batch implementation at plascon mobeni
DESCRIPTION
Batch Implementation at Plascon Mobeni. Gus Krüger Convenient Software Solutions (Pty) Ltd. Agenda. Introduction Project Solution Benefits Considerations Summary. Introduction. Introduction. Company Background Plascon More than 100 years of history - PowerPoint PPT PresentationTRANSCRIPT
![Page 1: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/1.jpg)
Batch Implementation at Plascon MobeniGus Krüger
Convenient Software Solutions (Pty) Ltd
![Page 2: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/2.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Introduction
![Page 3: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/3.jpg)
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.
![Page 4: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/4.jpg)
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
![Page 5: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/5.jpg)
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
![Page 6: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/6.jpg)
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
![Page 7: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/7.jpg)
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
![Page 8: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/8.jpg)
Introduction
► Why upgrade?▪ New production methodologies
• Address Challenges• Achieve Goals
▪ Industry standards• Tagnaming• Plant Modeling
![Page 9: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/9.jpg)
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
![Page 10: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/10.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Project Solution
![Page 11: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/11.jpg)
Project Solution
► Existing Topology
InTouch 9.5 View Clientand Development
InBatch Server
Quantum PLC
InBatch Development Client
Batch ReportingServer
![Page 12: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/12.jpg)
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
![Page 13: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/13.jpg)
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
![Page 14: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/14.jpg)
Project Solution
► PLC Software• Concept used for PLC Software• Tag name convention• Tags created in Excel and imported
Export
Archestra
Concept
![Page 15: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/15.jpg)
Project Solution
► PLC Software• S88 Structure• Standard device control
![Page 16: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/16.jpg)
Project Solution
► InBatch Implementation
•Storage Tanks
•Common Manifolds
•Finishing Tanks
![Page 17: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/17.jpg)
Project Solution
► InBatch Implementation•Incorporate Production Methodologies
![Page 18: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/18.jpg)
Project Solution
► InBatch Implementation▪ Recipe editor
• Master Recipes• Plant chemist able to build recipes
![Page 19: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/19.jpg)
Project Solution
► InBatch Implementation▪ Recipe Scheduling▪ Recipe Monitoring
![Page 20: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/20.jpg)
Project Solution
► Application Server 3.0▪ Historization
• Store forward configured
▪ Import Objects▪ Integration Scripts
![Page 21: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/21.jpg)
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
![Page 22: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/22.jpg)
Project Solution
► HMI / Graphics▪ Interlock Displays
• Operators always informed• Defined action to take
![Page 23: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/23.jpg)
Project Solution
► HMI / Graphics▪ Plant SCADA
![Page 24: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/24.jpg)
Project Solution
► Completion▪ Testing
• IO Testing• Off-line Testing• FAT Testing
▪ Commissioning• Hot Swap
![Page 25: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/25.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Benefits
![Page 26: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/26.jpg)
Benefits
► Quality Improvement▪ Less Contamination
► Production Schedule▪ Time Reduction
► Material Management► Reduced downtime
![Page 27: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/27.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Considerations
![Page 28: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/28.jpg)
Considerations
► Considerations▪ Involve different departments▪ Clear requirements▪ Communication
![Page 29: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/29.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
SummarySummary
![Page 30: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/30.jpg)
Summary
▪ Maintain high quality in production▪ Minimize negative human effect▪ Batch recipes optimize plant effectiveness▪ Operators proactive in preventing down time
![Page 31: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/31.jpg)
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
![Page 32: Batch Implementation at Plascon Mobeni](https://reader036.vdocuments.site/reader036/viewer/2022062310/56815db6550346895dcbe454/html5/thumbnails/32.jpg)
Any Questions?