Batch Process Concepts

8/16/2019 Batch Process Concepts

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Colloquium Colloquium – Knowledge ‘ Of ’ ,’ By’, & ‘ For ’ YBI ans

What is Batch Process

• A process that manufactures a finite quantity of

material by subjecting measured quantities of raw

materials to a sequential order of processing

actions using one or more pieces of equipment.

• Where as Continuous process control

involves maintaining desired processconditions.


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Applications of Batch Package

• Food Processing Industries

• Paper Plants

• Pharmaceuticals

• Chemical Plants


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06/02/16


YOKOGAWA Batch Package

- SP88 founded (1988/10)

- SP88 draft 1 (1990)

1970’s

- DCS

developed

- Batch data block

- Sequence able

! " p l e " e n t e d b # D C

S

c o n v e n t $ o n a l f u n c t $ o n %

- !S& S88'01 (199/)

- !*C11+-1 (199,)

S88

01

Standard

CS 1000/000

P!C. CS data%etup/acqu$%$t$on funct$on

- SP88 part +

Micro XL

Recipe Mgmnt

C*23-4

5ec$pe 36"nt

C*23-7

5ec$pe 36"nt

CENTUM-XL

XL Batch

- 5ec$pe Data

- or"ula

- 5ec$pe

Procedure

- Plant

$erarch#

1980’s

C*23 CS

5ec$pe 36"nt

CENTUM C

C Batch

1990’s


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ca!a"!e#stem

ca!a"!e#stem Re$%n$ant&!at'orm

Re$%n$ant&!at'orm

(pen )

Re!ia"!e

(pen )

Re!ia"!e

*irt%a! Test+%nction


Re'ine$

,M

Re'ine$

,Mtr%ct%re$

&roce$%re

tr%ct%re$

&roce$%re +!e.i"!e

(peration

+!e.i"!e

(peration

E''icient

Engineering

E''icient

Engineering

!eatures


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"calable "ystem

#" $atch 1000 and 000

- ifferent application si!es

- Identical soft"are functions

&ro$%ction

ca!e

ma!!

imp!e/Non-critica! Comp!e./Critica!

Large

Comp!e.it#

- CS1000 80 - 8:000 ta6%

- CS000 1:000 - 100:000 ta6%

&C(T


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Recipe management

Batch management

Unit management (process unit control)

are the basic functions of $atch. %he application of these functions changes

based on the batch comple&ity.

#$pical characteristics of a %imple &atch processing

"ingle'stream used to produce a single product one

batch at a time

"mall number of recipe changes in formula (aluesA procedure that rarely changes

"ystem usually consists of one process unit

)perator interaction is a normal acti(ity

*ata collection is manual

+e(els of solutions to batch applications


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#$pical characteristics of a 'edium &atch processing

,ulti stream -multiple line capability

,ultiple batches running simultaneously on same or different lines

,any recipes or recipes are changed frequently umerous procedures or the sequence of production changes

many process units

)perator interaction is an e&ception

,uch data collection is required for (alidation etc.

#$pical characteristics of a Comple( &atch processing

"ingle'stream is used to produce products one batch at a time

-may be parallel lines

+arge number of product recipes

,ultiple procedures required to produce product (ariations

,oderate operator interaction is required as system is automated

*ata collection is moderate

+e(els of solutions to batch applications


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Features

ca!a"!e#stem

ca!a"!e

#stem Re$%n$ant&!at'orm

Re$%n$ant&!at'orm

(pen )

Re!ia"!e

(pen )

Re!ia"!e



Re'ine$

,M

Re'ine$

,Mtr%ct%re$

&roce$%re

tr%ct%re$

&roce$%re +!e.i"!e

(peration

+!e.i"!e

(peration

E''icient

Engineering

E''icient

Engineering


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)edundant Platform

+C- Re$%n$ant C&U

, Batch erer - Master ) Bac%p

*-net2&rocess 3ata ,igh4a#5

Compact +C

2+C5

tan$ar$ +C

2L+C5

&LC

ooo

Ethernet

Recipe

Management

EN6 ,Batch C!ient


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"tandard *isplaysuic #reation of O*er*ie"s+ Control and #rend GroupsAutomatic #reation of Faceplates+ #ag etails+ Process Alarms and %$stem Pages

Automatic #reation of Control ra"ings+ ,ogic Charts+ %euence #a&les+ and %.BO, for

Phase ,ogic

#ustom Graphic ispla$s

Eas# 6eneration o' (perator 3isp!a#s an$

%ic ccess to 3esire$ n'ormation

$atch *isplays)ecipe O*er*ie"+ Product %etup+ Product O*er*ie"+ Product etail and Batch /ournal

3rocedural #ontrol (ia 45# based %euence Flo" Charts for )ecipe Procedure+

0nit )ecipe+ Operations

Automation #reation of Operator Guides 'essages -read only confirmation input

request types

)perator 7eyboard with !unction 7eys

)efined 1uman 'achine Interface


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%tandard ispla$s


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"tandard *isplays

&nd: - Proce%% &lar" ;$ndo;

- aceplate ;$ndo;

- $%tor$cal report ;$ndo;

- Proce%% report ;$ndo;- S#%te" &lar" ;$ndo;

- !S Setup ;$ndo;

- S#%te" Statu% ;$ndo;

- Sequence able ;$ndo;

- Control Dra;$n6 ;$ndo;

- elp D$alo6 bo


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$atch *isplays


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.(ecution of )ecipe

1 $$ Ra4

3ischarge:

,eating ; $$ Ra4 B

1 $$ Ra4

3ischarge:

,eating ; $$ Ra4 B

$$Ra4

,eating 3ischarge

$$Ra4 B

1 $$ Ra4

3ischarge:

,eating ; $$ Ra4 B

1 nter!oc Chec

Lee! Lo4;

*a!e (pen

C!ose *a!e:

En$<

.perat$on

5e%ervat$on HIS Server/Clients

Master Recipe

FCS Unit : REACTER-A

RecipeManageent


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Fle(i&le Operation

Unit 1

Unit ;Unit

• $namic 0nit Assignment

• #he Operator can select "hich 0nit to &e used for 0nit )ecipe 2 &efore ischarging

• #he Operator can select the 0nit depending on the current a*aila&ilit$ of 0nits andthe priorit$ of the Batches to optimi!e the plant performance

1 Unit Recipe 1

Unit Recipe

Unit= co!!ection o' associate$ e!ements/contro! mo$%!es

) e>%ipment mo$%!es/that per'orms the coor$inate$

+%nctions? %nit operates re!atie!# o' one another ?


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Generic 3ame

%euence ,i&rar$- 0nit Procedure+ %FC %euence

0nit %uper*ision- %tatus #ransition 'atri(+ 'ain Program e(ecution+ Interrupt processing+

'onitoring Operation+ 0ser efined data

3ormal %euence 4 .(ceptional Processing

%tandard ,anguages according to I.C 5565-6- Function Block iagram 7Control ra"ing8+ %euential Function Chart 7%FC8+

%tructured #e(t 7%.BO,8+ and others 7,ogic Chart+ %euence #a&le+ Calculation Block8

)ecipe %tructure

5educ$n6 otal Co%t of .;ner%h$p

.fficient .ngineering


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8eneric ame

=C101

>

>

>

? ? ? ? ? ? ? ? ? ? >

>

>

4101

3101410+

+LT101

410

@**5!C &3*

&@ 23B*5

&C2& 2!

101 +01

=!1

!1

41

4+

4

3

=!C101

41.1

410+

410

3101

4+01

4+0+

4+0

3+01

??? +01

???

4+01

4+0+3+01

+LT01

4+0

+01

• Generic 3ames are designed for 0nits9

• All the %euence logic are implemented "ith Generic 3ame+ not "ith actual #ag

3um&er• .ach 0nit has the con*ersion ta&le &et"een Generic 3ame and #ag 3um&er9

• If not a*aila&le+ #ag 3um&er for Generic 3ame does not ha*e to e(ist in some 0nits9


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"equence +ibrary -"hared "equence

• "!# "equence +ibrary

• 9nit 3rocedure +ibrary

• "5$)+ 9ser !unction

=C101

>

>

>

? ? ? ? ? ? ? ? ? ? >

>

>

4101

3101410+

+LT101

410

@**5!C

&3*

&@ 23B*5

&C2& 2!

101 +01

=!1

!1

41

4+

4

3

=!C101

41.1

410+

410

3101

4+01

4+0+

4+0

3+01

??? +01

???

4+01

4+0+3+01

+LT0

4+0

+01

1 nter!oc Chec

Lee! Lo4;

*; (pen

C!ose *;:

En$<

SC Sequence

5ack$n6(for 101)

Operation

5ack$n6(for +01)

Operation


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3rocess *isplay

FIC

CS

FWVCS

CIP

CO2V

AIRV

RESTV

CO2V

AIRV

RESTV

PICPIC

VCMV

SFTYV

FTKLSM

FTKV1FTKV2

PUMP

CLV1

CLV OPV

CLV

TTKV2

CLV

TAV01TAV02

TTKV1

FTKLSM

SFTYV

VCMV

FTT ST


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!perati"n

Pre 5$n%e

5ack$n6

nl 5$n%e

Trans#er $r"ced%re

#r" Ferentati"n

tan& t" St"rage Tan&

Recipe Unit $r"ced%re

Pr Control

Aater Cut

ran%fer

Aater Pu%h

!n$t$al$e

+8 C!'P4

1

C!'P4C!101'P4

C!S* 1

Step

$'ase

1 E 4&4* .P* &DC.D2C!4!F C*CG E

+

E

E

E

+, dr$ve H4401.P*I

*rr1

+8 ;a$t unt$l (C!'P4 J C!S*)

E

E

EB(L/ e>%ence

Ta"!es/ or Logic Charts

"tructured 3rocedure

!n$t$al$e

Pre 5$n%e

5ack$n6

nl 5$n%e

*nd


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*esign of 9nit

• A group of equipment

: ;esident 9nit ''' !i&ed 9nit 3rocedure

: on';esident 9nit ''' ;ecipe 9nit 3rocedure

Unit

Unit Unit

Unit


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'A3AG.'.3#

'AI3 .:.C0#IO3

#onfiguration of 9nit

BNORM L PROCESSING

'O3I#O)I3G

I3.P.3.3# %.;0.3C.

STATUS CHANGE COMMAND

STATUS MODE SUSPEND PAUSE

RUNNING AUT PAUSED.A.PAUSA

SEMI PAUSED.A.PAUSA

MAN

AUT

SUSPEND

#)A3%I#IO3 'A#)I:

03I# I3%#)0'.3#

%euence general

configuration

AF#.) PA0%.

P)OC.%%I3GONDITION CHECK

V LVE OPER TION

ME SUREMENT

'AI3 .:.C0#IO3

P)OG)A'

AB3O)'A,

P)OC.%%I3G

INITI L

PROCESS

END

03I# ).CIP.

P)OC.0).

AF#.) %#OP

P)OC.%%I3G

AB3O)'A, P)OC.%%I3G

'O3I#O)I3G


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%tate #ransition 'atri(

• 0sers< 0nit Operation 'ethod can &e implemented

• Actions and %tatus are 0ser configura&le

Co""and

Statu% 3ode

PS&5 P&2S* S*P 5*S*

&B.5*D &ut

Se"$

3an

*1D: &: *1D

*1D: S: *1D

*1D: 3: *1D

5211!1@ &ut

Se"$

3an

P&2S*D: &: P&2S&

P&2S*D: S: P&2S&

S2SP*1D &ut

Se"$ 3an

S2SP*1D: &: S*P

S2SP*1D: S: S*P

P&2S*D &ut

Se"$

3an

*1D &ut

Se"$

3an

5211!1@: &: S5&

5211!1@: S: S5&

Total 9

en$

pstart

&a%se

restart

repeat

scomp

step

en$

3LE RUN EN3

&UE3


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21! 3&1&@*3*1 D*&!8S

9!S 21! !S S&5*D 3&12&88F .5 BF S.3* .9*5 21!

9* &C!4!F D.1* BF 9!S 21! !S @!4*1 B*8.A'

・5*C!*P .0 .9*5 P5.C*SS A9!C9 9&S B**1 S&5*D

・5*C!*P .0 .9*5 P5.C*SS A9!C9 9&S B**1 C.3P8**D

・C.1D!!.1 C9*CG B*0.5* S&5!1@ &1F P5.C*SS

・8!1*2P D&&B&S* D.A18.&D

・P5.C*D25* D.A18.&D

D&& S* 21! C9*CG 9* D&& S* 0.5 9* 1*7 B&C9

C.1D!!.1&8 C9*CG B*0.5* S&5!1@ 9* P5.C*SS '

・&1G K 8!1* S&2S C9*CG

・C!P 8*0 .2 !3* C9*CG

・*=2!P3*1 !1SP*C!.1 C9*CG

・S&0*F/4&CC23 4&84* S&2S C9*CG

・&1G 8*4*8 C9*CG

・P5*SS25* C.15.8 C9*CG

・.9*5 C9*CGS B&S*D .1 9* P5.C*SS

&1G/8!1* D&&

S.5&@* 21!*&C9 &1G/8!1* D&& A!88 B* 2PD&*D

C!P 21! &2 C!P 5*=2!5*D/1.、C!P P&*51 S*8*C!.1 95.2@9 @5&P9!CS'

P5.C*SS3&1&@*3*1 21!

C.1D!!.1 C9*CG 21!

*&C9 P5.C*SS 、A!9 5*SP*C . *&C9 &1G A!!8 B* 3&D* &4&!8&B8*

0.5 *&SF .P*5&!.1。P5.C*SS 21!

8!1*2P !10.' 21! 8!1* 2P !10. A!88 B* P5.4!D*D B&S*D .1 9* P5.C*SS S*8*C*D !19& 8!1*'

5ach 9nit ,anagement *etails


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5&ception 3rocessing

• ;esponses to 5&ceptions can be programmed in dedicated $loc

• 5&ception ;esponse can be initiated by<

Other 0nits 7%ignal8

Operator 7%tatus Change Command e9g999 Pause+ )estart88

.perat$on% act$ve $n a Batch un$t

1 $$ Ra4

Reaction:

,eating ; $$ Ra4 B

Unit &roce$%re is $etermine$ "# theRecipe Monitoring (peration is a!4a#sctie

@ contin%o%s e.ception chec

(n nterr%pt Asigna! &RE-,6,

L1/;

(n nterr%pt Atate ChangeL1?:

L1/;

@ Reactor press%re is too high

UNT D T(&

RECT?mo$e D AMN

$rie ,ET - *L* D CL(EF

Monitoring

" d d +


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"tandard +anguages

TM&,EF?op D TMTRT @ tart

timer

ERECT?mo$e D AUT @Ena"!e

$rie C& - *L* D (&ENF

$rie C& - &UM& D (NF

&,E D ACLENN6

$e!a# 1000 @ C& 'or min%tes

$rie C& - &UM& D (++F

K

S

5

.5

Logic Chart 2B35

EB(L

e>%ence 3ecision Ta"!e

Cond$t$on F

F F F

&ct$on

F F F

(peration

&roce$%re

Unit &roce$%re

&hase

88?01


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;ecipe "tructure

Recipe G Recipe G 1

1 &reparation

+i!tration;

Reaction

: Centri'%gation

Recipe &roce$%reUnit Recipe G Unit Recipe G 1

1 $$ Ra4

Reaction:

,eating

< 3ischarge

; $$ Ra4 B

+orm%!a

&roce$%re Charge = 100 LCharge B = 7< L

,eat time =


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- 5educ$n6 ProLect ead $"e

- *n6$neer$n6 and e%t $n the off$ce

6eneration6eneration

3esign3esign

TestTest

=irtual #est Function

1 d . i


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Pro>ects .(ecuted ?

1ands on .(perience

%untor$ 7Beer Process8 %$stem C%6@@@ FC% ?2@ 1I% ?

Asahi enka 7Cake Process8 %$stem C%6@@@ FC% ? 1I% ?

.,CO 7,u&e Oil BlendingGrease8 %$stem C%6@@@ FC% ?2 1I% ? 2

Recipe

Management

Unit Supervision

Batch Design

User deined !"S

"ustomi#ed Batch report

$%Sign ool

Standardi#ation o Batch

Gu>i Film 7Film Process8 %$stem C%6@@@ FC% ?2 1I% ?

#akeda Pharma 7#a&lets Process8 %$stem C%6@@@ FC% ?D 1I% ?

"omple'it o Batch Batch report

Wh t i B t h ) tEE


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What is a Batch )eportEE

Reports containing process & user supplied

information,collected manually orautomatically,

before, during, and after completing thebatch.

! 9 * fi iti


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Tool used to modify the FCS Databaseaccording to

the requirement.

!cs 9ser *efinition

B t h 0 i = %i # l


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Batch 0sing =-%ign #ool

VSign means Visual Sebol des!"# $tilities.

•Dra% a o% Chart for Sequential functions%ith custom Visio Shapes 'S()*+ parts.

•Con-ert Flo% Chart to S()*+ code.

•Creation of ne% custom Visio shape 'S()*+ parts.

•Database management tool to register or modify a Visio

Shape 'S()*+ parts and S()*+ code lined %ith it.

'erits of Batch Package 5


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'erits of Batch Package-5

3ro(ides a cost effecti(e solution-%emplate usage

3ro(ides better recipe management-)ff'line recipe creation with any 3# pro(iding security for confidential files

4mpro(e design simplfy your installation

;educe integration engineering requirement-%ag assignments for status and alarmfunctions/3redefined data transfer.

3ro(ides 3roduction enhancement

,anage recipe changes on the plant floor


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'erits of Batch Package-2

3ro(ides information about batch status-3re'defined ,onitoring/"ummary screens

;educe product changeo(er time<

;unning multiple batches simultaneously-%racing/%esting/continuing

9se consistency basic operator interface

"oftware screens communicate info to operator in ordinary batch language

terminology such as procedure/operation/formula/phase etc as per 4"A standards.

'erits of Batch .ngineering =s %;#


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'erits of Batch .ngineering =s %;#

Batch

1. 5ase of 9nderstanding

2. $uilt in feature for )peration "tart

. $uilt in feature for ,essaging

>. o restriction for messaging in lengthwise can be dynamic

?. $atch set data ma& of 2?6 with arraydefinition is possible

6. 3rogram can be written any no of lines upto 102> bytes and this can also beincreased.

@. A(ailability of built in functions -gettime /get date

. "ub routine programs facility a(ailable

B. 8eneric name concept is one of major merit

10. %emplate "tandardi=ation is possible whichreduces the 5ngg. Acti(ity helps in ;e(ampor addition in future.

11. 3rogram can be written in te&t file and can be imported later.

%euence #a&les

1. 9nderstanding is *ifficult

2. "tart )peration to be defined in some

other table

. ,essaging through builder

>. ,essaging length wise is restricted in the builder

?. $atch "et data blocs are restricted per!#".

6. )nly 2 #onditions/Actions can bedefined per sequence table.

@. o built in function as such

. "ub routine Achie(ing thru "% isdifficult.

B. o such concept

10. %emplate "tandardi=ation is not possible5ngineering acti(ity is more.

11. #reation to be done in builder only

3acages Cith ;ele(ant !unctions


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3acages Cith ;ele(ant !unctions

%l93o escription 3ecessar$ Package Function )emarks1. "uper(isory computer 4nformation ,anagement "ystem

pacages -%ouchu4nformation from this 3# will

be down loaded to 58"

2. 58 ' 5ngg. "tn. #"$atch 1000/000 $uilder3acage-3D" ?160/+D" ?160

All the builder le(eloperation and down loadingto !#" can be done using this3# and all master files will

be a(ailable in this.

. D4" $atch ser(er 1000/000 ;ecipe ,anagement3acage-3D" ?161/+D" ?161

All receipe files creation anddown loading to D4" will bedone using this 3#.

$ac'up 1000/000 ;ecipe ,anagement3acage-3D" ?161/+D" ?161

"ame function as that ofmaster can be achie(ed inthis.%his acts as a bacup for

the master but when themaster fails EAuto changeo(erF is not a(ailable.G,anual change o(erG to bedone by operator.


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5+#)


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Documents

Batch Process Concepts