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Batch Implementation at Plascon Mobeni

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

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Batch Implementation at Plascon Mobeni

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  1. Batch Implementation at Plascon Mobeni Gus Krüger Convenient Software Solutions (Pty) Ltd

  2. Agenda Introduction Project Solution Benefits Considerations Summary Introduction

  3. 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.

  4. 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

  5. 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

  6. 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

  7. 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 Shared Plant Equipment Batch Arbitration

  8. Introduction • Why upgrade? • New production methodologies • Address Challenges • Achieve Goals • Industry standards • Tagnaming • Plant Modeling

  9. 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

  10. Agenda Introduction Project Solution Benefits Considerations Summary Project Solution

  11. Project Solution • Existing Topology InBatch Development Client InTouch 9.5 View Client and Development Quantum PLC InBatch Server Batch ReportingServer

  12. Project Solution • New Topology InBatch Development Client InTouch View Client Redundant Automation Object Servers Information Server Data Historian InBatch Server Wonderware Development Studio Quantum PLC Galaxy Repository

  13. Plascon Mobeni General Paints Batching Manifold Master Mix Area Agitator Process Cell Motor Unit Inlet Valve Plant S88 Raw Material Storage Equipment Module Pump Control Module Control Module Equipment Module Control Module Project Solution • Design Phase • Operational Requirements • Batching model functionality • Tag name convention • Standards for device control • Graphical Display objects App Server

  14. Concept Export Archestra Project Solution • PLC Software • Concept used for PLC Software • Tag name convention • Tags created in Excel and imported

  15. Project Solution • PLC Software • S88 Structure • Standard device control

  16. Project Solution • InBatch Implementation • Storage Tanks • Common Manifolds • Finishing Tanks

  17. Project Solution • InBatch Implementation • Incorporate Production Methodologies

  18. Project Solution • InBatch Implementation • Recipe editor • Master Recipes • Plant chemist able to build recipes

  19. Project Solution • InBatch Implementation • Recipe Scheduling • Recipe Monitoring

  20. Project Solution • Application Server 3.0 • Historization • Store forward configured • Import Objects • Integration Scripts

  21. 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

  22. Project Solution • HMI / Graphics • Interlock Displays • Operators always informed • Defined action to take

  23. Project Solution • HMI / Graphics • Plant SCADA

  24. Project Solution • Completion • Testing • IO Testing • Off-line Testing • FAT Testing • Commissioning • Hot Swap

  25. Agenda Introduction Project Solution Benefits Considerations Summary Benefits

  26. Benefits • Quality Improvement • Less Contamination • Production Schedule • Time Reduction • Material Management • Reduced downtime

  27. Agenda Introduction Project Solution Benefits Considerations Summary Considerations

  28. Considerations • Considerations • Involve different departments • Clear requirements • Communication

  29. Agenda Introduction Project Solution Benefits Considerations Summary Summary

  30. Summary • Maintain high quality in production • Minimize negative human effect • Batch recipes optimize plant effectiveness • Operators proactive in preventing down time

  31. 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

  32. Any Questions?

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