On this project, Nimble designed and developed a Batch Template Monitoring pilot system which statistically analyzes historical data from “good” batches, contained in the OSI Software PI historian, and provides a real-time trend comparison of current batch data with past known-good batch data to a plant operator so that he can adjust current control parameters for better product quality control.

• System has two components: a batch template analysis tool and a batch online monitoring service which interact with an OSI Software PI historian where historical data is stored
•  The Template Manager allows an engineer to visually select past “good” batches and key process variables from which the tool produces/saves composite trend graphs of the variables throughout a typical batch production phase/operation (key variable average) and upper/lower control bands
• On the start of a new batch, the Template Monitor allows an operator to graphically monitor the key variables from the current batch against the stored average past trend line and the past upper and lower control bands
• The Template Monitor generates batch alarms if control bands are exceeded allowing the operator to adjust the production controls in real-time to avoid a bad batch
• Pilot system was commissioned at a plant owned by a global chemical company and has since been released as a commercial product
• Developed in Microsoft Visual Basic 6.0