Batch Implementation at Plascon Mobeni
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Transcript of Batch Implementation at Plascon Mobeni
Batch Implementation at Plascon MobeniGus Krüger
Convenient Software Solutions (Pty) Ltd
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Introduction
Introduction
► Company Background▪ Plascon
• More than 100 years of history• First to introduce ready-mixed products• Implemented InBatch in 1995/1996• Velvaglo, Woodcare Varnishes, Super Universal Enamel• Batching of liquid components• Batch sizes range between 800 L and 10,000 L.
Introduction
► Company Background▪ Convenient Software Solutions (Pty) Ltd
• Complete industrial automation/process control solutions• Wide spectrum of industries• Experts in batching implementation• ArchestrA certified• Offices in Durban and Gauteng• www.cs-solutions.co.za
Introduction
► General Paints Plant Background▪ Plant flexibility
• Cater for wide range of products• Products and raw materials unique
▪ Production schedules• Different types of paints batched at the same time
Introduction
► Existing system▪ InBatch server▪ InBatch Development Client
• Recipe Creating
▪ One InTouch PC• Plant SCADA• Batching client• Development• MBEnet IO server
▪ Batch Report Server• Batching reports
Introduction
► Why upgrade?▪ Meet Business Objectives
• “ To produce products of the highest quality, whist maintaining a challenging production schedule in a increasingly competitive market”
▪ Obstacles• Batch Model ≠ Physical Plant• Consistency in Quality• Production Scheduling more challenging
Introduction
► Why upgrade?▪ New production methodologies
• Address Challenges• Achieve Goals
▪ Industry standards• Tagnaming• Plant Modeling
Introduction
► Why Wonderware?▪ InBatch for batch control
• Proven to be reliable• Stable• Highly configurable plant modeling• Reporting facilities
▪ Application Server 3.0 / InTouch 10.0• Flexibility and Scalability• Creation / Maintenance of standards• Galaxy Repository
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Project Solution
Project Solution
► Existing Topology
InTouch 9.5 View Clientand Development
InBatch Server
Quantum PLC
InBatch Development Client
Batch ReportingServer
Project Solution
► New Topology
Galaxy Repository
Wonderware Development
Studio
Redundant Automation
Object Servers
Quantum PLC
InBatch Server
Information Server
InTouch View ClientInBatch Development
Client
Data Historian
Project Solution
► Design Phase• Operational Requirements• Batching model functionality• Tag name convention• Standards for device control• Graphical Display objects App Server
AreaAreaProcess CellProcess Cell
UnitUnitEquipment ModuleEquipment Module
Equipment ModuleEquipment Module
Control ModuleControl Module
Control ModuleControl Module
Control ModuleControl ModuleS88PlasconPlascon
MobeniMobeniGeneral PaintsGeneral Paints
Batching ManifoldBatching ManifoldMaster MixMaster Mix
AgitatorAgitator
Raw Material StorageRaw Material Storage
MotorMotor
PumpPump
Inlet ValveInlet ValvePlant
Project Solution
► PLC Software• Concept used for PLC Software• Tag name convention• Tags created in Excel and imported
Export
Archestra
Concept
Project Solution
► PLC Software• S88 Structure• Standard device control
Project Solution
► InBatch Implementation
•Storage Tanks
•Common Manifolds
•Finishing Tanks
Project Solution
► InBatch Implementation•Incorporate Production Methodologies
Project Solution
► InBatch Implementation▪ Recipe editor
• Master Recipes• Plant chemist able to build recipes
Project Solution
► InBatch Implementation▪ Recipe Scheduling▪ Recipe Monitoring
Project Solution
► Application Server 3.0▪ Historization
• Store forward configured
▪ Import Objects▪ Integration Scripts
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► HMI / Graphics• Common Look & Feel• Common Navigation• Standard graphics for devices such as tanks and valves• Plant and system health and interlocks clearly displayed
Project Solution
► HMI / Graphics▪ Interlock Displays
• Operators always informed• Defined action to take
Project Solution
► HMI / Graphics▪ Plant SCADA
Project Solution
► Completion▪ Testing
• IO Testing• Off-line Testing• FAT Testing
▪ Commissioning• Hot Swap
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Benefits
Benefits
► Quality Improvement▪ Less Contamination
► Production Schedule▪ Time Reduction
► Material Management► Reduced downtime
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Considerations
Considerations
► Considerations▪ Involve different departments▪ Clear requirements▪ Communication
Agenda
Introduction
Project Solution
Benefits
Considerations
SummarySummary
Summary
▪ Maintain high quality in production▪ Minimize negative human effect▪ Batch recipes optimize plant effectiveness▪ Operators proactive in preventing down time
Summary
► End User Quote“This first phase implementation has paved the way for
all sections of the plant to be integrated into one system. Future upgrades will be more cost effective, not only from a Rand’s and Cents perspective, but from time to implement, as well as downtime.”
Andrew AlexanderNational Engineering ManagerPlascon
Any Questions?