Presenter: Chris Morse Honeywell

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1 2015 Honeywell Users Group Europe, Middle East and Africa Increase Productivity & Reduce Costs with Experion Batch Manager Presenter: Chris Morse Honeywell

2 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 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 Honeywell International All Rights Reserved

.to here C300 Redundant and / or Remote I/O Better reliability with all batch levels on a redundant platform

3 Experion Batch Manager Controller Based Moving batch execution from here... Batch Server TotalPlant Batch ACE..or here..to here C300 Redundant and / or Remote I/O 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% Honeywell International All Rights Reserved

5 S88 Typical Server Application Execution Procedure: PRODUCT A (RCM) Unit Procedure: PREMIX (RCM) Operation: MIX (RCM) Phase Logic: ADD MAT 1 (SCM) START PREMIXER MIX PRESSURE RESET PRESSURE..STATUS = COMPLETE READY PREMIX:1.STATUS = COMPLETE MIX.STATUS = COMPLETE HEAT REACTOR TRANSFER HEAT.STATUS = COMPLETE VALVE OPEN PUMP ON REACTOR.STATUS = COMPLETE TRANSFER:STATUS = COMPLETE SAMPLE LEVEL >= XYZ BLENDER SAMPLE.STATUS = COMPLETE PUMP OFF MATERIAL A BLENDER.STATUS = COMPLETE MATERIAL A.STATUS = COMPLETE Batch Server C300 Controller Honeywell International All Rights Reserved

6 S88 Batch Manager Recipe Experion Procedure: PRODUCT A (RCM) Unit Procedure: PREMIX (RCM) Operation: MIX (RCM) Phase Logic: ADD MAT 1 (SCM) START PREMIXER MIX PRESSURE RESET PRESSURE..STATUS = COMPLETE READY PREMIX:1.STATUS = COMPLETE MIX.STATUS = COMPLETE HEAT REACTOR TRANSFER HEAT.STATUS = COMPLETE VALVE OPEN PUMP ON REACTOR.STATUS = COMPLETE TRANSFER:STATUS = COMPLETE SAMPLE LEVEL >= XYZ BLENDER SAMPLE.STATUS = COMPLETE PUMP OFF MATERIAL A BLENDER.STATUS = COMPLETE MATERIAL A.STATUS = COMPLETE C300 Controller Honeywell International All Rights Reserved

7 Increasing Productivity Server Based Cycle Time Batch 52 Start Mixer Start Material 1 Mix Sample Discharge Batch Complete Material secs C300 Based Cycle Time Cycle Time Reduction = More Production Batch 53 Start Mixer Start Material 1 Material 2 Mix Sample Discharge 2 secs Batch Complete Honeywell International All Rights Reserved

8 Reducing Lifecycle Costs Operability Server Based Lifecycle $ Special skills Microsoft Alignment Management of Recipes Routine Change Single Point of Failure Batch Manager Lifecycle $ Operability Single Operator Environment Special Skills Single Engineer Environment Management of Recipes Class Based Recipes Routine Change Single point maintenance Single Point of Failure Bumpless Redundancy Honeywell International All Rights Reserved

Fermenter Recipe 1 2 Fermenter Recipe 1 3 Fermenter 1

9 Reducing Routine Maintenance Costs Recipe 1 Mixer 1 Recipe 2 Mixer 1 Recipe 3 Mixer 1 Recipe n Mixer 1 Recipe 1 Fermenter Recipe 1 2 Fermenter Recipe 1 3 Fermenter 1 Recipe n Fermenter Honeywell International All Rights Reserved

10 Reducing Routine Maintenance Costs Recipe 1 Mixer 1 Recipe 2 Mixer 1 Recipe 3 Mixer 1 Milk Homogenise Homogenise Recipe 1 Recipe 1 Mixer 2 Recipe 2 Recipe 2 Mixer 2 Recipe 3 Recipe 3 Mixer 21 Recipe n Mixer 1 M1 M2 Recipe n Recipe n Mixer 1 Recipe 1 Fermenter Recipe 1 2 Fermenter Recipe 1 3 Fermenter 1 Recipe n Fermenter 1 F1 F2 Recipe 1 Fermenter Recipe 1 2 Fermenter Recipe 1 3 Fermenter 1 Recipe n Fermenter 1 Class Based Recipes Honeywell International All Rights Reserved

Business Integration - Batch Application Services

11 Business Integration - Batch Application Services 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 Experion Server C Honeywell International All Rights Reserved

avoid errors RCMs & Master Recipes only built assigned & loaded in Recipe Builder

12 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 Honeywell International All Rights Reserved

13 EBM Batch Structure Procedure PRODUCT A Unit Procedure REACT A Operation REACT TRAN Phase SCM PRESS Made up of 3 x Unit Procedures Made up of 2 x Operations Made up of 4 x Phases & 1 x Confirmation Step Made up of 6 x Steps PUMP STOP RECIPE PRODUCT A Recipe Data Block MIXERA REACTA BLENDA REACMIX REACTRAN PRESS HEAT SAMPLE OPEN KSV991 KSV990 OPEN KSV998 KSV959 TARGET REACHED PT919 MATA OPEN KS6995 KS6994 = Parameter path S88 Procedural Elements OPERATR START KS Honeywell International All Rights Reserved

Batch Control in Process Displays 16 2015

Batch Control in Process Displays 17 2015

Batch Control in Process Displays 18 2015

Productivity Improvement Sequence Visualization Why is this mixer

Productivity Improvement Sequence Visualization I see it s

Productivity Improvement Sequence Visualization Transfer in to the

Productivity Improvement Sequence Visualization..it is stuck on step 30.

23 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 Honeywell International All Rights Reserved

24 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 Honeywell International All Rights Reserved

25 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 Honeywell International All Rights Reserved

26 EBM Summary Experion Batch Manager TPB/Other Batch Products Your Business Benefit Reliable, deterministic Batch Execution in the controller Production reliability assured by full redundancy Fast, deterministic transitions between procedural elements for efficient batch cycle times Batch out of the box configured in familiar builder for engineering & operational efficiency No production interruptions - online modification for all batch functions Distributed batch execution in any controller Batch Execution at a server Production depends on warm restart or high availability server platform Longer transition times extending batch cycle times Additional package involving training & support Shutdown required for equipment & phase configuration Batch execution on a single server Improved production reliability Improved production reliability Increased plant throughput Reduced project & lifecycle costs Easy system modifications without interruption to production System scalability up and down Honeywell International All Rights Reserved

Field Products. Experion LX. Proven DCS for a wide range of industrial applications

Field Products. Experion LX. Proven DCS for a wide range of industrial applications Field Products Experion LX Proven DCS for a wide range of industrial applications Tried-and-True Technology. Experion LX is an extension of Honeywell s award-winning Experion Process Knowledge System (PKS)