Batch Implementation at Plascon Mobeni

Gus KrügerConvenient 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 Client

InBatch Development Client

Data Historian

Project Solution

► Design Phase• Operational Requirements

• Batching model functionality

• Tag name convention

• Standards for device control

• Graphical Display objectsApp Server

AreaArea

Process CellProcess CellUnitUnit

Equipment 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

Project Solution

► 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?