Processes in industrial operation occur often at different time scales, some are fast (sub seconds to hours), and others are slow (hours, days, weeks, or months). In a biotechnology facility for example, there are slow moving batch processes, fast purification steps and very fast filling lines. Capturing events at different time scales and analyzing them, requires a data strategy for the acquisition, storage, and analysis.
To optimize storage space and network bandwidth, the OSIsoft PI system differentiates between high frequency data also known as snapshot values and compressed or archived data. Data are archived from the snapshot table by applying a swinging door compression algorithm. This data strategy has proven to be great balance between displaying real time data in high resolution as well as storing sufficiently enough data for historical data analysis.
The drawback of this approach is that the snapshot queue contains only a single value for each process variable, so analysis based on snapshot or event driven data is limited to single point. There are some valuable use cases such as statistical process control, alarm management or event triggers. However, Machine Learning (ML) or multivariate models (MVA) are usually based on time series vectors.
To accommodate advance modeling of high frequency data, the OSIsoft PI system requires expansion off the snapshot table to a low latency time series storage:
The requirements for the Snapshot Db are primarily driven by read speed as well as write speed. Some open-source time series databases such as QuestDB that allows a million writes per seconds are available now. The read speeds are even more impressive: We measured ~ 800K read/sec for a standard OSIsoft PI system, whereas a low latency TSDB is faster by a factor of 800 - 1,000 (see demo: QuestDB · Console )
An additional benefit of using open source TSDB is that it allows us to add open-source ML and MVA libraries as well as, to take advantage of the very rich open-source visualization ecosphere. For example, the following shows a Grafana Dashboard of the Snapshot Db:
The OSIsoft PI system has been designed to capture real time events in a snapshot table and store compressed data in the PI Data Archive. This data architecture is optimized for short term event data and long-term data storage. Missing in this scenario are capabilities to store and analyze high frequency data for which modern low latency time series databases can provide. By adding a dedicated high frequency data store, fast processes can be monitored and analyzed in parallel to an already existing data infrastructure. This will open a large range of new uses cases that are difficult or impossible to realize with existing systems.
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TQS Integration announces launch of their latest software release, ODIN, empowering the connectivity of real time data with cloud-based systems, machine learning and AI platforms in an easy, secure, and affordable way. This newly developed software enables TQS to help their customers achieve process manufacturing advances and propel towards industry 4.0.
Equipped with an easy to use, web-based interface, cloud data transfer through ODIN allows for real time and on-demand data egress to enable machine learning and supports multiple source and destination platforms. ODIN is compatible with both OSIsoft PI and Wonderware historians, allowing efficient and secure transfer of valuable information from multiple historians to cloud-based destinations including Amazon S3, Microsoft Azure Data Lake Gen 2, IOT Hubs, Event Hubs, SQL Server and more.
"We are very excited about what ODIN can do for our customers to provide an easy-to-use tool to solve the need for automated data extracts and remove the time-consuming process of extracting and contextualizing data. ODIN will allow that valuable time to be refocused back to data science and empower analytics and Industry 4.0.” says Emmett O’Connor, Global Head of Product Development at TQS."
The complex nature of cloud data transfer is now made easy as ODIN automatically aggregates, filters, contextualizes and delivers formatted real time information efficiently via a user-friendly GUI (Graphic User Interface) that enables ease of monitoring job success. In-built auditing and distributed agent’s nodes also ensure configurations are monitored for compliance, while transfers are seamless, secure, and scalable.
ODIN can help manufacturing companies to prepare compliance and regulatory reports, run predictive advanced analytics, integrate operations information with business information, ultimately gaining valuable insights to make optimized business decisions and cost savings. This tool allows TQS to deliver competitive advantage in digital transformation for their clients.
"ODIN enables companies to make key business decisions and operational improvements through the utilization of existing data – it brings Industry 4.0 and digital strategies to the next level. This further strengthens our position as the industry leader in data intelligence. TQS has seen significant expansion in recent years, more than doubling staff numbers over the past two years, and we are planning to add an additional 50 jobs in the next 12 months to support our continued growth" comments Korie Gleeson, COO at TQS.
About TQS Integration
TQS Integration is a global data intelligence company providing turnkey solutions in system architecture and application design, engineering, system integration, project management, commissioning and 24x7 “follow the sun” support services to valued customers. TQS is at the forefront of data intelligence for over 20 years, working with an extensive client base in the Pharmaceutical, Life Science, Food & Beverage, Energy and Renewables industries. As the go-to partner for data collection, cloud data transfer, contextualization, visualization, analytics, and managed services, we are the main drivers in the world’s leading companies — helping them become leaders in Industry 4.0.
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Multivariate Analysis (MVA) is a well-established technique to analyse highly correlated process variables. It is well known in batch, but also successfully applied in discrete or continuous processing. In comparison to single variable applications, for example statistical process control, MVA has shown to be superior in the detection of process drifts and upsets. In practice, the implementation of MVA requires two different data structures or models:
Event Frames are usually autogenerated from the batch execution system (BES) and reflect the logical\automation sequences for recipe execution. Both AF Elements and Event Frames are being used to create MVA models and calculate statistics. Below is an example of a multivariate model that combines the autogenerated Event Frame “Unit Procedure” and process variables in the Element: “Bio Reactor 0”:
This type of analysis is typically used for batch-to-batch comparison (T2 and speX statistics) and batch evolution monitoring in the pharmaceutical, biotech and chemical Industry.
One of the shortcomings of using automation phases is that they seldom line up with time frames that are critical for the underlying process evolution (process phases). Often there is a mismatch in the granularity, process phases are either longer or shorter in duration compared to the automation phases. Also start and end might be based on specific process conditions, for example temperature, batch maturity, online measurements and others. The mismatch between automation and process phases causes misalignment in the MVA model and a broadening of the process control envelopes. . The resulting models are often not optimal.
SEEQ has developed a platform that excels in creating time series segments as well as time series data cleansing and conditioning. The platform provides several different approaches to define very precise start and end condition. The following show the definition of a new capsule based on a profile search that solely focuses on the process peak temperature:
These capsules can be utilized in other applications through an API and blended with other PI data models to create very precise multivariate models:
Multivariate Analysis is a powerful method to analyze highly correlated process data. It depends on equipment\process models and time series segments. OSIsoft PI provides data models for both. And typically time segments are automatically populated from a BES or MES systems. SEEQ provides new capabilities to create highly precise time segments called capsules, that refines the MVA analysis and creates meaningful process envelops. The integration is seamless since both systems provide powerful API’s to their time series data and models. The resulting MVA models target specific process phases that can be used to create improved process control limits or regression analysis.
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