as a central development • inputs for new functionality's from different sites

  22. Whishes for OSI • Add new functionalities in data link • Accept tag or Alias • Self expanding arrays • Time functions • count • …. • Add to the design of new batch tools • times, count functions, • multiple batches with same batch Id • flexibility in batch declaration • need or reporting on multiple batches

  23. Questions ?

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