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► Outdated Supervisory System▪ Difficult to Maintain and Improve On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