Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Tweet About It Using #PSUG Flexible Batch Solution Simplifies Formulation and Recipe Changes Cybertrol Engineering Tim Barthel, Lead Engineer Doug Jaques, Technical Director November 2014

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Cybertrol Engineering Overview  Founded 1996  50 Employees, 34 engineers  Rockwell Automation SP (Control/Process/Information)  Automation and IT Services  UL508 Panel Shop  Thousands of projects for 400+ clients

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Abstract  New Ice cream manufacturing facility  Flexible batching with over 100 source/batch/destination tanks  Virtualized/fault tolerant server environment  Corporate formulas imported into site specific recipes  FactoryTalk ® Batch utilized for flexibility  Interface into FactoryTalk Batch allows formulation and recipe changes without programming changes

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG End User Overview  New plant built to be largest in the world  Global food manufacturer  400+ employees at new facility  Ice cream manufacturing facility  Four ice cream filling lines with three freezers per line  Twelve novelty lines and expanding  Four batching cells – each with three individual batching units  Corporate recipe management interface required  mix-proof valves – arbitration between production and cleaning critical  Robust infrastructure needed for operation

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Robust Plant Floor Controls  Operation runs  Minimal maintenance requirements  Programming standards  Ease of installation  Localized Troubleshooting

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Robust Controls – Design Solution ControlLogix ® PAC’s – EtherNet/IP IO  1756-L7x PAC Controllers  CENTERLINE ® 2100 MCC’s - PowerFlex ® VFD’s  1734 Point I/O  EtherNet/IP field instruments  GuardLogix ® EtherNet/IP

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Batching Process Functionality  Accurate use of raw ingredients with different analytical values to produce the highest quality product with the least cost formulation of ingredients on hand  Multiple source tanks with various raw ingredients to multiple storage destinations throughout the batching process utilizing mix proof valve arrays  High volume output with minimal workforce

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Batching Process – Design Solution  Direct and seamless integration with the ControlLogix platform

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Batching Process – Design Solution  Arbitration of device paths controlled at server and controller level to help ensure product and cleaning solution does not intermix  Process and cleaning operation controlled through FactoryTalk ® Batch

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Recipe Formulation Functionality  Corporate recipe structure that needed to be integrated into the batching formulation without engineering or programmer intervention  Frequent formulation changes from R&D – daily uplinks to corporate database

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Recipe Management System Integrated with FactoryTalk Batch - Solution  Interface to FactoryTalk Batch utilizing Microsoft ® SQL for recipe management and scheduling

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Accurate Reporting  Reporting ingredient usage – critical for inventory control  Reporting of cleaning cycles – critical for proper verification of quality  Simplified access with additional data

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG FactoryTalk Batch Event-based Reporting - Solution Batch Reporting

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG FactoryTalk Batch Event-based Reporting - Solution CIP Reporting

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG FactoryTalk Batch Event Based Reporting - Solution Full Batch Event Reporting

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Zoned Safety Across Many Areas  Many rooms  Common “safe zones”  Large distance between areas

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG GuardLogix ® Safety - Solution  Safety  GuardLogix allows logical zoning for safety utilizing Ethernet/IP Zone B Zone A STOP Okay to RUN Ethernet infrastructure in place STOP Activated

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Proper Server Infrastructure  Server system required for operation  FactoryTalk Batch/SQL  Isolation of applications  Redundancy  Backup and Recovery

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Virtualization with Fault Tolerance - Solution  VMware ® virtual server infrastructure  High Availability/Fault Tolerance  Shared storage and scheduled backups

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – The S88 Model Design Strategy  The Instrument Society of America S88 Batch Protocol Standards provides a framework to define process and automation hierarchy. S88 compliance also provides an organized methodology in the use of ordered sets of information using defined terminology.  The overall process consists of one or more process stages.  Each process stage consists of one or more process operations that in turn may consist of one or more process actions.  The control of the process is similarly described as a procedure that is comprised of one or more unit procedures. Each unit procedure may contain one or more ordered operations that each may contain one or more ordered phases.

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – The S88 Model Design Strategy  Physical Area Model in FactoryTalk Batch developed from P&IDs as well as operational requirements.  One-to-one correspondence between FactoryTalk Batch equipment modules and Phase Manager phases in PAC.  Phase operation conforms to S-88 state model. =

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – The S88 Model Design Strategy  Batch sequence is controlled from the FactoryTalk ® Batch server.  Sequence changes are made without any program changes in the PAC.  Recipe format is Sequential Function Chart (SFC).  Easy to create and/or follow complex sequences.

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – Installation  New facility – plant and production lines came up piece by piece.  System built for full production – each cut in had to be done while previous lines in operation stayed running  Plant-wide Ethernet in place first with network interface panels for all areas installed for future phases for communication infrastructure  Batch area model designed with all units, and phase manager programming in PLC in place to allow for cut in

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – Production Startups  Recipes not available for scheduling until released for production within FactoryTalk ® Batch Recipe Editor and web application

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Success Story  Now is largest ice cream plant in the world  Easy to use scheduling and recipe management allows even new operators to make batches properly  Interlocking through FactoryTalk Batch and ControlLogix protects operation from production and chemical mixing  Highly available system is supported remotely

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Success Story You Scream I Scream We ALL Scream For:

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Tweet About It Using #PSUG Learn more at Tim Barthel Phone: (763) November 2014