1 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Providing a...

1 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Providing a Single Point for Accessing and Reporting

Historical and Batch Data

Jeffrey Leverton

Controls Engineer

Diosynth

a Part of Schering Plough

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“We use the PI system internally to provide a single point to access batch and historical data from our ABB, Allen Bradley, Siemens and G.E. platforms”

Customer Business Challenge

Solution Customer Results / Benefits

The Challenge: Single data historian and reporting tool for multiple systems.

• Provide quick data retrieval for our legacy ABB MOD 300 DCS

• Provide a means for Batch comparison of campaign Batches

• Integrate and provide a means of reporting for our Siemens, Allen Bradley and G.E. systems

• Leverage our PI system to provide a means or retrieving data from our Unix based ABB MOD 300 DCS

• Using Batch View we can compare different batch runs from the same campaign

• Based on client needs we have the requirement to support specialized equipment

• Without the PI system it would take approximately 10 minutes per day per tag to retrieve the same data

• Comparing batch runs allow us to anticipate, recognize and correct problems that may arise

• Independent of the control system we always have the requirement to provide consistent data collection and reporting

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Diosynth a part of Schering Plough

Custom Manufacturing of

Biopharmaceuticals

Size: 140,000sq ft

Employees: ~500

Technology:

• Mammalian and Insect Cells Cell Culture

• Bacteria and Yeast Fermentation

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Facility Design

CELL CULTURE (Mammalian and Insect Cells)

• Two cell culture inoculum preparation suites

with

20 L seed bioreactors

• Dedicated small-scale production areas with

two x 110 L bioreactors

• Intermediate-scale production train:

- 150, 650 and 2,000 L production cell culture

bioreactor train

• Dedicated buffer and media preparation areas

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Facility Design

FERMENTATION (Bacteria and Yeast)

• Two inoculum preparation suites with 30 L seed

fermentors

• Dedicated small-scale production areas with two x

140 L fermentors

• Two separate intermediate-scale suites:

- One 150 L and 3 x 2,000 L production fermentors

• Capability to process high density cultures with high

cooling demands

• In-line mass spec gas analysis process control

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Facility Design

FERMENTATION - Harvest and Recovery

One small-scale & two intermediate-scale recovery

suites with:

– Holding tanks

– Centrifuges (disc stack, nozzle discharge)

– Two Homogenizers – up to 1,000 bar

– Recovery vessels – up to 3,000 L

– Refold suite

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Facility Design

CELL CULTURE - Harvest and Recovery

– Dedicated harvest suite

– 2,000 L harvest vessel

– Microfiltration equipment – up to 200 ft2

– Centrifuges / homogenizers

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Facility Design

PURIFICATION (Cell Culture and Fermentation)• Four Class 100,000 small-scale purification suites

• Three Class 10,000 intermediate-scale purification suites

• Two solution preparation suites – up to 3,000 L

• Chromatography skids – up to 1,000 L/h

• Column sizes up to 100 cm diameter

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Facility Design

PURIFICATION (Cell Culture and Fermentation) (Cont)

• Full range of chromatographic methods (SEC, IEX, HIC, HCIC, affinity and expanded bed)

• Ultrafiltration / diafiltration skids (filter area 5-200 ft2)

• Two small-scale and intermediate-scale bulk filling suites with Class 100 areas

• Class 10,000 small-scale Final Formulation suite

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Current Automation Systems

The Diosynth facility is divided into three main automation systems

ABB MOD 300 Unix Based System

• Currently controls most of the plant

• The historians interpolate data after

approximately 45 days from tapes for data

• Batch reports are generated by our in house

Batch Reporting System

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Current Automation Systems

ABB 800xA System

• Currently in the process of upgrading the MOD

300 system to the 800xA system

• Reporting is accomplished using Crystal Reports

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Current Automation Systems

Miscellaneous control systems

• G.E. Unicorn systems (chromatography skids),

reporting completed by local system

• Allen Bradley PLC’s (glass washers and

autoclaves), reporting by local printer

• Siemens PLC’s (disposable bioreactors), reporting

through ABB 800xA

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The Problem

• The historians interpolates data after approximately 45 days from tapes for data

• This requires to us to retrieve information from tapes

• This process takes approximately 10 minutes per tag per day

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The Solution

• Use the PI system to collect the data from the MOD

300 system

• This allows us to quickly retrieve data

• Also by implementing the PI Batch Database and

BatchView we are able to quickly retrieve run data

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Benefit

• In order to pull a year’s worth of date for a single point it would take us approximately 36 hours to pull the data.

• It costs approximately $3600 dollars to pull the data.

$100 per hour * 36 hours = $3600

• It takes us approximately 30 minutes to pull the data from the PI system.

Savings = $3550

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The Problem

• Identify issues and differences between batch runs in

a product campaign

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The Solution

• Use Batchview and PI Module Database to compare

production runs in our manufacturing system

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The Solution

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Benefit

• The cost of losing a single batch of a product conformance run is almost equal to our the cost of our PI software.

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The Problem

• Currently our glass washers and autoclaves print cycle

information on thermal and impact printers

• Thermal printer paper tends to fade over time.

Because of this we scan in all cycle information so that

we have long term records of our cycles.

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The Solution

• Pull the cycle data into our PI system

• Purchase RtReports and develop cycle reports

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Benefit

• It takes us approximately 1 hours to process the print out from a single glass washer cycle.

• Estimate 5 cycles a day

• Therefore if we pull the data into PI we can show a saving of almost $500 dollars a day. $100 * 5 hours = $500

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Technical Benefits

• Data is “backed up” in a real-time fashion to the PI server

• Report generation is paperless since RtReports permits saving to PDF

• Will be able to remove thermal and impact printers on our autoclaves and glass washers

• Since we are able to compare campaign runs to each other we will be able to minimize the chances of losing a batch

• We can quickly retrieve process data

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The Return on Investment

• The amount of time an engineer requires to retrieve data is 1/10 of the time required to pull data from backup tapes

• If we can prevent the loss of even a single batch the work and cost put into creating batch overviews will pay for itself

• By removing the thermal and impact printers from the plant we are reducing the cost of maintaining the printers which can be problematic

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Solution Challenges

• Pulling the required information from our glass washers and autoclaves

• As we add the ability to overlay process development with manufacturing runs we have to align tags from different control systems with each other

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Next Steps and Future Opportunities

• Upgrade to high availability PI servers

• Purchase RtReports and Webparts

• Add the ability to overlay process development batch runs with manufacturing batch runs

• Combine our batch reporting systems into a single batch reporting platform using the RtReports

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Questions?