Batch Implementation at Plascon Mobeni Gus Krüger Convenient Software Solutions (Pty) Ltd

Agenda Introduction Project Solution Benefits Considerations Summary Introduction

► Company Background ▪ Plascon More than 100 years of history First to introduce ready-mixed products Implemented InBatch in 1995/1996 Velvaglo, Woodcare Varnishes, Super Universal Enamel Batching of liquid components Batch sizes range between 800 L and 10,000 L.

Introduction ► Company Background ▪ Convenient Software Solutions (Pty) Ltd Complete industrial automation/process control solutions Wide spectrum of industries Experts in batching implementation ArchestrA certified Offices in Durban and Gauteng

Introduction ► General Paints Plant Background ▪ Plant flexibility Cater for wide range of products Products and raw materials unique ▪ Production schedules Different types of paints batched at the same time

Introduction ► Existing system ▪ InBatch server ▪ InBatch Development Client Recipe Creating ▪ One InTouch PC Plant SCADA Batching client Development MBEnet IO server ▪ Batch Report Server Batching reports

Introduction ► Why upgrade? ▪ Meet Business Objectives “ To produce products of the highest quality, whist maintaining a challenging production schedule in a increasingly competitive market” ▪ Obstacles Batch Model ≠ Physical Plant Consistency in Quality Production Scheduling more challenging

Introduction ► Why upgrade? ▪ New production methodologies Address Challenges Achieve Goals ▪ Industry standards Tagnaming Plant Modeling

Introduction ► Why Wonderware? ▪ InBatch for batch control Proven to be reliable Stable Highly configurable plant modeling Reporting facilities ▪ Application Server 3.0 / InTouch 10.0 Flexibility and Scalability Creation / Maintenance of standards Galaxy Repository

Agenda Introduction Project Solution Benefits Considerations Summary Project Solution

► Existing Topology InTouch 9.5 View Client and Development InBatch Server Quantum PLC InBatch Development Client Batch ReportingServer

Project Solution ► New Topology Galaxy Repository Wonderware Development Studio Redundant Automation Object Servers Quantum PLC InBatch Server Information Server InTouch View Client InBatch Development Client Data Historian

Project Solution ► Design Phase Operational Requirements Batching model functionality Tag name convention Standards for device control Graphical Display objects App Server Area Process Cell Unit Equipment Module Control Module S88 Plascon Mobeni General Paints Batching Manifold Master Mix Agitator Raw Material Storage Motor Pump Inlet Valve Plant

Project Solution ► PLC Software Concept used for PLC Software Tag name convention Tags created in Excel and imported Export Archestra Concept

Project Solution ► PLC Software S88 Structure Standard device control

Project Solution ► InBatch Implementation Storage Tanks Common Manifolds Finishing Tanks

Project Solution ► InBatch Implementation Incorporate Production Methodologies

Project Solution ► InBatch Implementation ▪ Recipe editor Master Recipes Plant chemist able to build recipes

Project Solution ► InBatch Implementation ▪ Recipe Scheduling ▪ Recipe Monitoring

Project Solution ► Application Server 3.0 ▪ Historization Store forward configured ▪ Import Objects ▪ Integration Scripts

Project Solution ► HMI / Graphics Common Look & Feel Common Navigation Standard graphics for devices such as tanks and valves Plant and system health and interlocks clearly displayed

Project Solution ► HMI / Graphics ▪ Interlock Displays Operators always informed Defined action to take

Project Solution ► HMI / Graphics ▪ Plant SCADA

Project Solution ► Completion ▪ Testing IO Testing Off-line Testing FAT Testing ▪ Commissioning Hot Swap

Agenda Introduction Project Solution Benefits Considerations Summary Benefits

► Quality Improvement ▪ Less Contamination ► Production Schedule ▪ Time Reduction ► Material Management ► Reduced downtime

Agenda Introduction Project Solution Benefits Considerations Summary Considerations

► Considerations ▪ Involve different departments ▪ Clear requirements ▪ Communication

Agenda Introduction Project Solution Benefits Considerations Summary

▪ Maintain high quality in production ▪ Minimize negative human effect ▪ Batch recipes optimize plant effectiveness ▪ Operators proactive in preventing down time

Summary ► End User Quote “This first phase implementation has paved the way for all sections of the plant to be integrated into one system. Future upgrades will be more cost effective, not only from a Rand’s and Cents perspective, but from time to implement, as well as downtime.” Andrew Alexander National Engineering Manager Plascon

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