Slide 4 Invensys Enterprise Control Offerings Manufacturing / Production Operations Corporate Integration and Collaboration Platform Automation Invensys and Third Party Software Applications Invensys and Third Party Enterprise Control System IT Platform Corporate Systems
Slide 5 Integration & Collaboration Platform Enterprise Integration Workflow Open Device Integration Web Portal Application Toolkit Historian Third-Party Offerings Software Applications Execution Manufacturing Execution Systems Batch Enterprise Asset Management Mobile Workforce Management Performance Enterprise Manufacturing Intelligence Performance Measurement and Reporting VisualizationQuality Asset Performance Optimization Operator Training Design Advanced Process Control Simulation / Optimization Control DCSPACSCADAHMI Safety Safety Instrumented Systems General Purpose Safety Turbomachinery Control Measurement & Instrumentation Controllers Recorders Automation Software Applications Where The Offerings We Will Discuss Fit Within The InFusion Enterprise Control System
Slide 6 Batch Management Recipe Management Batch Execution Management Batch Management Systems are traditionally composed of two subparts: One assuring the creation and configuration of the recipes, and; The other assuring the execution of the recipes, i.e., driving the equipment to make a product according to a production order.
Slide 7 What is Wonderware InBatch software? InBatch is Flexible Batch Management Software Designed to Model and Automate Batch Processes Model-based - Easy recipe creation -Consistent with ISA88 Beyond ISA88 - Connection & Transfer Management Comprehensive production history - Electronic Batch Records and Material genealogy, Web based reports Out-of-the-box batch simulation Control System independent via state interface and DA Servers Scalable System Architecture – single node to large systems, integration to ArchestrA System Platform Security options and FDA CFR21 Part11 compliance Built-in Redundancy concepts
Slide 8 Wonderware InBatch, a Short History of Batch Management in Invensys 1994 FoxBatch Batch Manager (Soft Systems/Foxboro) 1996InBatch (Soft Systems/Wonderware – WINDOWS port) 1999I/A Batch/InBatch (Foxboro/Wonderware) Unix/Windows 2003I/A Batch 8.1 – InBatch 8.1 (Foxboro - Wonderware) 2005I/A Batch 8.1 SP1 – InBatch 8.1 SP1 (Foxboro - Wonderware) 2009Code alignment + New Features + ArchestrA integration = Wonderware InBatch Software InBatch 9.0 SP1 & InBatch 9.5 SP2 – necessary steps towards Wonderware InBatch Software InBatch 9.5 SP1 …. InBatch 2012 R2 (v10.0)
Slide 9 Wonderware InBatch Software … is specifically designed to address the needs of the process industry, in other words, it is made to manage the production wherever free fluent materials are processed InBatch allows managing complex, networked process equipment and is usually seen as Process MES InBatch provides S88 conformity and allows going beyond S88 with its Transfer Classes and Material Management capabilities InBatch is used more than 1000 times around the globe, often for more than 10 years
Slide 10 High Fidelity Batch Processes Ingredients Recipes often times complex Conditional / dynamic rules assessed during batch execution Recipes often times complex Conditional / dynamic rules assessed during batch execution Equipment Equipment can be used to make many product families No pre-determined use of equipment – varying material path through shared equipment Equipment can be used to make many product families No pre-determined use of equipment – varying material path through shared equipment Procedure Sequence of operations can vary widely for different types of products Can incl. complex conditional statements Sequence of operations can vary widely for different types of products Can incl. complex conditional statements Common Characteristics of demanding Batch Processes
Slide 11 Modeling through ISA-88 Forces a structured approach Decouples production procedures from PLC Logic Allows the user to model the physical equipment within an ISA-88 Process Cell Modeling includes not only equipment but also possible flow paths through the equipment Leaves Batch Control in controller but introduces the concept of Batch Management as a system
Slide 12 Units: BS1,BS2,R1,R2,HT1,HT2 Connections: Blk1_Rx1 Blk1_Rx2 Blk2_Rx1 Blk2_Rx2 Segments:Blk1_Out Blk2_Out Rx1_In Rx2_In Common Blk1_Out Rx1_InRx2_In Blk2_Out Common ISA-88 Model Hold Tank 1 Hold Tank 2 Reactor #2 Reactor #1 Bulk Storage 2 Bulk Storage 1
Slide 13 Process Class: Reactors Phases:Heat Cool Soak Agitate Manual Add Phase Parameters: Heat: Temperature Cool: Temperature Soak: Temp & Time Agitate: Speed & Time Manual Add: Quantity Hold Tank 1 Hold Tank 2 Define Phases And Their Parameters Reactor #2 Reactor #1 Bulk Storage 2 Bulk Storage 1
Slide 14 Phase Logic Block Required for each process and connection phase. – Control Parameters – Status Parameters – Interlocks – Formula Parameters Can reside anywhere, but most commonly found in DCS and PLCs. Modular, easy to maintain and re-use. Phase Logic Start Restart Abort Reset Ready Run Held Done Aborted Interlocked Control Inputs Formula Parameters Phase StatusPhase Control Interlocks Control Outputs Hold Unified Phase Logic
Slide 15 PHASE 4 PHASE 5 PHASE 6 Phases modeled in System Platform Extremely flexible and powerful batch management capabilities Extremely flexible and powerful platform and plant model InBatch Server PHASE 1 PHASE 2 PHASE 3 Phases modeled within Control System MX communication System Platform Device Integration Device InBatch - System Platform Integration Phase Logic Start Restart Abort Reset Ready Run Held Done Aborted Interlocked Phase StatusPhase Control Hold Phase Logic Start Restart Abort Reset Ready Run Held Done Aborted Interlocked Phase StatusPhase Control Hold
Slide 16 Recipe Header Recipe ID: F Recipe Name: Vanilla Yogurt Version #: 3 Version Date: 12/20/03 Author: Claire Grube Min. Batch Size: 100 Max. Batch Size: 1000 Def. Batch Size: 500 Formula Material Inputs: Milk Vanilla Material Outputs: Vanilla Yogurt Process Variables: Mix Time Temperature Equipment Class Attribute Blenders Capacity: 500 Reactors Lining: 1 Bulk Tanks Finish Tanks Hold Tanks Pack Lines Procedure Add Cool Mix Heat Master Recipe Content
Slide 17 Master Recipe in InBatchs Recipe Editor
Slide 18 Standalone System InBatch Server System Platform InTouch View InBatch Client I/O Server Control System FS System Architecture
Slide 19 Multi-Node Client/Server SCADA Nodes InBatch Server InBatch Development Clients Client Platforms InBatch Redundant Server SFS Control System InBatch Historian & WIS System Architecture
Slide 20 Multi-Node Client/Server SCADA Nodes InBatch Server InBatch Development Clients Client Platforms InBatch Redundant Server SFS Control System WIS InBatch Historian System Architecture
Slide 21 InBatch Value - Proposition & Benefits InBatch provides unmatched capabilities: Batch execution management for multiple batches at the same time Equipment allocation and arbitration, including Connections Comprehensive Electronic Batch Record (EBR) and reporting capabilities out of the box 21 CFR Part 11 compliance InBatch provides increased production flexibility and tracking Recipe procedure changes Material formulation changes Complete material genealogy - US and EU standards, IFS, Bio-terrorism InBatch & ArchestrA System Platform – a unique solution
Slide 22 How to Expand the Use of System Platform Combined with InBatch? Existing Batch System Desire for a modern Batch Management System Existing solution uses control code that cannot be touched and that does not reflect ISA 88 SOLUTION: Combine InBatch 9.5 & System Platform to create abstraction layer
Slide 23 Creating an Abstraction Layer… Use InBatch Model Editor to create the required Units…
Slide 24 Create Classes for Equipment with similar functionality and create their phases including the needed Control and Status Tags Creating an Abstraction Layer…
Slide 25 Add IBMX to the list of runtime services in InBatch. Remember that a platform needs to be deployed for the service to start Creating an abstraction layer…
Slide 26 Use the IDE to create object templates for your Units and Phases – This is where the rubber hits the road as it is your duty to know the existing PLC code and how to interact with the existing system Creating an abstraction layer…
Slide 27 The Other Problem Legacy APACS DCS still meets current needs Existing InBatch/InTouch versions no longer available / supported Operating System and Hardware no longer available / supported
Slide 28 Original Solution Original system used: MOORE APACS DCS (today Siemens-Moore) Siemens APACS driver Used InBatch v.7.0 and older Used InTouch v.7.1 and older Windows for Workgroups 3.11 or Windows NT 4.0 Siemens APACS Driver
Slide 29 Original Solution Challenge #1 Legacy APACS DCS at the end-of-life Siemens migration path offered Legacy DCS still meets user requirements Siemens APACS Driver
Slide 30 Original Solution Challenge #2 Latest InTouch runs on modern Windows OS Proprietary APACS driver only supports obsolete Windows OSs Users can not upgrade to latest version of InTouch Siemens APACS Driver
Slide 31 Solution: Use MatrikonOPC Server for APACS Direct Continue using APACS DCS Renew Hardware Use latest Windows OS Upgrade InBatch to latest version Upgrade InTouch to latest version No need for proprietary API driver!
Slide 32 MatrikonOPC Server for APACS Direct Connects to a NIM, IEM or RNI No Siemens software required Support for Windows 2008/7 OPC and SuiteLink support Simple tag syntax Automatic configuration
Slide 33 MatrikonOPC Server for APACS Direct Throttling options at the APACS resource level Advanced error recovery based on OPC Quality for OPC Items Fault Prediction Network and NIMs performance monitoring Get timestamps direct from the device or from local PC - your choice load-balancing and redundancy
Slide 34 InBatch Whats New? The ability to use a single Batch History Server as the central historian data repository for multiple InBatch Servers. InBatch Server Charlie S InBatch Historian WIS InBatch Server Alpha InBatch Server Piper
Slide 35 InBatch Whats New?
Slide 36 InBatch Whats New?
Slide 37 InBatch Whats New?
Slide 38 InBatch Whats New? The ability to use non US Date/Time Format for InBatch Reporting (!)
Slide 39 InBatch 9.5 – Whats New? Recipe Export and Recipe Import using XML documents based upon BML (Batch Markup Language) as defined by the World Batch Forum
Slide 40 InBatch 9.5 – Whats New?
Slide 41 InBatch 9.5 – Whats New? Recipe Export and Recipe Import are available through the Recipe COM Automation Server interface and allow creating branches – a major improvement for the ability to create recipes on demand…
Slide 42 InBatch 9.5 – Whats New?
Slide 43 InBatch 9.5 – Whats New?
Slide 44 InBatch 9.5 – Whats New?
Slide 45 InBatch 9.5 – Whats New? Recipe Names now up to 128 Characters long (16 before) Batch Display can now run many instances parallel, with specific focus on certain C/L/B through command line
Slide 46 InBatch 9.5 – Whats New? A NEW (stateless) API… that follows the design pattern introduced with Wonderware MES
Slide 47 InBatch 9.5 – Whats New? System Platform using InBatchs Stateless API in scripts
Slide 48 InBatch 9.5 – Whats New? Under the hood: More accurate use of Quality Status Messages for any I/O communication The Batch Manager waits for an I/O with non-initializing quality to determine if a tag failure has occurred. An I/O with initializing quality is not considered for tag failure by the Batch Manager. For status tags of bad quality, a Bad Quality Received message is sent to the operator displays and the batch is not put on hold. For parameter tags of bad quality, a ??? message is displayed on the operator displays. When the Batch Manager reads the parameter tags that have bad quality even at the end of the phase, it retries the read operation for a configurable amount of time (See Parm Timeout (sec) on page 62). If the parameter tags do not return to good quality during the retry period, an error message is sent to the operator displays and the batch is put on hold.
Slide 49 InBatch 9.5 – Whats New? Under the hood: More accurate use of Quality Status Messages for any I/O communication The Batch Manager waits for an I/O with non-initializing quality to determine if a tag failure has occurred. An I/O with initializing quality is not considered for tag failure by the Batch Manager. For status tags of bad quality, a Bad Quality Received message is sent to the operator displays and the batch is not put on hold. For parameter tags of bad quality, a ??? message is displayed on the operator displays. When the Batch Manager reads the parameter tags that have bad quality even at the end of the phase, it retries the read operation for a configurable amount of time (See Parm Timeout (sec) on page 62). If the parameter tags do not return to good quality during the retry period, an error message is sent to the operator displays and the batch is put on hold.
Slide 50 InBatch v10 – Whats Next?
Slide 51 Q & A Any Batch Related Questions? THANK YOU!