GENERIC

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• GENERIC
• BATCH REPORTING
• FOR SIMPLE UNITS

Marc Souche Elf Atochem - central engineering
group -Lyon -France Advanced Process Control
Manager
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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

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Elf Organisation
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1997 REVENUE 43 Bn
North America
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28
France
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42
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(No Transcript)
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CHEMICAL BRANCH ELF ATOCHEM
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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)

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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

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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
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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

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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

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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

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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)

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Another case
Cata Cata15
Prepo C15A
Main poly P15
Vacuum BV15
Prepo C15B
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Demo
MASTER
SLAVE
Preposeq1
Reacseq1
3 PHASES CHARGE REACTION VIDANGE
3 PHASES CHARGE REACTION VIDANGE
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Configuration
Configuration of fonction and destination cell
In this case unit name will be C15A or C15B
depending which route the batch has taken
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Example of Dialog Boxes
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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

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Exemple of configuration
Destination Cell
C15 stands for C15A or C15B Depending on which
prepo the batch has been made
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Batch Report example
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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)

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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

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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

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Questions ?