Automising batch production.

Perfect Batch is an Ai-powered manufacturing analytics solution launched by TwinThread. It is designed to optimise batch production processes by empowering manufacturers to standardise and consistently replicate their best performing or “golden batches”.

Unlike legacy systems that rely on passive alerts and static manual settings, Perfect Batch applies industrial AI to dynamically identify ideal batch profiles from historical data and actively recommend actions for increasing efficiency. This enables organisations to rapidly shift from reactive firefighting to proactive optimisation in a matter of weeks – not months or years.

Perfect Batch At-a-Glance

• Rapid Speed to Value: Perfect Batch connects to existing batch execution systems and automatically interrogates past data to build digital twins and apply models in hours.
• Dynamic Perfect Profile Learning: Instead of setting limits manually, Perfect Batch dynamically learns ideal control limits and process centerlines, based on actual process capability and historical performance.
• Unlocked Hidden Capacity: Granular cycle time analysis identifies bottlenecks and lost production time, facilitating capacity improvements from existing assets without new capital investment.
• Optimisation by Exception: Automated alerting and issue diagnosis empowers operations teams to focus on solving problems, without getting bogged down with endless troubleshooting and investigations.
• Optional Closed-Loop Action: Thread Builder, a real-time workflow engine that works with Perfect Batch, automates anomaly responses, performs automatic diagnoses, and can trigger specific corrective actions automatically.
• Automated Compliance: Tailored for regulated industries, Perfect Batch provides automated material tracking, quality and yield conformance, and audit-ready histories.

Perfect Batch furthers TwinThread’s position as a complete industrial AI platform. By continuously monitoring and simultaneously optimising five key dimensions—utilisation, cycle time, quality, process control, and yield—operations teams gain actionable intelligence that helps them drastically reduce investigation times, minimise waste, and accelerate continuous improvement activities. Available in both Simple Batch and Complex Batch tiers, the solution scales easily to meet the needs of process manufacturers of all sizes.

“This solution’s core promise is to empower operations teams to deliver the ideal batch every time, regardless of recipe, shift, or variations in raw materials,” says Erik Udstuen, co-founder and CEO at TwinThread. “By completely automating the discovery of hidden capacity and enabling proactive optimisation, we are giving manufacturers the power to eliminate inconsistencies and maximise financial performance of their existing assets.”

Beyond the plant floor, Perfect Batch helps drive strategic and collaborative alignment across organisations’ entire manufacturing portfolios by providing a global view of asset utilisation and batch making performance. As a result, the platform serves as a single source of truth for cross-functional teams. This offers a common lens that operations teams, engineering teams, and supply chain leaders can all use to identify, prioritise, and proactively execute improvement initiatives that optimise the deployment of capital across the supply network.

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@twin_thread #Ai #PAuto 

Geometric Process Control (GPC) and batch process.

Webinar: Multi-envelope models for batch, fed-batch, cyclic, grade-change and all types of continuous and dis-continuous processes

Most PPCL monthly webinars are in the category "Operating Envelopes 101 – part 1" because they are based on continuous processes where the continuous operation Mode can be described with a single Operating Envelope. 　

There will be four sessions to suit different time-Zones so choose the one closest to your time-zone and click on the appropriate link below to enrol. The webinars are listed by BST(British Summer Time) which is GMT+!.　 6 AM BST　Wednesday 29 June: UK (BST) 600, Dubai 900. Mumbai (IST) 1030, Perth 1300, Sydney/Brisbane 150 　 9 AM BST　Wednesday 29 June: UK (BST) 900, Europe (CEST) 1000, Doha (AST) 1100, Muscat (GST) 1200, Delhi (IST) 1330, Singapore (SGT) 1600 2 PM BST　Wednesday 29 June: UK (BST) 1400, Houston (CDT) 800, New York/Toronto (EDT) 900, Rio de Janeiro (BRT) 1000, Europe (CEST) 1500　 9 PM BST Thursday　29 June: UK (BST) 2100, Los Angeles (PDT) 1300, 　Denver/Calgary (MDT) 1400, Dallas (CDT) 1500, New Zealand (NZST) 800 1 July A Recording of one of the Sessions will be available after the webinar but it will not include the live Q&A Session.

"This is important because for many attendees our webinars are their first introduction to the sheer power of the Geometric Process Control (GPC) method based on parallel coordinates, n-dimensional geometry and multi-dimensional Operating Envelopes and Human Intelligence. And it is all available now so bring your process operations problems to us, whether you judge them be easy or hard, and we will show you how to solve them,"  said a spokesman for Process Plant Computing Limited (PPCL) the organisers.

Many real processes such as batch, fed-batch, cyclic, grade-change and all sorts of non-continuous processes require more than one Operating Envelope and that’s what this webinar will introduce. Envelopes can be made time-dependent by including time variables but even without a time variable it can be remarkable how models can cope with a changing relationship effectivel inferring time. Even continuous processes really have more than one operating Mode such as Start-Up and Shut-Down as well as Modes for Standby, different throughputs and Special Modes for, for instance, catalyst regeneration.　　 　

"You’ve probably seen batch processes controlled by trying to follow a defined trajectory on a very small number of variables such as reactor temperature or concentration. We will show you versions of models with and without time variables which may give you food for thought." 　

Operating Envelopes linked to form a chain allow control of the process into a multi-variable tube of hundreds of variables instead of just one or two and since the tube includes Result-variable range predictions find one or a chain of Operating Envelope better at recognising external disturbances and guiding the operation to achieve the desired end-points. 

"A Golden Batch every time is our ambition! Come and see how it is done by enrolling on this webinar," concluded the spokesman.

@ppcl_news #PAuto

Strategic MES partner.

Following a global bidding process, Sharp Packaging selected Werum IT Solutions as its strategic MES partner to implement an Electronic Batch Record (EBR) infrastructure at its Netherlands facility.

Rüdiger Schlierenkämper, CEO Werum
& John Hoey, Sharp IT Business Partner

“We see MES as a strategic system that gives us competitive advantages,” says John Hoey, Sharp IT Business Partner. “Investment in EBR will serve to improve our business opportunity pipeline and digitally transform the way in which the batch record process is executed. We have chosen Werum’s PAS-X MES because of its proven ability to handle the most complex batch records without significant configuration as well as it’s track record with a number of Sharp’s existing customers.”

By using Werum’s PAS-X MES, Sharp Packaging will benefit from greater compliance adherence, improved right first time and process standardization. The company starts its MES journey with the rollout of PAS-X at its production site in Heerenveen (NL). PAS-X fully integrates the existing Navision ERP system.

@Werum #PAuto  #MES

Cost-effective, high-quality and large-scale MBR creation.

Development of new drugs, process harmonization and standardization or efficient operation of manufacturing execution systems (MES) – pharmaceutical and biopharmaceutical companies face major challenges to remain competitive. In this regard, electronic master batch records (MBRs) are an essential factor.

Martin Gent

Werum IT Solutions now offers its customers a new service: “Design as a Service” – a complete solution for the cost-effective creation of lean, high-quality and streamlined MBRs. The package comprises pre-configured PAS-X Content Packages with industry-specific content based on best practices, ready-to-use concepts and guidelines for the efficient creation and optimization of MBRs and profound, first-hand PAS-X knowledge. As the company who developed PAS-X, Werum is able to provide an “end-to-end” MES solution that meets all customer requirements in terms of software, delivery and services.

“Our ‘Design as a Service’ offering allows us to provide our pharmaceutical and biopharmaceutical customers with much more than the mass conversion of paper-based recipes into digital copies which is usually referred to as MBR factory,” says Martin Gent, Consultant, Werum IT Solutions GmbH. “Our approach starts at an earlier stage and we reflect about the manufacturing processes together with our customers. Even during the MBR specification phase we consider the entire spectrum of manufacturing procedures, system environment and review processes. In combination with the profound process know-how of our staff we ensure optimized high-quality MBRs from the very beginning – an important prerequisite for the efficient operation of our PAS-X MES. Customers who want to save costs by commissioning the mere creation of MBRs often face extra costs when they need to revise their MBRs.”

Through “Design as a Service”, Werum does not only support the cost-effective high-quality creation of MBRs for new MES installations but also supports customers who already operate an MES and rather focus on process harmonization, PAS-X upgrades or the MBR creation for new products (ad-hoc service). As PAS-X is Werum’s proprietary software product, Werum can also consider future PAS-X functions when creating MBRs. “Design as a Service” addresses all phases of MBR development, such as MBR specification, MBR creation and finally MBR verification. The resulting MBRs are lean, efficient and optimized to meet the customer requirements in regard to “Review by Exception”.

Prototyping a Batch Process Control System!

Cormac Garvey

The Ireland Section of the International Society of Automation will host a technical presentation in September entitled: Prototyping a Batch Process Control System using ISA-S88 and ISA-S95. This is the start of this very active section's programme for the 2015-2016 season. Later in the season they are hosting the international ISA Food and Pharmaceutical Industries Division (FPID) Symposium.

Cormac Garvey
Cormac graduated from University College Dublin, Ireland, in 1992 with a degree in mechanical engineering. Since then, he has worked in both Engineering and IT software fields for the last 23 years. He is a qualified project manager (PMP®), Security specialist (CISSP®) , and published author on websites. As well as architecting and programming control systems, Cormac has managed the design , implementation, commissioning and validation of Control and MES systems in the pharmaceutical, Oil&Gas, and Semiconductor industries. His speciality is: Simplifying the industrial Automation and information system landscape through the use of open standard data modelling and implementation of design patterns.

In this presentation Cormac Garvey, Chief Technology Officer, Hal Software,* will discuss the concept of using prototyping for a batch control system. Prototyping is a relatively new concept in control systems, but is standard in many other industries.

He will cover what exactly prototyping can be used for in process control, what are the benefits of prototyping, and, how one would go about using prototyping.

Cormac will then give a practical demonstration of how one would build a prototype of a simple batch process control system using the ISA-S88 design pattern.

*Hal Software
Hal Software is a 100% owned Irish company that provides software to assist in the design, programming and test of Industrial Control and MES systems. The company was founded in 2012, and launched its first product, Spike Prototype, earlier this year at the Hannover Fair. They also exhibited at Achema in Frankfurt/Main (d). They plan to participate in next years Hannover Fair as well.

• Meeting Details: Rochestown Park Hotel in Cork on Wednesday, 16 September 2015 @ 19.30hrs. Tea and Coffee @ 19.15hrs.

Batch control system support! #PAuto

Burkert  has launched a new system service for designing, manufacturing and commissioning packaged batch control solutions for use in markets such as hygienic processing, water treatment, brewing, food and beverage, pharmaceutical, medical/biomedical, chemicals - and many more.
Burkert’s batch control solutions offer the advantages of integrating a world class range of fluid control products, with third-party products - where required - in systems that are bespoke to customer requirements, fully optimised for maximum performance and designed to meet specific sector requirements regarding hygiene.

The batch control solutions are the result of Burkert’s unique ability to combine process and laboratory automation, valve elements, sensors, flowmeters, water treatment systems and networked communications into single source customised systems that deliver higher process efficiency and also higher yields with reduced waste.

The scope of Burkert’s service involves complete project responsibility, from conception through design, manufacture, assembly and testing. It covers both small and large production runs, extends to integration of third-party equipment, and offers the key benefit of simplifying equipment designs; making them more compact and easier to use.

The batch control solutions can be housed in control enclosures of almost any material, including GRP and stainless steel, and integrate comprehensive levels of instrumentation: level, pH, conductivity, ORP, combined flow rate, pH, ORP, temperature and conductivity, as well as visual displays and controllers.

“What is increasingly evident, today, is that the complexity of modern processes cannot always be satisfied with standard batch control,” said Tom Carnell, Manager of Burkert UK’s System Division.

"The requirements for process systems used in medical, biomedical and analytical applications are becoming ever more demanding. To meet these demands, specialised systems are often required. This could involve Burkert in producing a totally individual design, or, more simply, modifying an existing batch process product. Whatever the requirement, a team of engineers and technicians is always on hand to provide the most cost effective solution, and the closest correlation between market demands and equipment performance.”

The batch control solutions are a further development in Burkert’s overall systems capability. At its Stroud facility, Burkert already provides products ranging from ATEX certified control cabinets, to MicroFluidic multi-station dosing and mixing units for DNA synthesis, to systems based on its mxControl, multi- parameter controller that fully automate and optimise water treatment and purification processes.

• Burkert are marketed in Ireland by Petrochem Pipeline Supply.

Integration key to optimising performance in batch processing

An integrated solution to optimise real-time performance, specifically designed for complex batch processes is now available through SolutionsPT, the automation and IT solutions provider for manufacturing and industrial clients.

Wonderware InBatch 2012 R2 is a new version of its already established InBatch software which incorporates System Platform to provide a unified answer to the complexities of batch processes, while still maintaining maximum flexibility.

InBatch 2012 R2 Batch process overview

Batches often have to endure handovers to other self-contained processes such as filling and packaging. The use of InBatch 2012 R2 removes the need to integrate these separate applications making production more time efficient.

By eliminating these islands of automation and replacing with this integrated set of manufacturing operations management, it is possible to lower costs and increase operational efficiency.

Sue Roche, Business Manager, Wonderware UK and Ireland, comments “Incorporating System Platform with existing InBatch technology to create this new software provides a unified application and information environment across the complete manufacturing process. By making batch management data available to users and systems throughout the plant, the software increases operational effectiveness and enables better levels of business optimisation in real time.”

SolutionsPT client, Akzo Nobel, has implemented InBatch at its plant in Birmingham - which produces packaging coatings primarily for the food and beverage industry - as part of an overhaul of its industrial IT technology.

InBatch has enabled this company to deliver accurate, consistent recipes time after time, with the flexibility to add new recipes and production lines. Standardising the production process in this way ensures customer satisfaction with an end product which is of consistent quality and reduces the costs associated with the disposal of hazardous waste, which cannot be simply sent to landfill and is subject to stringent regulations and substantial disposal costs.

InBatch has also proved invaluable in being able to trace the exact provenance of every single batch which leaves the site, recording exactly what went into it and how it was created.

Integrated production control system enhanced!

The CENTUM® VP R5.03, from Yokogawa is an enhanced version of the company’s flagship integrated production control system.

Yokogawa has been continuously developing and enhancing CENTUM VP as a cornerstone of its Industrial Automation business’s VigilantPlant® vision for operational excellence. In accordance with the strategies set out in the company’s Evolution 2015 mid-term business plan, CENTUM VP has been enhanced with a variety of new functions.

New features in CENTUM® VP R5.03 include a wide area communication (WAC) router for control via public communications networks, enhanced batch functions, easy integration with intelligent electric devices (IEDs), and an eight-loop operation keyboard.

VigilantPlant
VigilantPlant is Yokogawa's automation concept for safe, reliable, and profitable plant operations. It aims to enable an ongoing state of operational excellence where plant personnel are watchful and attentive, well-informed, and ready to take actions that optimise plant and business performance. Based on this concept, Yokogawa introduces a variety of solutions through its Safety Excellence, Asset Excellence, Production Excellence, and Lifecycle Excellence initiatives.

Yokogawa has developed a WAC router that enables a CENTUM VP system to remotely monitor and control equipment over a wide area network (WAN) established using public communication lines, satellite links, and the like. The WAC router provides the same high reliability and security as the Vnet/IP control network that is used with Yokogawa production control systems. It compensates for limited bandwidth and transmission delays by prioritising communications based on data type and target. For added reliability, the router has dual redundant communication modules. Each of these modules can be linked with the WAN by up to two communications lines. When two lines are employed, they may be of the same type or of different types, e.g. satellite link and fibre-optic cable. The router enables reliable and inexpensive monitoring and control of widely distributed facilities such as the offshore platforms used in oil and gas exploration and production.

The CENTUM VP R5.03 batch package is based on ISA-88 and has enhanced functions that allow greater flexibility when accommodating changes in production procedures. The number of operating procedures has been increased, and the recipe procedure has been provided with additional levels of granularity, simplifying the process of making recipe changes. CENTUM VP R5.03 is thus ideal for companies that employ complex batch production processes and are engaged in such industries as foods, pharmaceuticals, and speciality chemicals.

CENTUM VP R5.03 supports the IEC 61850 communication protocol, which has been widely adopted in the electric power industry and other industries that operate extensive electrical facilities. This latest version of CENTUM VP can integrate data from intelligent electric devices and can be used to monitor the operations at power plants whose electrical facilities have been designed based on the IEC 61850 standard. This allows better integration with power plant operations, and also enables the monitoring of electrical facilities at many other types of plants.

A new keyboard has been released with sets of dedicated function keys that can be used to simultaneously adjust eight control loops. For graphic, alarm, and trending operations, there are also dedicated control keys, operation confirmation keys, window call-up keys, a total of 64 special function keys, and keys for alarm acknowledgment and key locking. This keyboard has been designed to make it easier for plant operators to perform their tasks.

Major Target Markets
Process control and monitoring applications in industries such as oil and gas, petrochemicals, chemicals, electric power, pulp and paper, pharmaceuticals, foods and beverages, iron and steel, and water supply and wastewater treatment

Applications
Control and monitoring of plants and production equipment

Future development
With CENTUM VP as its core platform, Yokogawa continues to develop a variety of production control systems. Based on the Evolution 2015 mid-term business plan, Yokogawa is strengthening its range of comprehensive solutions for targeted markets.

ISA standards for effective decision support

The Ireland Section of the ISA has landed a big hitter for their May technical talk.

Dr Maurice Wilkins is Yokogawa's Head of Global Strategic Marketing on the 29th May 2013. Putative attendees should not the this meeting is scheduled for the afternoon at 15.30.

Dr Maurice Wilkins

The presentation is on "The Integration of ISA Standards for Effective Decision Support" is scheduled for Rochestown Park Hotel in Cork (IRL). Dr Wilkins will highlight and incorportate the followimng ISA standards:-

• Alarm Management (ISA-18.2)
• HMI Management (ISA101)
• Procedure Management (ISA106 & ISA-88 - Batch Control)


Dr. Wilkins has made many significant contributions to automation and control. He has been dedicated to the establishment of a procedural automation standard for the continuous process industries to improve safety and efficiency at manufacturing sites and to capture the knowledge of the aging workforce.

He was responsible for proposing the ISA106 (A standard framework for automating operating procedures in continuous processes) standard defined by the International Society of Automation (ISA) and is now managing director of the ISA106 committee.

From 2004 to 2009, he was chairman of the World Batch Forum (WBF), an association of users and manufacturers that helps with understanding and implementing standards for manufacturing automation. In this role, he demonstrated strong leadership and commitment, and contributed to the progress of the association even during the global economic downturn.

He was selected in 2011 for the Control Magazine's Process Automation Hall of Fame.

He is known for strong expertise and experience in leadership and team building, strategic consulting, batch control, procedural automation, APC, human factors, process analysis and has worked for Exxon Chemical, Honeywell, KBC, Breakthrough Process Consulting, Millennium Specialty Chemicals, Lyondell, ARC  as well as Yokogawa.).

Attendance is free of charge however they would like pre-registration if possible here!

Batch recording in pharma plant!

One of the leading Japanese pharma groups chooses Werum again!

Astellas plant in Killorglin

Astellas Ireland has decided to implement Werum´s PAS-X MES at its production facility in Killorglin, County Kerry (IRL). The MES will introduce efficient and state-of-the-art paperless Electronic Batch Recording functionality supporting compliant, efficient and lean production processes. The MES will be fully integrated with the SAP ERP system, the shop floor equipment and process control systems. Astellas intends to roll out the MES to all production processes in a phased approach.

Astellas is the second largest pharmaceutical group in Japan with three European production sites. Werum’s PAS-X is already installed in the Astellas site in Meppel (NL)

The Ireland Section of the International Society of Automation are holding a Seminar on Alternative Energy Sources and Plant Tour at Astellas in Killorglin, Co. Kerry on Tuesday 15 May 2012 @ 13.45P.M. sharp. Places limited!

High-speed, high-accuracy filling or dosing

Accuracy and speed of Micro Motion® Model FMT filling mass transmitter significantly improves system response time and reduces batch cycle times

GF S.p.A. has reduced filling times, improved accuracy and repeatability, and enabled tighter filling tolerances for its filling machines by using the latest Micro Motion® Model FMT filling mass transmitter from Emerson Process Management.

Based in Parma (I), GF S.p.A. is a leader in the design and manufacture of high technology filling equipment and quality control systems. Its filling machinery is used in the pharmaceutical, medical and food industries for the precision measurement of injectables, infusions, ophthalmic preparations, syrups and detergent solutions.

"In this highly competitive market, we are always looking for ways to improve the performance of our machines," said Marco Serventi, Sales Manager, GF S.p.A. "Emerson’s Micro Motion Coriolis technology is accurate, reliable and user-friendly, adding value for our end user customers."

GF had been using filling technologies based on time-pressure instruments, as well as piston-syringe and peristaltic (roller type) pumps, for filling machines being supplied to the pharmaceutical industry. GF wanted to improve the speed and accuracy of its machines and also enable its customers to change media without the need to replace the measuring instrument. A further requirement was to enable in-line sterilisation without disassembling the machine.

GF met these objectives by using the Model FMT filling mass transmitter with Micro Motion ELITE® and H-Series flowmeters. For example, GF was able to significantly improve system response time and reduce batch cycle times by taking advantage of integrated valve control from the transmitter, rather than the traditional pulse output set up through a programmable logic controller (PLC).

In addition, the rangeability of the Coriolis flowmeter allows different media to be dispensed without changing any mechanical components of the machine. For example, fillings can be in the range from 0.5g to 5Kg.

"The high reliability and accurate results provided by the Micro Motion instruments have now been validated by GF customers over a number of successful applications," continued Serventi. "Based on this successful collaboration with Emerson, our company has adopted Micro Motion meters on a range of filling machinery."

The Micro Motion Model FMT transmitter is designed for any process that requires high-speed, high-accuracy filling or dosing. The Filling Mass Transmitter is compact and light, minimising space requirements and reducing installation cost and effort. Easy to integrate into almost any filling machine, the slim profile and compact dimensions reduce the footprint and allow for the maximum number of fill heads.

The electronics are immune to temperature shocks from CIP/SIP procedures, and the sensors feature a hygienic drainable design. They are 3A-authorised and EHEDG certified for hygienic use, and designed for fast and easy cleaning with rounded corners, polished exterior surfaces, and no internal crevices.

Data from the flowmeter is logged as part of a data management system to help meet the requirements of the U.S. Food & Drug Administration’s 21 CFR Part 11 rules for electronic records. Any filling errors or drift away from the set-point can be used to generate alarms for the operator so that corrective action can be taken.

In addition, the temperature measurement integrated into the Micro Motion ELITE Coriolis flowmeter enables the operator to check that critical parts of the machine have been correctly sterilised by recording that temperatures up to 160ºC have been reached.

Updated software improves tank farm and terminal operations

Invensys Operations Management has released a new version of its Off-Sites software suite, featuring a completely revised integration structure between its Blend Optimization Supervisory System, Order and Movement Manager and Movement Automation System. Additional improvements and new capabilities are new user access options to manage permissions and to support single sign on; new management capability for Certificates of Quality (COQ) and handling of movement deviation alarms in the Tank Information System; support for industrial handheld devices for lineup management as part of the Movement Automation System; extended analyzer management functions in the Blend Optimization Supervisory System, and a new graphical pipeline system configurator in the Batch Tracking Manager Module.

Product overview:
Invensys offers a powerful DCS-independent off-sites and terminal operation solution that addresses inventory management and product blending-- two of the key areas contributing to overall refinery, petrochemical and chemical plant performance improvements. The Invensys Off-Sites Solution includes consulting, implementation, integration, training and support services in combination with the feature rich, modular, scalable and configurable Off-Sites Software Suite. Consistent and accurate refinery inventory information is important in optimal planning, scheduling and material loss management. Increased automation and operational performance reduces the cost of operation, while at the same time improves safety compliance and business performance.

Key capabilities:
• Accurate tank inventory, order and movement management;
• Off-line blend setup, validation, pre-blend and online optimization;
• Automated and precise tank emissions monitoring and reporting;
• Quality analysis, analyzer management and validation, which address operational quality procedures such as EPA 40CFR80 requirements;
• Modular, scalable, platform independent and sustainable standard software application with integration to existing DCS or PLC systems through open industry standards.

Batch control

RA33 Batch Controller controls valves and pumps to ensure the exact dispensing of predefined batch quantities

The Endress+Hauser RA33 Batch Controller provides precise sensing and dispensing of liquids into a container or process vessel in food, chemical, pharmaceutical, oil & gas and other process industry applications. It monitors flow, temperature and density; controls valves and pumps; and dispenses the exact amount requested by the programmed recipe. The controller can work with a single valve and pump in automatic or manual mode, or with two valves for two-stage batching. Two of these controllers can work together for batch mixing of two ingredients.

It calculates the exact volume to be dispensed based on an analog or pulse signal from a flow sensor and its built-in temperature/density compensation functions. For example, mineral oils can be corrected according to the ASTM D1250-04 standard. The volumes of other media can be corrected using expansion coefficients, or the volume can be converted to mass by measuring the density. It also makes an automatic after-run correction for constant and extremely accurate results, and advanced error diagnostics detect leakage, fill deviation and "no flow" conditions.

It has a compact housing for wall, panel or DIN rail mounting, making the device usable in all environments. It works in ambient temperatures of -4 to 140°F, has an IP65-rated front panel, and the housing meets IP66 and NEMA 4X requirements.

The unit accepts inputs from flow, temperature, pressure and density sensors. Outputs can control two valves and two pumps, and it has up to four digital outputs for one- or two-stage valve control or for the control of other devices such as signal lamps. The RA33 also has optional USB, RS485, Ethernet, and Modbus TCP and RTU interfaces for communications with an external control system or PC.

Configuring the Controller
The RA33 Batch Controller has a multi-line, backlit LCD with selectable operating languages. A simple and quick configuration can be carried out on-site via buttons, or with the help of a USB interface and Endress+Hauser FieldCare software. Configuration functions include recipes and safety settings, such limiting the preset counter entry to a maximum allowable value. The RA33 Batch Controller is also available pre-programmed.

Predefined universal inputs support simple and quick commissioning and are suitable for connecting to and powering all commonly used flow sensors, pressure transducers, temperature sensors and density sensors.

Recording Batch Data
The RA33 Batch Controller has a logbook for batch reports and an event logbook, and it maintains statistics regarding the number of fillings and filled quantities for day, month and year. For direct documentation, a printer can be connected to the serial interface of the RA33, and a printout of the batch report can then be automatically initiated at the end of each filling process.

Using Endress+Hauser Field Data Manager Software, the stored batch reports, events, and the device configuration can be read out automatically and stored tamper-proof in an SQL database.

If it is connected using Ethernet, customers can use the built-in web server to read out measurement data, calculated values and device data using a standard web browser. Because the web server is built-in and because access is via a browser, there’s no additional software to be installed on a PC or other device used for data monitoring.

Quenching Brazilain thirst!

Installation of the rotating filler at Krones 

Well-packed: Crate used to transport the filler

BATCHFLUX 5500 C filling EMF with ceramic measuring tube

Krones' largest ever filler is completely equipped with BATCHFLUX filling EMFs from Krohne. Built for Coca-Cola Andina, Chile, the huge system is currently being commissioned at its destination in Brazil. It will be used to bottle (carbonated) soft drink products in a variety of bottle sizes ranging from 2.00 to 2.75 litres. In one hour, the machine can fill 37,000 2-litre bottles. And that is not even its maximum capacity: its capacity of 78,000 litres an hour means that the filler will be able to fill 3.0 litre bottles at a rate of 26,000 bottles per hour in the future.

Equally as spectacular as the performance data is the way the filler was transported: Krones packed the almost 30 tonne machine in a crate measuring nine by seven by 3.4 metres. It travelled over land from the Krones factory in Neutraubling to Hamburg, where it was then shipped to Brazil.

A total of 162 BATCHFLUX 5500 C devices are installed on the rotating filler. BATCHFLUX 5500 is an electromagnetic flowmeter (EMF) for the volumetric measurement of conductive liquids. As a so-called filling EMF, it was especially designed to be used with filling machines and features an extremely dimensionally stable ceramic measuring tube. It boasts high repeatability and long-term stability of measurement and is resistant, even throughout frequent hot water and vapour cleanings. Krones has relied on the quality and long life cycle of the BATCHFLUX for over 10 years and uses this type as the standard filling EMF.

About Krones: The Krones Group, headquartered in Neutraubling, Germany, plans, designs and manufactures machines and complete systems for process, filling and packaging technology as well as for intralogistics. Information technology and factory planning round out the company's portfolio. Millions of bottles, cans and containers are "processed" using Krones systems, especially in breweries, the soft drink industry and by producers of wine, champagne and spirits as well as in the foods and luxury foods industry and the chemicals, pharmaceuticals and cosmetics industries.

Programming & Modbus

Enhanced productivity features make updating programs simpler, and add high accuracy modes and a new Modbus TCP Client/Server functionality

GE Fanuc Intelligent Platforms has just announced the release of its latest VersaMax® Micro Plus controller firmware revision 4.0. The new release expands the controller’s applicability to an even wider range of applications by integrating some exciting new features and enhances the company's PLC family capability.

“With this release GE Fanuc has enabled the VersaMax Micro Plus to improve productivity, substantially expand communications connectivity, add high precision temperature sensing and increase the amount of devices that con be controlled with a low end controller,” said Bill Black, Controllers Product Manager for GE Fanuc Intelligent Platforms. “The VersaMax Micro is a surprisingly powerful PLC for its size and price, and the new features add more functionality, keeping it at the forefront of its class of controllers.”

The new OnLine Programming feature enables the user to edit and download logic to the PLC without stopping it. Not requiring a PLC to come off line for changes saves significant downtime and potential expense for lost productivity and scrap. The OnLine programming streamlines debugging during machine commissioning and is ideal for applications that are continuous process.

The VersaMax Micro Plus has been enhanced to support Ethernet Modbus TCP Client and Server protocol. This powerful communication addition enables the Micro to handle a wide range of applications that historically required a more sophisticated control platform. A simple function block enables the Modbus TCP communications commands to be easily integrated into the users logic. Up to eight Modbus TCP channels are supported with one channel configured for Modbus TCP Client and the remaining are used for Modbus TCP servers.

“The Modbus TCP connectivity enables the Micro Plus controllers to address many complex applications that require the integration of variable frequency drives, motor control centers, SCADA and other Ethernet devices. In addition, security settings have also been added to minimize hacking into the controller,” he continued.

The new VersaMax Micro 4.0 firmware release also supports High Accuracy Thermocouple/Millivolt and RTD input Modules. The Thermocouple and RTD expansion units can now support the High Accuracy mode with 16-bit resolution. This provides higher precision in temperature monitoring and strain gauge applications.

Additionally, there are four new 64-point expansion modules that are compatible with the new Micro Plus controller, so the Micro Plus can support up to 320 I/O points. The high-density expansion modules enable the Micro Plus to be very cost effective for low-end applications.

Console recorder

Message from the PR Rep of Lonwatch which accompanied this release: I’ve been a PR hack for 20+ years, and I’ve NEVER used the word “breakthough” to describe a client’s product. (I admit to once using “paradigm shift” back in the 1980s, and for that I apologize). As you know, most products are not breakthroughs, best-in-class, state of the art, award-winning, or leading edge, except in the mind of the vendor’s PR people. But this time I have such a breakthrough product! The Console Recorder from Longwatch is a virtual time machine, a software package that lets companies see what the operator was watching on the HMI when the plant blew up. It records the video signal to the HMI and archives it, so companies can see exactly what happened during an alarm, explosion, plant upset, leak or any other event. If three monitors are available, the company can put archived plant video on one screen, display what the operator was watching on another screen, and show data from the historian on a third screen—in other words, the company can reconstruct the EXACT situation as it occurred in the control room at the time of the incident. I will leave it to your fertile editorial imagination to consider what this might mean in terms of legal implications, accident investigations, event reconstruction, regulatory concerns, training, operator procedures and process control/automation in general. I am with child in anticipation of reading what you might say. Rich Merritt

Unique event, alarm or process upset record!
Video software records exactly what was on HMI screens when an event occurred, archives it, and plays the video back for training or analysis purposes.

Longwatch has launched the Operator’s Console Recorder, a software module that automatically records images being shown on multiple HMI or SCADA operator’s displays. The module takes its signals directly from each HMI screen’s video software driver, so it records the actual video being sent to the HMI. The software can accommodate video signals from an unlimited number of HMIs to show what operators were watching at the time of an event, alarm or process upset.

Few, if any, companies have taken the simple step of making sure that their human interfaces are delivering necessary information in a timely and unambiguous fashion so that the operators make timely and appropriate command actions. Playing back what the operator was seeing can be a very valuable method for troubleshooting, training and process improvement. It can also be an important tool to help analyse what went wrong, or what can be done to avoid future problems.

Video images can be combined with the automatic data mapping capability of their Video Historian, so the Console Recorder can automatically retrieve and replay operator displays simply by clicking on a time-based alarm or system message. Playing back what the operator was seeing at the time of an event can be a valuable tool for training and analysis purposes, and can help mitigate insurance and regulatory issues by eliminating guesswork and conjecture.

Videos used for monitoring plant activities can also be combined with the operator console videos and data from a process historian. This enables engineers, analysts or investigators to see what was happening in the plant, what the operator was seeing on the HMI screen at the time, and all relevant real-time data that occurred at the time of an event.

For example, in the case of a leak at a pumping station, investigators could watch plant video taken at a remote site showing fuel oil creeping across the floor of a pumping station, real-time data being acquired from pumps, valves and the receiving tank while the leak is occurring, what appeared on the operator’s HMI screen, and the alarm screen that came up when the leak detector went off. Investigators can then watch the operator switch the HMI screen to live video feed from the pumping station, observe the leak, and take action from the HMI to shut off the pump. Plant video would show the arrival of a maintenance crew to repair the leak. Analysis of all data and videos might show that the leak detector was poorly positioned and an alarm condition is needed for when fuel oil is being pumped but is not being received at the storage tank.

With a typical three-display system, as found in many process control applications, it would be possible to display remote pump video on one screen, video from the operator’s display at the time of the event on a second screen, and process historian data on a third screen, thus getting a simultaneous view of what happened and what the operator saw.

To help mitigate insurance and regulatory issues, the combined video and historian information could help determine that the operator acted correctly and the spill was cleaned up with no damage to the environment. The Longwatch Operator’s Console Recorder and Video Historian fills the gap between normal plant data acquisition and actual plant management, because it shows everything that happened during an event; i.e., what actually happened, what the data acquisition equipment monitored and recorded, and what was reported to the operator on the HMI screen.

"Capturing the actual video feed to the operator HMI is a much better solution than traditional methods," says Steve Rubin, president of Longwatch. “Before Longwatch, recording and playback of an operator’s HMI was clumsy and limited. One method was to put a camera over the operator’s shoulder. This is intrusive and intimidating, and the camera has a limited ability to read what’s on the screen,” he explains. “In an installation with multiple HMIs, this solution would require a camera on each screen.”

Another method is to use process historian data. “It’s possible to recreate the console display the operator should have been watching by driving it with data from the process historian,” says Rubin. “This requires the historian to record all the data values present on every display. However, no one knows which screen an operator was actually watching at the time of the event. An operator could have been looking at a trend display, not the alarm summary screen.”

With the Longwatch system, there is no problem reading the screens, and no doubt which screens operators were watching. By combining video data from plant locations, video from HMI screens, and data from the historian, investigators can go back in time to see exactly what happened and make a better analysis of what to do about a similar situation in the future.

Food ingredient flow

PD flowmeter system measures high-viscosity fluids in food ingredient applications
DC-F/IM system provides superior performance where batch repeatability is desired

Flow Technology (FTI) has announced the DC-F/IM (Ingredient Measurement) positive displacement (PD) flow meter system. Featuring a bearingless design with only two moving parts, the DC-F/IM is ideal for measuring high-viscosity fluids in food applications where batch repeatability is desired.

Food manufacturers use various flow meter designs to measure a wide range of thick and/or abrasive liquids, including chocolate, caramel, corn syrup, mayonnaise, frosting, etc. In many of these applications, however, higher viscosity requires that Coriolis meters be specified at a larger line size to minimize pressure drop, which inherently limits the low-end measureable flow rate compared to a smaller line size meter.

Employing Flow Technology's Decathlon Series DC-F PD flow meter, the DC-F/IM system helps improve quality control in food manufacturing. The DC-F/IM is suitable for measuring flow rates as low as 0.001 Gallons per Minute (GPM) and is designed for applications involving high pressure and pulsating flow streams. Due to its unique geometry, the PD meter can be utilized in the optimal line size, which minimizes pressure drop and enables accurate measurement across the entire desired flow range.

The DC-F sanitary PD flow meter employs 316 stainless steel construction, advanced thermoplastic impellers, and a non-intrusive pickoff sensor. The meter offers repeatability of +/-0.05% of rate and up to 1,000:1 turndown, and can measure viscosities up to 1,000,000 cP+.

Unlike some flow meter technologies, the DC-F/IM system is Clean-in-Place (CIP) compatible - ensuring a low cost-of-ownership. The PD meter can also be quickly opened in-line for inspection and physical maintenance if needed.

It is available for 1/8 inch to 2-inch lines sizes.