increase productivity & reduce costs with experion batch manager
TRANSCRIPT
2015 Honeywell Users Group
Europe, Middle East and Africa
Increase Productivity & Reduce Costs with Experion Batch Manager
Presenter: Chris Morse Honeywell
2 © 2015 Honeywell International All Rights Reserved
Flexible Batch - what the market asked for
1. “We cannot accept a server as a single point of failure to complete a batch procedure. The business impact and safety risk of the server failing are too great.”
2. “Finding and funding the skills to maintain a batch system is difficult and high cost. We need a batch system integrated into the DCS, not bolted on top. This would mean that any of our DCS resources can maintain it.”
3. “For operator acceptance, to avoid errors and improve efficiency we need a single, consistent user interface”
4. “We must be able to make routine batch configuration changes at any time. Currently we have to stop production to make a change which means changes get backed up for months.”
5. “8 years ago I had 80 recipes, I now have almost 300. I need a more efficient way of managing these recipes than my current system gives me.”
3 © 2015 Honeywell International All Rights Reserved
Experion Batch Manager – Controller Based
Redundant and / or Remote I/O
Batch Server
TotalPlant Batch ACE
C300
• Better reliability with all batch levels on a redundant platform
• Reduced Hardware & associated Lifecycle Costs
• Improved plant efficiency by reducing batch cycle times
• Typical plant calculates an annual increase in throughput of 3%
..or here
..to here
Moving
batch
execution
from here...
4 © 2015 Honeywell International All Rights Reserved
Typical Batch Plant
Pre Mixer
Reactor R2 Reactor R1
Blender B1 Blender B2
Material 1 Material 2
Material 3 Material 4
5 © 2015 Honeywell International All Rights Reserved
S88 Typical Server Application Execution
Phase Logic:
ADD MAT 1
(SCM)
Operation:
MIX
(RCM)
Unit Procedure:
PREMIX
(RCM)
PUMP OFF
PUMP ON VALVE OPEN
LEVEL >= XYZ
RESET
START
READY
PRESSURE
HEAT.STATUS = COMPLETE
HEAT
MATERIAL A .STATUS = COMPLETE
MIX
MIX.STATUS = COMPLETE
TRANSFER
TRANSFER:STATUS = COMPLETE
PREMIXER
PREMIX:1.STATUS = COMPLETE
REACTOR
REACTOR.STATUS = COMPLETE
Procedure:
PRODUCT A
(RCM)
BLENDER
BLENDER.STATUS = COMPLETE
C300 Controller
SAMPLE
MATERIAL A
PRESSURE. .STATUS = COMPLETE
SAMPLE .STATUS = COMPLETE
Batch Server
6 © 2015 Honeywell International All Rights Reserved
S88 Batch Manager Recipe Experion
Phase Logic:
ADD MAT 1
(SCM)
Operation:
MIX
(RCM)
Unit Procedure:
PREMIX
(RCM)
PUMP OFF
PUMP ON VALVE OPEN
LEVEL >= XYZ
RESET
START
READY
PRESSURE
HEAT.STATUS = COMPLETE
HEAT
MATERIAL A .STATUS = COMPLETE
MIX
MIX.STATUS = COMPLETE
TRANSFER
TRANSFER:STATUS = COMPLETE
PREMIXER
PREMIX:1.STATUS = COMPLETE
REACTOR
REACTOR.STATUS = COMPLETE
Procedure:
PRODUCT A
(RCM)
BLENDER
BLENDER.STATUS = COMPLETE
C300 Controller
SAMPLE
MATERIAL A
PRESSURE. .STATUS = COMPLETE
SAMPLE .STATUS = COMPLETE
7 © 2015 Honeywell International All Rights Reserved
Batch 52 Start
Mix Sample Discharge
Material 2
Material 1
Mixer Start Batch Complete
Server Based Cycle Time
Batch 53 Start
Mix Sample Discharge
Material 2
Material 1
Mixer Start Batch Complete
C300 Based Cycle Time
Cycle Time Reduction
= More Production 10-12 secs
2 secs
Increasing Productivity
8 © 2015 Honeywell International All Rights Reserved
Reducing Lifecycle Costs
Single Point of Failure
Routine Change
Management of Recipes
Microsoft Alignment
Special skills
Operability
Single Point of Failure
Bumpless Redundancy
Routine Change
Single point maintenance
Management of Recipes
Class Based Recipes
Special Skills
Single Engineer Environment
Operability
Single Operator Environment
Server Based
Lifecycle $
Batch Manager
Lifecycle $
9 © 2015 Honeywell International All Rights Reserved
Reducing Routine Maintenance Costs
Recipe 1
Fermenter
1 Recipe 2
Fermenter
1 Recipe 3
Fermenter
1
Recipe n
Fermenter
1
Recipe 1
Mixer 1
Recipe 2
Mixer 1
Recipe 3
Mixer 1
Recipe n
Mixer 1
10 © 2015 Honeywell International All Rights Reserved
M1
Homogenise
Homogenise
M2
F1 F2
Milk
Recipe 1
Fermenter
1 Recipe 2
Fermenter
1 Recipe 3
Fermenter
1
Recipe n
Fermenter
1
Recipe 1
Mixer 1
Recipe 2
Mixer 1
Recipe 3
Mixer 1
Recipe n
Mixer 1
Recipe 1
Fermenter
1 Recipe 2
Fermenter
1 Recipe 3
Fermenter
1
Recipe n
Fermenter
1
Recipe 1
Mixer 2
Recipe 2
Mixer 2
Recipe 3
Mixer 21
Recipe n
Mixer 1
Recipe 1
Recipe 2
Recipe 3
Recipe n
Class Based Recipes
Reducing Routine Maintenance Costs
11 © 2015 Honeywell International All Rights Reserved
Business Integration - Batch Application Services
C300
Experion
Server
MES/ERP:
Master Recipe: GR1102
Batch ID: TD12345
Batch Size: 75%
Initiator: 1.9 Kg
Unit Mixer: M1
Master Recipe: GR1102
Batch ID: TD12345
Batch Size: 75%
Initiator: 1.3 Kg
Initiator: 1.9 Kg
Unit Mixer: M1
MES
12 © 2015 Honeywell International All Rights Reserved
Control Builder + Recipe Builder – different roles
Control Engineer Formulator
• Segregates Recipe Building role from Control Building role
• Reduce maintenance time & avoid errors
• RCMs & Master Recipes only built assigned & loaded in Recipe Builder
• Control Builder remains tool to do everything
13 © 2015 Honeywell International All Rights Reserved
EBM Batch Structure
PUMP
STOP
OPEN
KSV998
KSV959
TARGET
REACHED
PT919
OPEN
KS6995
KS6994
START
KS6999
OPEN
KSV991
KSV990RECIPE
PRODUCT
A
PRESS
SAMPLE
MATA
HEAT
Recipe
Data Block
OPERATR
REACTRAN
REACMIX
REACTA
MIXERA
BLENDA
Procedure
PRODUCT A
Made up of 3 x
Unit Procedures
Unit
Procedure
REACT A
Operation
REACT TRAN
Phase
SCM PRESS
Made up of 2 x
Operations
Made up of 4 x
Phases &
1 x Confirmation
Step
Made up of
6 x Steps
= Parameter path S88
Procedural
Elements
14 © 2015 Honeywell International All Rights Reserved
Batch Summary
Batch
Summary
Grid
Batch
Command
Buttons
Details
Pane
Batch
Creation
Button
Navigation
Links
Batch
Commands
15 © 2015 Honeywell International All Rights Reserved
Batch Creation Dialogue
16 © 2015 Honeywell International All Rights Reserved
Batch Control in Process Displays
17 © 2015 Honeywell International All Rights Reserved
Batch Control in Process Displays
18 © 2015 Honeywell International All Rights Reserved
Batch Control in Process Displays
19 © 2015 Honeywell International All Rights Reserved
Productivity Improvement Sequence Visualization
Why is this mixer
taking so long?
20 © 2015 Honeywell International All Rights Reserved
I see it’s
transferring
Productivity Improvement Sequence Visualization
21 © 2015 Honeywell International All Rights Reserved
Transfer in to the
Fermenter is running
Productivity Improvement Sequence Visualization
22 © 2015 Honeywell International All Rights Reserved
…..it is stuck on step 30. I see
not all additions are complete.
I’ll go check them
Productivity Improvement Sequence Visualization
23 © 2015 Honeywell International All Rights Reserved
Experion Device and Loop Control Operator View
• Control Modules (CM) ‒ Graphical Building with
extensive function block
library
‒ Visual identification of active
interlocks and outputs
‒ Operator Instructions
‒ Embedded links to
documentation
24 © 2015 Honeywell International All Rights Reserved
Flexible Batch - what the market asked for
1. “We cannot accept a server as a single point of failure to complete a batch procedure. The business impact and safety risk of the server failing are too great.” Batch in the Controller – No Single Point of Failure
2. “Finding and funding the skills to maintain a batch system is difficult and high cost. We need a batch system integrated into the DCS, not bolted on top. This would mean that any of our DCS resources can maintain it.” Common Operator/Engineering Environment all Functions
3. “For operator acceptance, to avoid errors and improve efficiency we need a single, consistent user interface” Single Consistent User Interface with Smart Visualization
4. “We must be able to make routine batch configuration changes at any time. Currently we have to stop production to make a change which means changes get backed up for months.” All Changes to Configuration are On Process – No Exceptions
5. “8 years ago I had 80 recipes, I now have almost 300. I need a more efficient way of managing these recipes than my current system gives me.” Class Based/Other Recipe Features Reduce Recipe Maintenance
25 © 2015 Honeywell International All Rights Reserved
Batch Manager Business Benefits
• Batch Manager delivers more on-spec product from a batch plant with lower engineering & support costs
• Sustained operations over server based applications: ‒ Reduce unplanned downtime
Reduce cost of rework of problem batches
Reduce disruption to production from server problems
Improved availability with bumpless redundancy
‒ Improved plant productivity
Reduced unproductive time between steps
Typical plant calculates an annual increase in throughput of 3% to 5%
‒ Improved efficiency through Experion integration
Standard Experion displays in all user environments
Reduced recipe maintenance with Class Based Recipes
Powerful reporting with Procedure Analyst
26 © 2015 Honeywell International All Rights Reserved
EBM Summary
Experion Batch Manager TPB/Other Batch Products Your
Business Benefit
Reliable, deterministic Batch
Execution in the controller
Batch Execution at a server Improved production reliability
Production reliability assured
by full redundancy
Production depends on warm
restart or high availability
server platform
Improved production reliability
Fast, deterministic transitions
between procedural elements
for efficient batch cycle times
Longer transition times
extending batch cycle times Increased plant throughput
Batch out of the box
configured in familiar builder
for engineering & operational
efficiency
Additional package involving
training & support Reduced project & lifecycle
costs
No production interruptions -
online modification for all
batch functions
Shutdown required for
equipment & phase
configuration
Easy system modifications
without interruption to
production
Distributed batch execution in
any controller
Batch execution on a single
server
System scalability up and
down
27 © 2015 Honeywell International All Rights Reserved
Increasing Productivity & Reducing Costs with
Experion Batch Manager