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Hybrid Process Automation System Digital Solutions Components: 3 Tips for Selection

To drive efficiencies, manufacturers are always pushing themselves and their machines harder to boost output and improve productivity. Implementing up-to-date plant automation system digital solutions is a proven way to support these goals and achieve growth and higher profitability. However, in industries where hybrid automation system environments are required (systems that address both the process and discrete steps of a manufacturing operation), a lack of information on selection of proper components often drives up costs unnecessarily and leaves end users with a less-than optimized system.

A careful review of typical Distributed Control System (DCS) and hybrid DCS requests for quotations (RFQs) reveal included features that add cost to the digital solutions but that add little to no value to the end user. For instance, some consultants include products and features in their proposals that were originally designed to meet the requirements of refining, petrochemical, and heavy chemical industries. However, for industries like specialty chemicals, pharmaceuticals, food & beverage, paints, resins, inks, adhesives, polymers, and flavors & fragrances, where hybrid processes are common, such features are unnecessary to assure smooth operations.

Three Ways to Cut Unnecessary Industrial Automation System Components in Digital Solutions

When we at Supertech, an automation systems integrator, certified Schneider Electric Schneider Electric Alliance Partner and EcoXpert, and energy solution provider, meet with manufacturers who run hybrid processes, we help them avoid paying for automation components in digital solutions they don’t need. When selecting industrial automation system components that support hybrid manufacturing environments, be cautious in these three areas:

Avoid unnecessary redundancies – In some cases, particularly in environments where risk analysis has been performed and the level of hardware component reliability is high, the chances that automation system components will fail due to a manufacturing defect are low. In such environments, some batch processes can be intermittently stopped and resumed without much of an issue. Advanced level diagnostics also ensure that systems can be restored within a short period of time if the critical spares are available. In such environments, paying for additional redundancies may not be essential.
Opt for more open communication systems – Some legacy DCS manufacturers provide proprietary buses instead of cost-effective, open, and high-speed Ethernet for communication between the CPU and the system I/O. Industrial automation platforms that are more open allow end users to modernize and integrate more easily. By prioritizing Ethernet I/O, end users can avoid higher integration costs when modernization and upgrades are needed in the future.
Verify whether G3 conformal coating is needed – Many RFQs specify automation system components that conform to G3 level of ISA Conformal Coating Standard 71.04. In pharmaceuticals, food & beverage, and performance chemicals industries, some control rooms and plant environments are exceptionally clean. If that is the case, the G3 level coating may not be required. Therefore, the possibility exists that overall costs and component delivery lead times can be reduced.

If these features are specified by a consultant who is managing an end user’s RFQ, end users should push back. By requiring an explanation for their inclusion and removing them if not relevant, you can save cost and avoid added complexity.

Desirable Options that Bolster Hybrid Process Performance

As end user stakeholders work through the automation system component selection process, look at functions that can significantly enrich the performance of the new system in the hybrid manufacturing environment. For example, a system with template libraries that are industry-segment specific for batch process operations will help engineers to speed-up application development. Insisting on either Ethernet I/P, Modbus TCP/IP, or OPC UA protocol support for third-party communication to devices (i.e., tank weighing systems, mass flowmeters, variable frequency drives (VFDs), Intelligent motor starters, and PLCs) will simplify commissioning and allow for more seamless operations.

By: Supertech | Date: November 26, 2020

CHANDRASHEKHAR LIMAYE
Director- Supertech Instrumentation Services (I) Pvt. Ltd.

Three Ways to Cut Unnecessary Industrial Automation System Components in Digital Solutions

Avoid unnecessary redundancies – In some cases, particularly in environments where risk analysis has been performed and the level of hardware component reliability is high, the chances that automation system components will fail due to a manufacturing defect are low. In such environments, some batch processes can be intermittently stopped and resumed without much of an issue. Advanced level diagnostics also ensure that systems can be restored within a short period of time if the critical spares are available. In such environments, paying for additional redundancies may not be essential.
Opt for more open communication systems – Some legacy DCS manufacturers provide proprietary buses instead of cost-effective, open, and high-speed Ethernet for communication between the CPU and the system I/O. Industrial automation platforms that are more open allow end users to modernize and integrate more easily. By prioritizing Ethernet I/O, end users can avoid higher integration costs when modernization and upgrades are needed in the future.
Verify whether G3 conformal coating is needed – Many RFQs specify automation system components that conform to G3 level of ISA Conformal Coating Standard 71.04. In pharmaceuticals, food & beverage, and performance chemicals industries, some control rooms and plant environments are exceptionally clean. If that is the case, the G3 level coating may not be required. Therefore, the possibility exists that overall costs and component delivery lead times can be reduced.

Desirable Options that Bolster Hybrid Process Performance

By: Supertech | Date: November 26, 2020

Digital Batch Management Solutions for Simple Batch Processes

In the past 20 years, several specialty chemicals, pharmaceutical, F&B, CPG companies have grown from having dedicated manufacturing facilities towards diverse multi-product facilities across the supply chain. Many of them also have 3rd party manufacturing sites. The point will be clearer if I give some examples – paints, toothpaste, chocolates, adhesives, pharmaceuticals, lube oils, packaged food, alcoholic and non-alcoholic beverages, flavours & fragrances, soaps & detergents, agrochemicals, specialty chemicals. How do they ensure that a product being produced at several facilities is meeting the same quality standards? In older times there was a belief that batch processes cannot be automated as the quality of the product depended on the skills and experience of the operator. Ageing and higher turnover of skilled manpower are posing challenges to this belief. Many products of these industries are for direct human consumption and therefore, subject to strict regulatory compliances and need end-to-end traceability. More companies are turning to digital batch management techniques to meet these challenges. Digital batch management is a great solution for knowledge retention as it allows transfer of the operator skills to the system and enables the organization to protect the Intellectual Property. It also ensures data integrity in the operation by providing tamperproof batch records. These could be used to meet regulatory compliances and analyze the batch performance with reference to the benchmark and allow improvements. The new generation batch management systems can be integrated with ERP systems. It significantly increases organizational agility by reducing time and cost to bring new products to the market.

Batch process involves executing steps one by one from a predefined sequence of operations called a “recipe”. Automated batch processes often involve some operations e.g. prechecks, small quantity additions, quality checks etc. that are easier and economical to perform manually. A Digital Batch Management System allows you to integrate the automatic operation with manual process steps. The level of automation is always a techno-commercial decision and depends on factors such as the size of the plant (number of processing equipment), nature of process, whether having multilocational facilities along the supply chain, integration with ERP and budget etc.

Supertech offers cost effective solutions for digital batch management for all types of batch processes. The solutions are built around “EcoStruxure Process Expert” the new generation DCS from Schneider Electric. For simple batch processes with dedicated plants, Sequencer template available in the customized Process Expert Library can be effectively used. This solution does not require any extra hardware or software. The Sequencer template is customized for each batch process by our experts to meet specific needs.

For complex batch operations, multilocational manufacturing facilities, multiple recipes, flexible batch management based on ISA S88 batch standard with or without ERP integration, we have two options – one with “SUPERBatch”, by Supertech and second with “InBatch” – By Aveva (Schneider Electric). Details about SUPERBatch and free trial are available on Schneider Electric Exchange on the following link: https://shop.exchange.se.com/en-US/apps/60517/superbatch—isa-s88-based-batch-management-software. Description about our solutions based on ISA S88 Based Batch Management systems will be covered in our subsequent blogs.

Process Expert DCS based Batch Management with Sequencer Template

A simple, cost effective recipe-based batch operation within the DCS is achieved with the Sequencer Template. The sequence of operations is carried out in either auto, semi-auto or manual mode. The template is designed for processes sequence up to 64 steps and 5 parameters control. The Individual steps transitions from one step to the other consecutive step depending upon the predefined logic conditions. The template provides informative and operator friendly sequence control with operator guide message feature. For more information on the Sequencer Template, 30 days free trial or purchase, please visit Schneider Electric Exchange on the following link:

https://shop.exchange.se.com/en-US/apps/52223/hybrid-dcs-template-library—sequencer-for-batch-processes

Following live example of a specialty chemicals plant in India will illustrate various features of the Sequencer Template based batch management. The process involves a batch reactor with following operations:

Manual pre-checks
Charging of two raw materials automatically
Charging of two catalysts manually
Agitation
Heating
Temperature maintenance
Cooling

The recipe is as follows:

The recipe shows the batch steps with step description, quantities of raw materials to be charged, time and temperature set points for heating and cooling.

Following screenshot of the DCS display shows the Reactor R-101. It is part of a multistage batch process involving three batch reactors. One reactor is shown in the example. Other two reactors are also having similar recipes. Each reactor is having a separate batch sequencer.

On the top left corner, you can see the batch control panel, an expanded view of which is shown below for better understanding:

It shows the Batch number, time elapsed since the batch started, time elapsed since the step started, step number, batch status whether running or stopped, Auto/ Manual status. It has control buttons for AUTO/ MANUAL, PAUSE/RESUME, ABORT, NEXT STEP, PREVIOUS STEP.

On pressing the ↓ button, 5 steps of the running recipe are shown on top left corner. Current step is indicated by green background, completed steps are shown in gray background and further steps are shown in white background. At any point of time during the execution, you can pause the batch sequence, change from AUTO to MANUAL, advance or go back to the previous step. Recipe editor allows the operator to add, edit or delete steps in the sequence, modify the step transition criteria, the time, material quantity and temperature set points. These changes can also be done during batch execution for the remaining steps. You can also create multiple recipes and save in the DCS.

The system is very user friendly as it continuously shows the live status of the batch, allows changes in the recipe even during the execution, has an easy to operate control panel and shows customized operator guide messages for each step. The template does not have any provision for creating batch reports. However, Batch logs are automatically created in the DCS event logger. For detailed Batch Reports, separate reporting module with standard as well as customized reports are available. In this plant, we have given a reporting module based on “Dream Reports” from Ocean Data Systems. A weekly KPI report is automatically generated every Monday at 7.00 am and e-mailed to the Director.

With the DCS Sequencer based Batch Management system, customer has achieved 100% consistency in the quality of the product. The dependence on the skills of the operator has reduced. New operators could be easily trained as the operation now depends more on the system than the skills of the operator. This was particularly useful during and post COVID lockdown when the availability of skilled people was low. There was a 15% reduction in the batch cycle time and 10% saving in the energy consumption.

In conclusion, Batch Management with Process Expert Sequencer Template is a solution for knowledge retention and Intellectual Property Management. It allows meeting regulatory requirements by maintaining highly accurate and granular batch data and provides traceability. Depending on the size and budget of the plant, it allows integration of manual process steps in the recipe without compromising the data integrity. In current times this is an absolute necessity to survive in a fiercely competitive global market. Only those industries who recognize the changing needs and adopt such manufacturing automation technologies will survive and thrive.

By: Supertech | Date: October 17, 2020

CHANDRASHEKHAR LIMAYE
Director- Supertech Instrumentation Services (I) Pvt. Ltd.

Process Expert DCS based Batch Management with Sequencer Template

https://shop.exchange.se.com/en-US/apps/52223/hybrid-dcs-template-library—sequencer-for-batch-processes

Manual pre-checks
Charging of two raw materials automatically
Charging of two catalysts manually
Agitation
Heating
Temperature maintenance
Cooling

The recipe is as follows:

The recipe shows the batch steps with step description, quantities of raw materials to be charged, time and temperature set points for heating and cooling.

On the top left corner, you can see the batch control panel, an expanded view of which is shown below for better understanding:

By: Supertech | Date: October 17, 2020

Digital Transformation in Hybrid Process Industries (Specialty Chemicals, Pharma, Food & Beverages, Consumer Packages Goods)

This paper defines “Hybrid Process Industries” and explains how their unique automation requirements can be addressed by new generation DCS like “EcoStruxure Process Expert” from Schneider Electric. Supertech, with over 30 years successful track record in these industries and a Master Alliance Partner with Schneider Electric, will be your ideal partner not only in the plant automation but also the complete Digital Transformation journey. A real-life batch process where these techniques were successfully employed is also discussed. The customer has achieved 20% increase in productivity, 100% consistency in quality, 15% energy saving, 50% less manpower, 20% increase in availability of equipment, material traceability from finished goods to raw materials, tamper-proof electronic batch records, real-time integration with ERP by posting of raw material consumption and production after every batch.

What are Hybrid Process Industries?

When we started the automation system integration business in early nineties, the system integration was all about selling PLC based systems to OEMs and discrete segment of end users. DCS companies used to sell DCS to large process industries. The smaller process industries such as Specialty Chemicals, Pharma, F&B were by and large manually operated because the automation systems were not able to provide the agility and flexibility needed for their process and also openness in their integration with other third-party systems

Examples of Hybrid Process Industries

When the winds of liberalization started blowing, these industries felt the need for automation with their expanding capacity. Major driving factors were increasing size and complexity of processes, pressure of maintaining consistent quality in the light of global competition, need to improve productivity, regulatory compliances, and reduce dependence on human effort and skills. Smaller process industries involve processes with several automated batch operations, with manual interventions in between those steps. It comes with large number of discrete signals. PLC based system with their success in manufacturing industry were used for these applications primarily because of the boolean logic processing, lower cost and simplicity. Large process plants such as refineries, petrochemicals, use continuous process and has large number of analog signals. DCS were used due to its robust analog processing capabilities and algorithm library. As the smaller industries are getting more automated, the manual interventions are being eliminated. The automation needs of these industries have evolved from couple of discrete batch operation process to integrated batch and continuous processes with no manual interventions. These industries are therefore called Hybrid Process Industries.

Till the new generation of Automation systems were launched, the automation in these industries was limited to automating operation of valves and motors, transfer of liquid raw materials and solvents from storage tanks to day tanks, monitoring of process parameters, switching of utilities in multipurpose API reactors etc. However, it was still short of expectations of the end users. It was because of two reasons, first due to the lacunae in the automation systems and second the inexperience of the implementors, be it the system integrators or the DCS companies.

Digital Transformation in Hybrid Industries

Digital transformation is the process of using digital technologies to create new — or modify existing — business processes, culture, and customer experiences to meet changing business and market requirements. Among the various business processes to be transformed, manufacturing is one of the most critical. Digitalization of manufacturing processes in hybrid industries is in simpler words “Automation”. To achieve the real benefits of Digitalization, a holistic approach towards automation is necessary.

The key business values driving the need for Digital Transformation are:

Smart Design and Engineering :-

Efficient Engineering

Enhanced Commissioning

Lifecycle Management

Asset Performance :-

Asset Reliability

Maintenance Excellence

Asset Optimization

Investment Continuity :-

Extended Lifespan

Modernization

Asset Portfolio Management

Energy Efficiency :-

Energy Management

Demand- Response

Let me explain how the new Generation DCS “EcoStruxure Process Expert” from Schneider Electric has helped in addressing the basic Automation needs as well as the overall Digitalization needs of the hybrid industries.

Majority of the hybrid industries are batch processes. Various options of Batch Management starting from Batch sequence templates available in the DCS library to ISA S88 based Batch Management using specialized Batch management software SUPERBatch (From Supertech) or InBatch (From Schneider Electric) are available.
Customized templates for liquid raw materials transfer from storage tanks to day tanks and from day tanks to reactors/ mixers/ blenders makes this automation plug and play.
Conventional PID control does not work for temperature control of Batch Reactors. Customized templates have been prepared for temperature control of exothermic or endothermic reactions, split-range control for high accuracy, controlled addition of reactants with simultaneous cooling with temperature control, automatic switching of utilities and adaptive temperature control for multipurpose API reactors.
Templates for Intelligent Motor Starters and Relays Tesys U and Tesys T, Altivar range of VFDs from Schneider Electric provide robust DCS-Intelligent MCC interface and monitoring of motor data.
Library for Energy Management. Easy connectivity with Multifunction meters, Intelligent breakers. Data from Energy Management softwares PME and PSO on OPC. Energy dashboards, specific energy consumption.
Open architecture based on Ethernet. Flexible system architecture with Ring, Star and Bus topologies
Seamless integration with MES, ERP and other IT systems.
IIoT solutions “Augmented Operator Advisor” for operator empowerment, Secure Connect” for secure remote connectivity for trouble shooting, program modifications, “Maintenance Advisor” for Predictive maintenance, “Equipment Efficiency Advisor” a real time software tool for process improvement that provides online monitoring of the OEE
With “AVEVA Insight”, cloud based Historian, you can collect data from multiple sources, store it in the cloud and have visualisation plus cloud based MES functionality, condition management, advanced analytics, machine learning, mobile reporting and more…
The awareness about Functional safety and IEC 61508 in increasing. Hybrid Industries having hazardous processes are carrying out HAZOP study and safety assessment. SIL 3 safety controllers are available in the same controller family. They are used for Emergency shutdown systems, safety interlock systems, Burner Management, systems etc.
EcoStruxure Process Expert provides connectivity with third party systems on a variety of protocols such as Modbus TCP, Ethernet IP, Profinet, Profibus, Modbus serial etc. It helps interfacing with OEM equipment such as Boilers, Thermopacks, Chillers, Filling machines, Robots, Conveying systems, Storage systems etc.
End products of many hybrid industries such as Pharma, F&B and CPG are for direct human consumption and hence subject to strict regulatory compliances. Features such as User management, Audit Trails, compliance with 21CFR11 etc. help in meeting the regulatory requirements.

An Example

Following is an example of an Automation system consisting of many features mentioned above. It was implemented recently for a 100,000 TPA Paint manufacturing plant in India, which is likely to double its capacity shortly. The system architecture is as follows:

The system consists of “EcoStruxure Process Expert” DCS from Schneider Electric with 2 no. Operation Servers, 1 no. Engineering Server, 8 nos. Operating Clients, 2 sets of M-580 Hot Standby Process Automation Controllers. 55 nos. remote I/O stations, 8 nos. Intelligent MCC panels with Tesys T intelligent relays and Altivar VFDs are connected on an Ethernet ring network. Third party PLCs for OEM systems with Modbus Serial, Modbus TCP/IP, Ethernet I/P, Profibus and Profinet have been integrated with the DCS on the same network with suitable gateways wherever required. Multifunction meters in Electrical panels have been connected to “Power Monitoring Expert” (PME) software for Energy management. Relevant energy data has been provided in the DCS and Batch through OPC DA. About 75 nos. Load-cell based weighing systems and 60 nos. mass flowmeters have been connected to the system through Ethertent I/P and Profinet respectively. The system has approx. 14,000 I/O. Archiving of critical data and customized reports have been provided through the Historian. Wonderware InBatch has been used to provide advanced ISA S88 based Batch Management. The system has on-line interface with the customer’s SAP system. Process orders are received from the SAP, scheduled in the InBatch, and executed in the DCS as per the recipes. On-line batch and process data is transferred to the SAP phase by phase. At the end of a batch comprehensive batch reports are automatically generated. The system will be shortly upgraded with MES to improve its analytical capabilities. A 64” display is provided in the control room to show the dashboards with critical operating parameters.

Selecting the Right Partner

Having the right partner with you is absolutely essential for a successful Digital Transformation Project. Your investment can go down the drain with a wrong selection. You can see that the process involves integration of various components, customization to your needs and support. Only experienced Service providers like Supertech with both the domain as well as the automation expertise can provide you the integration, services and support, all under one roof.

Supertech is a leading automation solution provider with 30 years of proven track record in hybrid industries. Supertech is a Master Alliance Partner with Schneider Electric (one out of ten globally) for Control Systems and Hybrid DCS and a segment specialist partner in Consumer-Packaged Goods. Other Alliance partnerships with Schneider Electric include “Intelligent MCC Integration”, “EcoXpert – Critical Power Expert” for Energy Monitoring Systems and Wonderware software platforms. Supertech has in-house expert teams available in each of these areas and you will have a seamless experience through your digitalization journey. Supertech also undertakes the responsibility of supplying the smart and non-smart field instruments, valves, erection material from the best-in-class sub-vendors and services of installation, calibration and commissioning. Supertech supports its installed base through 24×7 customer support with telephone, e-mail, secure remote support and AMCs.

By: Supertech | Date: September 17, 2020

CHANDRASHEKHAR LIMAYE
Director- Supertech Instrumentation Services (I) Pvt. Ltd.