Quad Automation Application of Archestra Technology in an Edible Oil Refinery Martyn Daniels Quad Automation Operational Unit Manager.

QuadAutomation

Application of Archestra Technology in an Edible Oil Refinery

Martyn DanielsQuad Automation

Operational Unit Manager

QuadAutomationPresenter : Martyn Daniels

Agenda

► The Business End of things▪ The Business▪ The Problem▪ The Solution▪ Into the bargain Benefits

► System Overview▪ Architecture▪ Area & Derivation Model▪ Typical Mimics, Popups and their benefits

► Formulation Management & Batch Scheduling► Materials Management ► Integration of Information into System Platform

QuadAutomationPresenter : Martyn Daniels

The Business

► Receives▪ Various Crude and Semi-Refined Oils

• From on-site Sunflower Seed Mill• From Tankers – sourced from all over the world

► Processes▪ Batch

• Bleaching, Hardening & Post Deod. Blending▪ Semi-Continuous

• Deodorizing▪ Continuous

• Caustic Refining & Winterizing

► Dispatches▪ Processed Oils

• To on-site Customers• To Tanker• To Packaging

QuadAutomationPresenter : Martyn Daniels

The Problem

► Outdated Supervisory System▪ Difficult to Maintain and Improve On

• Not truly Object Orientated, No built-in development security and auditing, Unmanaged and no Server Scripting Code

► Skill Levels▪ Technical Staff changing constantly

• System Standards started to diverge, Quality of System was slowly being eroded.

▪ Operational Staff low skill levels • Downtime and Efficiencies being affected by lack of

understanding of the Process and the Control System

► Implement with minmum downtime.

QuadAutomationPresenter : Martyn Daniels

The Solution

► Replace the Supervisory System with one that is▪ Truly Object Orientated & Secure

• Enabling improvements to be made easily, quickly and in a controlled fashion so that standards are protected and maintained at all times. Thereby protecting the Control System investment.

• The ease of performing improvements would then allow a lower cost continuous optimization process that would address the Low Skill levels of operational staff by providing them with an easier to understand interface and more pertinent information.

QuadAutomationPresenter : Martyn Daniels

The Solution

► Replace the Supervisory System with one that is▪ Reliable

• Archestra V2 and V2.1 have a proven track record from small to VERY large systems. We have one system running 350 000 IO very successfully.

• Redundancy System works very well.

QuadAutomationPresenter : Martyn Daniels

The Solution

► Replace the Supervisory System with one that has▪ Managed and Server Side Scripting Code

• Enabling protection and securing of source code all in the same environment. Less need for externally developed ActiveXs and Controls and maintenance thereof.

• Server Side Code enabled common functions to be implemented at the back end. Reducing the duplication of Code, Utilizing the high-end server hardware more effectively & Lowering the hardware spec of Clients and the complexity of setting them up.

► Minimum Downtime• Allowing both systems to operate simultaneously with minor

production interruption by using scheduled stock takes.

QuadAutomationPresenter : Martyn Daniels

Before & After (Some Stats)

Before After Comment

PLC IO >65,000 30,000 FYI

SupervisorySoftware

Not the best Wonderware System Platform V3InTouch V10

Servers 4 2 -Can run on only 2 Redundant Servers

Windows +-700 +-100 -Objects Contain Graphics-Larger Screens used

Classes 0 150 OO in action

Instances 0 3015 OO in action

ActiveXs +-10 1 -All implemented in SP-Batch Engine Remains

VB Applications 3 0 -Formulation Management & Batch Scheduling Integrated

QuadAutomationPresenter : Martyn Daniels

Into the bargain Benefits

► Integration▪ The Archestra Technology and Components

also allow better integration of other sub-systems like• Batching Engine – InBatch V9• Formulation Management – FMM• Performance – WPS• MES – Factelligence

▪ Thereby enabling a further reduction in the use of custom Engineering, Components and further reducing the maintenance and skills requirement

QuadAutomationPresenter : Martyn Daniels

System Architecture

QuadAutomationPresenter : Martyn Daniels

Area Model

► Detailed Area Model enabling▪ Operators to be notified of

problems in their Areas of responsibility only

▪ Easier future application of Area based Functions• Intelligent and Conditional Alarms &

Events

• SOP & HAZOP Handling

▪ Easier future application of MES

QuadAutomationPresenter : Martyn Daniels

Derivation Model

► Detailed OO Modeling▪ Enabling global changes to be

made quickly and precisely

QuadAutomationPresenter : Martyn Daniels

Plant Overview Display - Areas

QuadAutomationPresenter : Martyn Daniels

Plant Overview Display – Areas Zoom

QuadAutomationPresenter : Martyn Daniels

Overview Displays

QuadAutomationPresenter : Martyn Daniels

Overview Displays - Zoom

QuadAutomationPresenter : Martyn Daniels

Typical Mimic

QuadAutomationPresenter : Martyn Daniels

Typical Mimic - Zoom

QuadAutomationPresenter : Martyn Daniels

Sequence Interfaces

► Sequence User Command.

QuadAutomationPresenter : Martyn Daniels

Formulation Manager► Is being

migrated to FMM

QuadAutomationPresenter : Martyn Daniels

Batch Scheduling► Is being

migrated to interface with FMM and RSBatch

QuadAutomationPresenter : Martyn Daniels

Materials Management Tank Farms/Storage Locations

► Raw Materials, WIP and Finished Goods are stored all over the factory in Tank Farms

► Many routes into and out of these Tank Farms are connected to several processes which can transfer in or out at any time

► Access to Tanks is governed by strict rules which are enforced to ensure that contamination does not take place

► Status, Quality and Age of all materials is monitored and reported on by the Control System

► Archestra object capability ▪ allowed these rules to be implemented in a structured

fashion which is easy to maintain▪ Allowed the implementation of a real-time material

search algorithm which assists operators in finding valid tanks quickly and reliably

QuadAutomationPresenter : Martyn Daniels

Materials ManagementTank Farms – Matrix - Zoom

QuadAutomationPresenter : Martyn Daniels

Materials ManagementTank Farms – Typical Mimic - Zoom

QuadAutomationPresenter : Martyn Daniels

Materials ManagementTank Selection – Search Algorithm

QuadAutomationPresenter : Martyn Daniels

Information Integration

► Large amounts of data is being stored▪ Historian▪ Material Transfer Transactions▪ Batching Transactions

• Data Logs

▪ Stock Takes▪ Quality Data▪ Receipts and Dispatches

► In the past it has been costly to make this data available to Operators where and when they needed it

► Archestra is the enabler to help make better use of all this information in a cost effective and maintainable manner

QuadAutomationPresenter : Martyn Daniels

Information Integration-Sequence History

► Uses WW SQLDataGrid

► Enables▪ Quick and easy

determination of what a sequence/phase has been up to

▪ Analysis of steps that are taking too long

▪ Further Reports available on the Intranet

QuadAutomationPresenter : Martyn Daniels

Information Integration-Device History

► Uses WW SQLDataGrid

► Enables▪ Quick and easy

determination of what a device has been up to

► Available on all devices e.g Sequences, Motors,Valves etc

QuadAutomationPresenter : Martyn Daniels

Information Integration-Status History

► Uses WW SQLDataGrid

► Enables▪ Quick and easy

determination of what device states have occurred

▪ Tracking of manual operations

► Available on Sequences, Motors, Valves etc

QuadAutomationPresenter : Martyn Daniels

Information IntegrationTank Ins, Outs and Stock

► Uses WW SQLDataGrid

► Enables▪ Quick and easy

determination of what material transactions have taken place

▪ On the spot Mass Balance

► Available on Storage and Process Vessels

QuadAutomationPresenter : Martyn Daniels

What does the future hold in store?

► Conversion of Crystal Reports based MIS Intranet to WIS/Reporting Services

► Wonderware Performance Software► InBatch V9► MES► The ability to react quickly to changing

▪ Market conditions▪ Customer Requirements▪ Raw Materials▪ Processing Technologies▪ Skills Levels

QuadAutomationPresenter : Martyn Daniels

Benefits Summary

► Enforced Standardization.► Decreased downtime & callouts.► Increased information to operators, process

& engineering personnel.► Lower cost of ownership.► Uses up-to-date technology.► Off-the-shelf implementation.► Ease of integration into 3rd party

applications

QuadAutomationPresenter : Martyn Daniels

Questions ?

► The Presenters Name is:▪ Martyn Daniels

• an Operational Unit Manager

• from Quad Automation - Johannesburg Office

► Please feel free to ask any questions