Integrated Process Management Accord Process Management Feb 2017 1 Secure Process Operation Built In Accord Process Management Feb 2017 2 Accord is used to provide secure Automation systems by automatically implementing process models in PLCs with automatic linking for HMI screens R ID: 605583
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Slide1
Accord
Integrated Process Management
Accord Process Management Feb 2017
1Slide2
Secure Process Operation – Built In
Accord Process Management Feb 2017
2
Accord
is used to provide
secure Automation systems by automatically implementing process models in PLCs, with automatic linking for HMI screens, Recipes, Reports and Plans.
Systems may be implemented with process knowledge, and the many built-in features means that coding and scripting are not needed, so system owners have flexibility for changes and improvements. Slide3
Optimising MS SQL for Process Automation
Accord is completely based in MS SQL and Visual Studio, which provides leading standards of Security and Portability.
Accord Process Management Feb 2017
3
Full Security Achieved using MS SQL as Historian,
with Audit Trail Reports and Checking,
W
ith Full Archiving, set-up of Off-Peak backup times and archive sizes
Slide4
Accord Modules:
>
Builder
–
Process Model and Documentation
>
Server – Data and Communications Management, Emulator Security, Historian, Redundancy, Tools> Simulator – Check process operation on PC before PLC testing.> PLC Engine – PLC Runtime Library
>
HMI
– PC / Panel PC Operator Workstations
>
Replay
– Review Process operation on HMI
> Reports – Program Reports by Event, Time> Recipe – Reconfigure programs for Setpoints, Step Order> Plan – Configure SOP and Program sequences
Accord Process Management Feb 2017
4Slide5
Accord Process Management Feb 2017
5
Linked and Managed Modules
Accord modules are fully integrated - Modules on one or many PCs communicate with Server for all data, without any tagging or scripting. Slide6
Full Management of All Items
Accord provides monitoring and management of all items in the Automation Model, using powerful built-in functionality
Automatically
applied
for all items;
Valves, Motors, Instruments, Programs, Plans, Setpoints ...
Accord Process Management Feb 2017
6
Every items, such as a Valve is
-Continually monitored for Error
-Interlock checked before activation
-Requires Log-In for activation or overrides
- Is automatically recorded for all functionsSlide7
>
Improved
Quality
- No Programming Errors,
Matching Validation Documents
, Data Checks
> Easier Maintenance - Standardisation of Projects due to framework - Easier to understand and modify than PLC languages.
>
Built in History Audits
- Server contains Audit for all Operations
Events
-
Builder contains Audit for all Model Development > Reduced Engineering with Built-In functionality - PLC system implemented from Project and Library. - Objects are automatically available for relevant functions. - Documentation Automatically GeneratedAccord Process Management Feb 2017
7
The Accord AdvantagesSlide8
Accord provides all required management of Equipment and Programs. The Equipment and Programs are set-up by configuration in Builder and then the PLC Library automatically implements all functions. Securely and Safely. In this way an Activation of a Valve in a Step will automatically occur in the PLC, with full checking, and without any PLC coding.
1. Build and Test
>
Builder -
Configure Model by generation listing equipment and programs
> Server -
Import Model for Testing
> HMI - Draw Screens and place Objects in Screen> HMI – Test Operation on PC
using
Emulator and Simulator
>
Builder
-
Generate Design and Test Documentation (MS Office)
2.
Deployment, FAT, Commissioning> Server – Import Model for Download to PLC> Server – Setup required functionality using configuration (no coding)
> Security > Historian >
Redundancy
>
Reports
>
Recipe
>
Plan/SOP
>
Server -
Commission
Process, Generate
Reports, Sync setpoints to Model> Builder - Generate As-Built Documentation (MS Office)
Accord Process Management Feb 2017
8
Making an Automation System..Slide9
Accord Builder provides modelling for Equipment, Programs, Steps, Activations, Alarms, all in a clear easy environment, with easy import to Server and download to PLC.
Accord Process Management Feb 2017
9
Clear Process ModellingSlide10
Accord HMI graphic environment - All items link automatically for control and recording.
HMI Screen with full Program control, and built in access to all Setpoints, Value
s,
Accord Process Management Feb 2017
10
Secure Powerful HMI Control Slide11
Access to Control and History is automatically built into each device and program in HMI.
Flow Transmitter, showing all Alarm points and access to Settings, Trends and History,
Accord Process Management Feb 2017
11
I
nstant Access to Monitoring and History Slide12
All configured Selections, Setpoints, Step Times are available for every Program in the Model. Step Order may also be changed for a new Recipe.
New CIP Program Setpoints for ‘Product Line’ without any re-programming,
Accord Process Management Feb 2017
12
Recipe Management for Production PersonnelSlide13
All configured Programs and Equipment Devices may be sequenced to start or Activate in a Plan. All Recipes may be selected for each Program. Selections automatically appear in HMI..
Plan for Automatic scheduling of Programs with Recipe selection and Report selection.
Accord Process Management Feb 2017
13
Plan and Schedule sequences of Programs Slide14
All configured Programs and Equipment may be included in a Report. Reports may be generated in many formats and may be automatically mailed at end of a Program or Plan
Report showing Status, Steps and Key Readings for a Program .
Accord Process Management Feb 2017
14
Full Reporting on Programs and Devices Slide15
All actions for operations and engineering are Automatically recorded and available in the Server Security Audit module.
Report showing Operator Device Overrides and Program Operation.
Accord Process Management Feb 2017
15
Full Security and Auditing Slide16
Product Aims
To Replace PLC and HMI Programming and MES Operations with
Object
Configuration - No Coding or
Scripting
To be suitable
for ISA S88 Systems To be 21CFR Part 11 Compliant
»
Faster Development and Better Quality
Graphic and List Based Configuration
Desktop process Emulation
Quality
(FDA/GAMP) Documents auto-generated» Faster Commissioning and Easier Maintenance» Easy Configure Recipes, Plan/SOP Sequencing, Reports,
Accord Process Management Feb 2017
16Slide17
Sample Installation – Evaporator Concentrator
At Sigma-A
ldrich, Israel
Control of
2
stage
evaporation,
to concentrate from 500 Litres to 6 Litres, with interfaces for Product and CIP. Control is using Siemens PLC and Accord Controls, for fast development and commissioning.
Accord Process Management Feb 2017
17Slide18
Sample Installation – Reactor
At Chemifloc, Ireland
Control
of Reaction Process for Oxygen content under high pressure and temperature, with product recirculation using injectors, with Safety, Pressure Test and Production programs
C
ontrol is implemented on Siemens PLC and Accord HMI
Accord Process Management Feb 2017
18Slide19
Project Path Comparison
> Standard >
Accord
- Generate Design
Documents - Configure Model
- Write PLC
code - Use PLC Data for HMI Data - Draw HMI screens - Draw HMI Screens - Implement
Historian
- Write Recipe Management scripts
- Write Reporting
scripts
- Write
Plan / SOP scripts
- Write Test Documents - Generate Design and Test Documents - System Integrator Internal Test - Test in Emulator Mode or on PLC
- Factory Accept Test - Factory Accept Test - Commissioning
- Commissioning
- Update Design and Test Docs
- Generate
As-Built
Documents
Accord Process Management Feb 2017
19Slide20
Builder Summary
>
G
raphical and list based
>
Sections
for Equipment and
Programs Equipment : Tanks and Lines, containing Valves, Motors… Programs : Steps, Conditions, Alarms, Steps : Transitions, Lists of Alarms, Lists of Activations….
>
Full Editing of Objects and Lists
Addition
u
sing ‘Drag-and-Drop’ from icons
Added Objects are available for Lists
Use of Drop-Down and Add/Remove for List configuration> Consistency Check for I/O Addressing and Object validation> Documents are generated automatically to standard templates Documents: I/O List, Process Description, FDS, SDS,
FAT, SAT, Equipment Test / Calibration, Activation Charts and Cross References
Accord Process Management Feb 2017
20Slide21
PLC Library Summary
Built-In for functions for Equipment and Programs
Performs all Standard Process Control functions
>
Valve/Motor Manual/Auto
Activate
, Alarms, Interlocks ...> Digital In Switches, with Delay On/Off, Override ...> Analog In Scaling, Process Alarms, Override ...
>
Analog Out Scaling, from PID,
Manual/Auto ...
>
PID Loops Manual/Auto, PID Tuning,
Deadbands ...
>
Programs Steps, with Alarms, Activations, Operations, > Items and Lists are represented by Data in defined structures> PLC Library processes downloaded configuration data. > Supported in Siemens, Vipa, Mitsubishi, Schneider PLCs
, Accord Process Management Feb 201721Slide22
Server Summary
>
Import of Project - Download of Data to PLC
Partial downloads provided to running systems
Tools for PLC Addressing, Config Reports, PLC
Scan Time
> Management of Equipment and Programs through HMI Controls Equipment: Manual, Overrides, Settings ... Programs: Start, Stop, Step On, Step To ...
Parameters, Step Times,
Schedules ...
>
Management of
Security per Object and Feature and User
>
Includes Historian with Logging per Object and Deadband> Provides Operator Audit, recording all Operator History > Management for MES: Recipes, Reports, Plan and SOP methods >
Fail-over Redundancy Feature with full automatic data restoration
Accord Process Management Feb 2017
22Slide23
HMI Summary
>
HMI Product with
.Net
Controls for PLC Objects
Unique
Operations Features
;> Navigation within controls gives access to Project Explorer which allows selection of any other device in the system, e.g. a motor can be accessed from the Alarm Banner if it is in Alarm. ... It is possible to provide entire HMI from 1 Control with Explorer > Recent History – Shows Operations on an object in recent time.
>
Built in Trends – All
Value controls
have built in
Trends.
>
Replay mode provides review of all operations on HMI.
> KPI controls show progress and variances for management overview> Runtime configurable KPI allows managers to make any query without programmingDevelopment Features;> Full Graphical Editor, with drop onto screen and item selection,
Ability to Dock, Anchor, Align, Space, etc., >
Managed by Server, using MS SQL
methods
for
all data,
Controls placed on Screen easily linked to PLC objects using
Explorer
>
Configuration is stored in MS SQL, so is very secure
>
HMI deployment uses SQL methods, so no file transfer is needed
Accord Process Management Feb 2017
23Slide24
Product Development History Summary
1.
Development of Siemens S7 Code
2.
Proof of Concept using Excel and VB
3.
Development of Builder 4. Development of Builder Documents5. Development of Server and communications over OPC 6. Visual Objects for use in WinCC, RS View, InTouch, VBA..
7.
Development of Reports
8.
Development of
S
erver Security, Historian,
Tools...
9. Development of Mitsubishi and Schneider PLC code10. Development of HMI and .Net Controls11. Development of Redundancy for Server
12. Development of Check diagnostics module13. Development of
Recipe and Plan
modules
14.
Development of
HMI Replay mode
15.
Development of Emulator
and Simulator modules
Accord Process Management Feb 2017
24Slide25
Recent Developments - 2016
Some of the recent developments are:
1
. HMI KPI Controls – Runtime configurable query controls for HMI
2. External Controls
–
Configurable controls
for External Applications3. Advanced Plan Module for SOP functions4. HMI Replay Mode – Review automatic operation using HMI Screens
Development Plan - 2017
We
intend to develop the following in the next year:
1.
CodeSys
Library, - for
Festo
, ABB, other PLCs2. Advanced Builder – with Wizards, additional functions 3. RS Logix PLC LibraryIn addition we intend to improve the existing modules based on Customer requirements
Accord Process Management Feb 2017
25Slide26
Suitable For:
Accord Process Management Feb 2017
26
Accord is suitable for many types of Process System,
including
Pharmaceutical
Food
and Beverage Dairy Purified Water Waste Water UtilitiesCIP Blending Process BiogasSlide27
Sample Installations
>
Food and Beverage
> Dairy
-
Large Water Bottling Plant - Evaporators and Dryers - Whey Crystallisation - CIP
> Waste Water
> BioGas
- 24 Hour Cycle
- 500kw BioGas Plant - Continuous Treatment > Pharmaceutical - Evaporator Condenser Set - Purified Water Distribution with Sanitisation
> Refinery > Industrial
-
Lead Smelting Plant (IRL)
- Vacuum Pump Sets
- Chemical Reactor
> Distribution
- C
onveying Systems
Accord Process Management Feb 201727