Regional Seminars - Template - OSIsoft

September 23, 2010 

Regional Seminar Series 

Stavanger, Norway 

OSI PI in Alginate manufacturing 

Per Magne Olsen 

Manager, IT & ELAUT 

FMC BioPolymer, Haugesund Alginate Plant 

Real Time Information – Currency of the New Decade 

© Copyright 2010, OSIsoft LLC. All rights Reserved.

AGENDA 

• Who is FMC BioPolymer and what is Alginate? 

• The amazing stuff that Alginate can be used for 

• The Plant in Haugesund and it’s usage of IT 

• OSI PI, background and status 

• Moving towards the Perfect Plant 

2 Real Time Information – Currency of the New Decade 


About FMC BioPolymer 



FMC BioPolymer 

• FMC Corporation - FMC Corporation is one of the 

world’s foremost, diversified chemical companies with 

leading positions in agricultural, industrial and 

consumer markets. 

• FMC BioPolymer – One of three divisions in FMC. With 

over 60 years of experience FMC BioPolymer is the 

leader in harnessing nature's renewable resources to 

create ingredients and technical solutions for the food, 

pharmaceutical, personal care and biomedical markets. 

• Global company out of US with strong presence in all 

regions. 

• Alginate Operations – Norway and Scotland 



Amazing world of alginate 

• Alginate – one of natures building blocks 

• Alginates are hydrocolloids, water-soluble biopolymers extracted 

from brown seaweed 

• Attributes: controlled release, viscosifier, disingrants, gel-former, 

structure builder 

• Sustainable harwesting of Norwegian 

seaweed 

• But as much as we’ve learned about 

alginates, we know that we’ve 

penetrated only the first layers of 

discovery 



Business Challenge / Problems Addressed 



Background 

• ABB DCS system for ProcessControl since 1990 

• MES-system (OPIS/BQIS) from 1995 

• SAP ERP from 2000 

• OSI PI from 2009, old MES-system terminated 2009 

• ABB 800xA upgrade 2010 

• FMC IT Architecture 

– SAP & Microsoft 

• Centralized SAP and MOSS (Sharepoint) environment 

– Haugesund 

• OSI PI server, WSS (Sharepoint) server, SQL 2005 server – 2009 

– PI Displays in WSS (RtWebParts) – 2009-2010 

– Shiftlog/report, dev/test 2009 

– Batch testing 2010 

• Vmware virtualization - 2010 



OSIsoft Software and Services Used 

- PI Enterprise Professional Server– 3000 tags 

- PI OPC for ABB 800xA OPC server 

- 3 PI Combo pack (concurrent users) 

- 2 PI Manage pack (individual users) 

- 13 PI Datalink (concurrent users) 

- 15 PI RtWebParts (concurrent users) 

• No Enterprise Agreement (EA) – OSI PI - FMC 



PI current state 

• PI versions 

• PI server 3.2.0.0 

• PI Datalink 4.0.3 

• PI SMTP 3.2.4.0 

• ProcessBook 3.1.3 

• PI BatchView 3.1.3 

• RtWebParts with Adobe SVG Viewer 

• PI system in operation since January 09. 

• Phase#1 – Historian with data from ABB process control system. ABB 800xA OPC 

server gateway to ABB 4xx controllers. Done. 

• Phase#2 – Build PI process displays for process visualization. Based on layouts 

in ABB system. Built in ProcessBook, mostly by temp junior resource, and 

published as webpart on WSS server. Done. 

• Phase#3 – Build infrastructure in PI/WSS for shiftreports (PI process tags, 

manual data tags, shiftlead comments, etc.) – Ongoing together with Amitec. 

• Our goal is to use SharePoint as the enduser environment and 

ProcessBook / Excel for the powerusers 



PI Current state 

• PI and WSS production servers 



Results 



Results 

• Support Alginate Integration projects 

– Haugesund Plant the only Alginate manufacturing site 

– Haugesund Plant to change from producing exstracts to 

produce, pack and ship API-products to end costumers 

– Major expansion of Plant 

– Major upgrade of Plant equipment 

• Establish system architecture to support continous 

expansion and improvements 



Future Plans / Next Steps 



Challenge / Problem Details 

• Urgent need to replace the retired OPIS-BQIS-System. 

• Currently users have to access several systems using non-value 

add methods to pull and analyze production and quality information 

and report key performance metrics (KPIs) 

• Lots of manual entry and double entry of manufacturing and quality 

data in non-rigid ways resulting in lack of recorded information or 

potential bad quality on information 

• Many islands of systems that needs to be managed, 

huge potential for consolidation and 

standardization to FMC approved 

system architecture 



Solution 



Solution 

• The scope is to implement/interface SAP MII with SAP R/3 and OSI PI. 

Which would replace the missing production processes and quality 

functionality which was leverage by the OPIS manufacturing system. 

Expanding SAP PI-PP/QM functionality beyond today's blender level to 

include the incorporation batches and Algenic Acid top off. In addition, it 

would replace the site developed FMCLogg functionality and local Access 

databases for environmental reporting. 

Production Management 

Operator SAP PP-PI Interface 

Batch Management 

Shift Logs 

Reporting 

Production Reports 

Consumption Reports 

Quality Reports 

Production Operator/Supervisor Dashboards 

Environmental Reporting 

Quality Management 

SAP QM Semi-Finished Goods 

Operator SAP QM interface 





Future Plans / Next Steps 



Thank you 

© Copyright 2010 OSIsoft, LLC. 

777 Davis St., Suite 250 San Leandro, CA 94577

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