increase productivity & reduce costs with experion batch manager

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.”


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...


Typical Batch Plant

Pre Mixer

Reactor R2 Reactor R1

Blender B1 Blender B2

Material 1 Material 2

Material 3 Material 4


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


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


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


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 $


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


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


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


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


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


Batch Summary

Batch

Summary

Grid

Batch

Command

Buttons

Details

Pane

Batch

Creation

Button

Navigation

Links

Batch

Commands


Batch Creation Dialogue


Batch Control in Process Displays


Productivity Improvement Sequence Visualization

Why is this mixer

taking so long?


I see it’s

transferring



Transfer in to the

Fermenter is running



…..it is stuck on step 30. I see

not all additions are complete.

I’ll go check them



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


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


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


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


Increasing Productivity & Reducing Costs with

Experion Batch Manager

increase productivity & reduce costs with experion batch manager

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