1. 412: Integrating SAP® Software into DeltaV
Philippe Moro, IT Manager
Lubrizol France - Rouen, France
Christopher Worek, Senior Principal Engineer
Emerson

2. Presenters
Philippe Moro
Christopher Worek

3. Introduction
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 3

4. Part 1 Introduction, Architecture Security, Integration Workflow and Data Structure
Philippe Moro

5. Introduction 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.

6. Introduction
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 6

7. The 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 7

8. 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 purposes
Online (active) data used in online analytics
Off-line (past) data used for data analytics model generation 8

9. Online/Off-Line Analytics
Lab data serves two purposes
Online (active) data used in online analytics
Off-line (past) data used for data analytics model generation 9

10. The 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 10

11. The Architecture of this Solution: Physical
SAP
SQL
IIS .net Web services
SAP QM Bapis
Lubrizol domain
Laboratory tests results
Firewall
Truck unload and batch information
OPC mirror on Emerson continuous historian
Batch exec &
Operator interface
PRO+
campaign mgr
Analytics
Embedded
analysis &
diagnostic apps.
Beta station
for multivariate
analysis
Continuous historian
batch historian
Control network

12. The Architecture of This Solution: Logical
External component
The Architecture of This Solution: Logical
Emerson component
Lubrizol component
SAP lab
analysis
Lubrizol Windows service
SQL 2005
SAP Web service
Lubrizol Windows service
Laboratory tests results
-Initial components
-In process
-Final
Truck unload and
batch information
Lubrizol Web service
Lubrizol domain
Firewall
Lubrizol Web Service
DeltaV domain
SQL Express
Emerson integration utility
lab and process control data
Delta V 8.3
Lubrizol Windows Service
Online multivariate analysis
Embedded
analysis &
diagnostic apps.
Beta station
for multivariate
analysis
Continuous historian
Delta V 9.3
Batch Historian
Continuous historian
OPC mirror on Emerson continuous historian 12

13. The Software Components
SAP® software is used for the lab data entry QE01, QE02, QE QE11,QE12

14. The Software Components
SAP® 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
SAP lab
analysis
Lubrizol Windows service
SQL 2005
SAP software Web services

15. The Software Components
SAP® Software ECC 5 Standard Bapis
The dialog between .net programs and SAP software is based on the usage of the following standard SAP software business application interfaces.
BAPI_INSPLOT_GETLIST
BAPI_INSPOPER_GETLIST
BAPI_INSPOPER_GETCHAR
BAPI_INSPOPER_GETDETAIL
BAPI_INSPLOT_GETDETAIL
Get the inspection lot list
for each inspection lot list
Get the operations associated
Get the lab test descriptions
Get the result for each
inspection point or each single point
Get the storage location for each
inspection lot

16. The Software Components
Microsoft .net reference to the SAP® software Web service
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)

17. The Software Components
SAP lab
analysis
Lubrizol Windows service
SQL 2005
Test results
for
in process
analysis
Lubrizol Web service
In process
inspection lot
Inspection Point
Inspection Point
Inspection point
Test Results
Test results
Test results
for
truck unload
analysis
Final
inspection lot
Inspection Point
Inspection Point
Lubrizol Windows service
Inspection point
Test Results
Test Results
Test results
Batch historian

18. The Software Components
SQL 2005
Test results
for
in process
analysis
Lubrizol Web service
Test results
for
truck unload
analysis
Lubrizol Windows service
Batch Historian

19. Security Considerations
Using Web services allows controlled penetration of existing firewalls
SAP® software
Web service
Lubrizol domain
Firewall
Web service
DeltaV domain 19

20. Security at 3 Levels Firewall  IIS configuration  Xml message 2 1 3
Microsoft Internet information service server
Web service
Windows® operating
system service 2
Lubrizol domain
Firewall 1
Delta V domain 3
XML
Windows® operating
system service
Microsoft Internet information service server
Lubrizol Web service 2

21. Firewall Security Stations are defined by Ip network groups 1
« Outside » = Lubrizol domain
« Inside » = DeltaV domain
Rules to control the traffic are defined between groups 1

22. Firewall Security
TCP port authorized is defined for each rule 1

23. IIS Security
Web services authorized are defined with the IIS Manager
TCP port authorized is defined for each Web site 2

24. XML Security 3 Easy to add/delete security information in the xml file
<?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>
</Results>
</LabData> 3
Easy to add/delete security information in the xml file
Easy to encrypt/decrypt

25. The Software Components
Web service developed to write SAP® software lab data on the DeltaV sql tables
Firewall
Lubrizol Web service
SQL Express

26. The Software Components
Test results
for
in process
analysis
Test results
for
truck unload
analysis
Batch
lab
parameters
Lubrizol Web service
SQL Express

27. The Software Components
Test results
for
in process
analysis
Test results
for
truck unload
aalysis
Lubrizol Web service
SQL Express
Emerson integration utility
lab and process control data
Embedded
analysis &
diagnostic apps.
Beta station
for multivariate
analysis
Batch
lab
parameters
Continuous historian

28. Part 2 DeltaV Integration and the Usage of SAP® Software Data
Chris Worek

29. SAP® Software Integration – Prerequisites
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
Web service signature (XML) agreed upon for pushing SAP software data down to DeltaV domain
SQL tables agreed upon to hold SAP software data for processing

30. 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 30

31. SAP® Software Integration – S/W Architecture

32. SAP® Software Integration Data Flow
New data entered into SAP software
Custom Lubrizol Gateway application detects new records
Gateway application calls Web service and passes XML representation of SAP software data
Web service parses XML and populates SQL database
Web service alerts LabData Utility that new data is available
LabData Utility queries SQL for new records
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

33. Application Flow 33

34. Additional 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 34

35. Using 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. 35

36. DvCH Data Extraction Select Data Points
Select points from the
list of available tags
Use > and < buttons to move tags between lists
Save – persists selected tags to disk
Load – verify saved tags and fill selected list
Reset – clears selected list and starts over

37. DvCH Data Extraction Select Timespan
Specify start and end times for data
Specify UTC or local time note DvCH points use UTC
Choose “Raw” when examining single points
Choose “Interpolated” to align multiple points

38. DvCH Data Extraction Select Output file
Enter a valid DOS filename – file does not have to exist
Use comma or tab delimited output format
Row numbers – integer count on each line output
Duration – incremental timespan from start time
BAD status – values with status other than GOOD are either written or omitted

39. Business 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

40. Part 3 Teamwork, Lessons Learned, Benefits of this Project
Philippe Moro

41. The Project Management
Global Organization and Alliance – Lubrizol and Emerson
OMS Executive Team
Alliance Sponsor
OMS Steering Team
Priorities and direction
Identify focus group activities
Metrics development
Coordination/communication
DPCS Migration Team
Migration guideline
Migration strategy
Timetable
Monitor progress
Integration/Architecture Team
Define integration strategy
Architecture of components
Support implementation
Standardization Team
Define global standards
Define mechanism to document
and share standards
Business Opportunities Team
Priorities and direction
Identify focus group activities
Metrics development
Coordination/communication
Technology Team
Manual batch
Loop tuning for controllers
Advanced control
Asset management

42. The Project Management
Global Organization and Alliance – Lubrizol and Emerson
Integration/Architecture Team
Define integration strategy
architecture of components
Support implementation
Operation Engineer Team
Process design
Functional specifications
Batch model definition
Tests validation
DPCS Team
DeltaV configuration
DeltaV programming
Control network
IS Team
Global architecture
Component development
Data security
Global network
Core Team
Core Team
Projects
Operation Engineer Team
Process Design
Functional specifications
Batch Model definition
Tests Validation
DPCS Team
DeltaV Configuration
DeltaV Programming
Control network
IS Team
Global architecture
component development
Data security
Global Network
Operation Engineer Team
Process Design
Functional specifications
Batch Model definition
Tests Validation
DPCS Team
DeltaV Configuration
DeltaV Programming
Control network
IS Team
Global architecture
component development
Data security
Global Network
Operation Engineer Team
Process design
Functional specifications
Batch model definition
Tests validation
DPCS Team
DeltaV configuration
DeltaV programming
Control network
IS Team
Global architecture
Component development
Data security
Global network
Site Teams
Site Teams

43. The Project Management
Lessons 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 43

44. Implications to Operations
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)

45. Importance 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

46. 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.

47. Where to Get More Information
Emerson Exchange 2008
Session ID: Process Analytics In Depth
Session ID: The Application of Data Analytics in Batch Operations
Session ID: Tools for Online Analytics

48. About the Presenters Philippe Moro - IS Manager, Lubrizol France
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. 48

49. About the Presenters
Christopher Worek, Senior Principal Engineer, Emerson Process Management
Chris 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. 49