Invensys Operations Management PBPC323 - Foxboro PAC for Simple Batch operations

2. Invensys Operations ManagementPBPC323 - Foxboro PAC for Simple Batch operations Jamie Stapleton Technical Product Portfolio Manager November, 2011

3. Agenda • Introduction • Where does PAC fit in the InFusion Enterprise Control System • Markets and Requirements • What are the challenges with Simple Batch Implementation? • PAC solutions to S88 modeling • Secure data recording for Electronic Batch Records (EBR) • Does this meet the market challenges? • Q&A • How the S88 based implementations with Foxboro PAC can be easy?

4. Introduction Foxboro PAC

5. Invensys Enterprise Control Offerings Corporate Systems Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Corporate Software Applications Invensys and Third Party Manufacturing / Production Operations Automation Invensys and Third Party Enterprise Control System IT Platform Integration and Collaboration Platform

6. PAC, SCADA and Enterprise Control Execution Integration & Collaboration Platform Enterprise Asset Management Mobile Workforce Management Manufacturing Execution Systems Batch Performance Software Applications Enterprise Manufacturing Intelligence Performance Measurement and Reporting Asset Performance Enterprise Integration Visualization Quality Optimization Workflow Advanced Process Control Simulation / Optimization Design Operator Training Third-Party Offerings Open Device Integration Web Portal Control DCS PAC SCADA HMI Automation Software Applications Application Toolkit Safety Turbomachinery Control Safety Instrumented Systems General Purpose Safety Historian Measurement & Instrumentation Recorders Instrumentation Controllers

7. It’s more than “just the hardware”. • Although the focus of this presentation is primarily about the Foxboro PAC product, it is important to keep in mind that it is the plant floor to top floor integration capabilities that can maximize the value that we can bring to a customer. From standalone control, to fully integrated systems, it’s more than just the hardware.

8. Foxboro PAC System - Overview • Wonderware Pack Software - Enterprise wide visualization • Proven Scalable Architecture with ArchestrA System Platform inside • Versatile scalable suite of software tools to ease the configuration workload, with extensive object symbol libraries • Store and Forward, Historian ERP and MES connectivity • Eycon - Visual Supervisor • Panel Mounting, Touch screen, Display and Control • Alarm Management, Batch, Recipe, Setpoint programming Open communications • Auditor software - 21CFR part11 compliant access control • T2750 PAC & T2550 PAC - Programmable Automation Controller • Maximises Process up time - High Availability Processor and I/O • Redundant Continuous & Sequential control and Data Recording • Signal conditioning and Direct field connection of universal I/O • Start Small - Grow Big: Ideal for New and Retrofit Applications

9. A2 Scalable System solutions we have today Foxboro PAC Solutions Eycon10/20 HMI Visualiser Historian HMI- Visualizer HMI- Visualizer Server T2750 (PAC) T2750 (PAC) T2750 (PAC) Control & I/O Small Systems <1000 I/O Unit Systems <250 I/O Large System & Cluster >3000 I/O

10. Markets and Requirements Foxboro PAC

11. Vertical Markets – Market Positioning High L E V E L O F A U T O M A T I O N Classic DCS PLC + HMI Refining Automotive Oil Chemicals Aerospace Gas Power Hybrid Markets -PAC Machine Parts Pulp & Paper Beverage Semiconductor Metals Fine Chemicals Food Water Pharmaceutical Glass Biotechnology Mining Low Scientifically-Oriented (Process) Craft-Oriented (Batch) Mechanically-Oriented (Discrete)

12. PAC System Requirements • Hybrid Markets PAC • Single vendor • Tightly integrated • Upward scalability • Downward scalability • Built-in Redundancy • High Availability • Flexible architecture • Low Entry - scalable • Central Configuration • Prebuilt interface • Lifetime support • Local SI support • Classic DCS • Single vendor • Tightly integrated components and common platform • Good upward scalability • Poor downward scalability • Built-in Redundancy • High Availability >99.999% • Moderately flexible architecture • High Entry Cost • Central Configuration • Prebuilt Operator interface • Lifetime support • PLC + HMI • Multi vendor • Loosely integrated components , many platforms • Poor upward scalability • Good downward scalability • Custom Engineering • Normal Availability • Highly flexible architecture • Low Entry Cost • Many config environments • Custom operator displays • Local SI support

13. Glass : Float, Bottling, Fibre, Solar Power : Biomass, Incinerators Small power plant < 150MW Renewable energy Metal : Heat Treatment Target Applications Target markets • Utilities : • Burner Management • Boiler Management • Pharmaceutical : • API, • EMS/BMS • Wastewater : • Municipality, • Industrial, • Desalination • Water Treatment

14. What are the challenges with Simple Batch Implementation? Foxboro PAC

15. Challenges with Simple Batch Implementation What are the challenges with simple batch process system implementation? • Simplify the architecture for single path type batch • Reduce Lifecycle Engineering costs • S88 Process Modeling • Easy (non complex) model implementation on the control system • Reduce documentation (validation) • Improve Compliance and Governance • Electronic Batch Records and reporting • 21CFR Part 11 • Increase Product quality

16. Simplification of the Architecture For these type of OEM machines, how can I simplify the architecture with keeping the full flexibility of the functionalities? Single use bioreactor Hospitals Multi chambers washer

17. Challenges with batch engineering

18. Challenges with batch records Exclusive contribution for Process PharmaTec - issue 01/2004

19. Challenges with batch records Sep 1, 2003Pharmaceutical Technology Europe

20. PAC Solutions to S88 Modeling Foxboro PAC

21. PAC Solutions to S88 Modeling • Batch engineering with Foxboro PAC • Solution architecture presentation • Demonstration of the different PAC S88 components • Identify the value generated by the Foxboro PAC

22. PAC Solutions to S88 Modeling Simple Architecture 1: (Option) FTP server for records & reports Redundant ‘Control’ Ethernet Network (ELIN – FTP – SNTP) UNIT1 USB

23. PAC Solutions to S88 Modeling • Simple Architecture 2: (Option) FTP server for records & reports + HMI Reports Redundant ‘Control’ Ethernet Network (ELIN – FTP – SNTP) “Clean” side “Dirty” side UNIT1 Transfer UNIT2 USB

24. PAC Solutions to S88 Modeling • S88 Model components required at the controller level: S88 Control Modules

25. PAC Solutions to S88 Modeling • S88 Model components required at the controller level: Dosage S88 Equipment modules S88 Phases Temperature controller

26. PAC Solutions to S88 Modeling • S88 Model components required at the controller level: Eycon S88 Unit – Recipes & Batch

27. PAC Solutions to S88 Modeling

28. PAC Solutions to S88 Modeling • PAC S88 Phase:

29. PAC Solutions to S88 Modeling • PAC S88 Phase:

30. PAC Solutions to S88 Modeling • PAC S88 simple recipe:

31. PAC Solutions to S88 Modeling • PAC S88 complex recipe:

32. PAC Solutions to S88 Modeling • PAC S88 Batch package:

33. PAC Solutions to S88 Modeling • PAC S88 Batch records:

34. PAC Solutions to S88 Modeling • Complementary value to Wonderware InBatch • Phase logic function blockdesign for InBatch in simpler implementations • High availability (Native controller redundancy) • Distributed system for unit control • Phase sequence files checksum controlled for validation purposes • Shared resource functionality for control modules • Local devolved phase control & HMI to secure a batch control

35. PAC Solutions to S88 Modeling Architecture: Galaxy Repository Information Server (Option) Historian Server TIER 2 InTouch (TS) Operator Clients Web Clients (Option) Historian Server TIER 1 & InBatch Historian Ethernet Data Network (with Firewall) InBatch Development clients Redundant (option) Communication Application Engine 1 & InBatch Server Redundant ‘Control’ Ethernet Network (ELIN – FTP – SNTP) UNIT1 CIP1 UNIT3

36. Store and Forward Extension for securing data recording for EBR Foxboro PAC

37. Store and Forward extension • Wonderware PAC Software, Foxboro PAC hardware and Eurotherm recording devices solutions to “minimise” data loss T2750 & T2550 Historian tags and Area/Alarm groups Mapping to hardware recoded tags Eycon 6000 recorders FTP / Ethernet Store and Forward extension service Wonderware Databases nanodac FTP Server

38. Store and Forward extension • Foxboro PAC, Eurotherm recording devices solutions to “minimise” data loss • Simplex or Redundant Processors • Simplex or redundant data logging with Profibus & Modbus communication • 32 MB logging capacity (on board non volatile flash) • up to 3 FTP server & up to 2 SNTP server for time synchronisation • Full integration to System Platform with Wonderware PAC • 21 CFR Part 11 tamperproof records Intelligent HMI including data management • Continuous and Batch data logging with Profibus & Modbus communication • 45 MB logging capacity (on board non volatile flash) • up to 3 FTP server & up to 2 SNTP server for time synchronisation • Full integration to System Platform with Wonderware PAC • 21 CFR Part 11 tamperproof records

39. Store and Forward extension • Store and Forward Extension solution to “minimise” data loss • Secure local historian files: • Tamperproof files • Checksum verification for corruption • Encryption • Contains time stampedprocess values • Contains time stamped Alarms and events • 21CFR Part11 compliant • Backward compatible for 20 years • ODBC interface (Data Secure ODBC)

40. Store and Forward extension • Store and Forward Extension solution to “minimise” data loss • When new hardware data set is available: • Query Historian server for data gaps • Update its analysis context and log files • Fill in Historian with the missing data • Secure writes to Historian API • Fill in Alarm history database • Secure writes to Alarm DB logger • Run as a service • Uses service networks accounts Historian tags and Area/Alarm groups Mapping to hardware recoded tags Store and Forward extension service

41. Store and Forward extension • Store and Forward Extension solution to “minimise” data loss • Compliancy: • Windows 32 bits OS (XP, 2003 Server) • Wonderware Historian 9 & 10 • ArchestrA System Platform 4.0 • Uses standard IIS FTP server • Works at UTC Time stamp level Historian tags and Area/Alarm groups Mapping to hardware recoded tags Store and Forward extension service

42. Does This Meet The Market Challenges? Foxboro PAC

43. Does this meet the markets challenges? • Accurate and secure records • Reduce Manufacturing cost • Achieve Faster Time-to-Market and Enhanced Productivity • Increase Product Quality • Improve Compliance and Governance • Electronic Batch Records and reporting • 21CFR Part 11 • Reduce Lifecycle Engineering costs • Central definition of equipment, independent master recipes & flexibility of phases management • Enforcing recipe procedures • Full 21CFR Part 11 compliant solution • Unique Invensys proposition • Full S88 compliancy across the complete solution

44. Does This Meet the Markets Challenges? • References & major successes: Ultra filtration Skids for Biotech industry Foxboro PAC T2550 and Eycon Multiple units has been delivered to the same end user. Simplicity of duplication Multi chamber washer for hospitals Foxboro PAC T2550 and Eycons We have delivered with this OEM 5 machines across the world

45. Questions and Answers Foxboro PAC

46. Thank You Hardware and Software Solutions for Real Time Success