Batch Implementation at Plascon Mobeni
Gus Krüger
Convenient Software Solutions (Pty) Ltd
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Introduction
► Company Background
▪ Plascon
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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
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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
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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
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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
► Existing Topology
InBatch Development
Client
InTouch 9.5 View Client
and Development
Quantum PLC
InBatch Server
Batch ReportingServer
Project Solution
► New Topology
InBatch Development
Client
InTouch View
Client
Wonderware
Development
Studio
Redundant
Automation
Object Servers
Quantum PLC
Galaxy Repository
InBatch
Server
Data Historian
Information
Server
Project Solution
► Design Phase
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Operational Requirements
Batching model functionality
Tag name convention
Standards for device control
Graphical Display objects
Plascon
Mobeni
General Paints
Batching Manifold
Master Mix
Agitator
Motor
Inlet Valve
Raw Material Storage
Pump
Area
Process Cell
Unit
Equipment Module
Control Module
Control Module
Equipment Module
Control Module
Project Solution
► PLC Software
• Concept used for PLC Software
• Tag name convention
• Tags created in Excel and imported
Concept
Export
Archestra
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
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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
► Quality Improvement
▪ Less Contamination
► Production Schedule
▪ Time Reduction
► Material Management
► Reduced downtime
Agenda
Introduction
Project Solution
Benefits
Considerations
Considerations
Summary
Considerations
► Considerations
▪ Involve different departments
▪ Clear requirements
▪ Communication
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
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 Alexander
National Engineering Manager
Plascon
Any Questions?