Batch Management Package

Technical Information
TI 33M05L10-40E
VP Batch Batch Management Package
Yokogawa Electric Corporation 2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan Tel.: 81-422-52-5634 Fax.: 81-422-52-9802
TI 33M05L10-40E Copyright Oct. 2010 (YK) 1st Edition Oct. 2010 (YK)
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Introduction
The VP Batch is the CENTUM VP Batch Management Package. VP Batch is designed for the management of batch operations with the CENTUM VP Integrated Production Control System. It has been derived from Yokogawas extensive experience with distributed control systems (DCSs) and wide-ranging batch applications, and complies with international standards of batch processes.
Documentation Conguration
This manual is composed of the following chapters: Chapter 1 introduces the concepts of batch processes. Chapter 2 covers ISA-88 compliance of the VP Batch software. Chapter 3 summarizes the VP Batch software. Chapter s 4, 5 and 6 describe its recipe management function, process management function, and unit supervision function. Chapter 7 describes the VP Batch Operation and Monitoring Windows. Chapter 8 introduces the Access Administrator function (FDA : 21 CFR Part 11) Chapter 9 is a glossary of terms.
Applicable Readers
This manual is intended for instrumentation/electrical engineers with basic knowledge about DCSs, who want to know the outline of VP Batch or are considering their application.
All Rights Reserved Copyright 2010, Yokogawa Electric Corporation
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TI 33M05L10-40E 1st Edition
CONTENTS
1. 2. 3. Batch Processes ...................................................................................... 1-1
1.1 Requirements for DCS Manufacturers ........................................................... 1-3
ISA-88 compliant VP Batch ..................................................................... 2-1 Overview of VP Batch Software .............................................................. 3-1
3.1 3.2 3.3 3.4 3.5 Recipes .............................................................................................................. 3-2 Recipe Structure ............................................................................................... 3-3 Recipe Setup and Downloading ...................................................................... 3-5 Batch-Operation Monitoring ............................................................................ 3-6 Unit Supervision ............................................................................................... 3-7 Overview of Recipe Management ................................................................... 4-2 Header ................................................................................................................ 4-4 Procedure .......................................................................................................... 4-5 Formula .............................................................................................................. 4-7 Equipment Requirements ................................................................................ 4-7 Access Control Function ................................................................................. 4-8 Overview ............................................................................................................ 5-2 Control Recipe Setup ....................................................................................... 5-3 5.2.1 5.2.2 5.3 5.4 5.5 5.6 Control Recipe Setup ......................................................................... 5-3 Reuse of Control Recipe .................................................................... 5-5
4.
Recipe Management Function ................................................................ 4-1

4.1 4.2 4.3 4.4 4.5 4.6
5.
Process Management Function.............................................................. 5-1

5.1 5.2
Batch Control .................................................................................................... 5-7 Batch Results .................................................................................................. 5-13 Server/Client Function Redundancy ............................................................ 5-16 Production Planning and Scheduling Interface ................................................. 5-18 Unit ..................................................................................................................... 6-2 Unit Data............................................................................................................. 6-3 Unit Procedure .................................................................................................. 6-4 6.3.1 SFC Language ................................................................................... 6-5 Operation ........................................................................................................... 6-9 Unit Mode and Status ..................................................................................... 6-11
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6.
Unit Supervision Function ...................................................................... 6-1

6.1 6.2 6.3 6.4 6.5
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6.6 6.7 6.8 6.9 Initialization and Monitoring Operation ........................................................ 6-13 Using Generic Name and Sharing Resources ................................................6-14 Status Transition Matrix ................................................................................. 6-15 The denition of link between Common Block & Operation ..................... 6-16
7. 8. 9.
VP Batch Operation and Monitoring Windows ..................................... 7-1 FDA : 21 CFR Part 11 Compliant ............................................................. 8-1 Glossary .................................................................................................... 9-1
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1.
Batch Processes
This chapter denes the word batch processes.
Batch Process
The term batch process is commonly used in contrast with continuous process. The continuous-process operation is performed continuously without any shutdown, often extending for a year or longer, at oil reneries and power plants, for example. In a continuous process, raw materials are input and products are output at the same time while maintaining steady states of temperatures, pressures, and so forth. The operation of distillation columns is a typical example. The batch-process operation is performed repeatedly in a cycle of a few hours or days. A recipe is used for process actions of charging, heating, reaction, cooling, and discharging, for example, in every operation cycle, to output a predetermined quantity of product, or a batch, in a predetermined period of time. The operation of reactors is a representative example. A batch process features an increase in operation frequency to increase production quantity and processs applicability to production of other products. A batch process applicable to only one product is called a single product process and one applicable to a number of products a multi-product process, which are further classied into single-path, multi-path, and variable path structures according to how the processes are incorporated in a plant. Thus there are the following types of batch processes: Single-path, single-product process (see below) Multi-path, single-product process (see next page) Single-path, multi-product process (see next page) Multi-path, multi-product process Variable-path process (see next page)
F010101.ai
Figure Single-Path, Single-Product Process
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Figure Multi-Path, Single-Product Process
F010103.ai
Figure Single-Path, Multi-Product Process
F010104.ai
Figure Variable-path Process
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1.1
The control of a batch process is dependent on the close alliance of continuous control and sequence control as in the control of a reactor. Now users demand the following DCS for batch processes:
Requirements for DCS Manufacturers
Adaptability
A DCS has a number of recipes in order to use the same group of equipment for production of different products. Each recipe contains data (charging volume, temperature setting, etc.) and process-phase control procedure. The DCS must exibly perform operation even if recipes and procedures vary. In batch processes, new recipes are often added. The new recipes may be different from the old ones in data and procedural combination only. In this case, new recipes must be added without affecting processes. The DCS must also support all types of batch processes from a single-path, single-product process to a variable process.
Easy Operation
Although DCS windows may be modied if batch-process recipes or procedures are varied, the standard windows should be used for uniformity in operation and monitoring and easy operation. In batch processes, an operation monitoring window is also required for every control unit because a batch process is often separate from each other.
Open Environment
It must be easy to download recipes and schedules from a supervisory computer, and to upload batch production data to the computer.
Compliance with International Standard (ISA-88.01 and 21 CFR Part 11)

ISA-88 of U.S. and NAMUR of Europe are working on standardization of batch process. Also, complying with 21 CFR Part 11, the regulation of electronic records and electronic signatures established by FDA (Food and Drug Administration) of U.S., is a recent key issue of the pharmaceutical companies. To increase internationalization of production, selecting the standardcompliant packages for batch process control is vital for enterprises.
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Higher Engineering Efciency

It is said that every batch control varies and is not uniform, and the programming of a batch process takes more time than that of a continuous process. By dividing programs in to layers, than sharing and reusing them, efciency in the programming and maintenance can be improved. The VP Batch is designed to automate and systemize batch processes to fulll these demands.
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2. ISA-88 compliant VP Batch
2-1
2.
ISA-88 compliant VP Batch

This chapter covers ISA-88 compliance of VP Batch software. For VP Batch software, see Chapter 3.
ISA-88
The Instrument Society of America (ISA) -88 Batch Control Standards Committee has been organized to provide batch control standards. The Batch Control Part 1: Models and Terminology was released as ISA-88.01 in 1995. Purpose To dene terminology, models and functions for batch manufacturing plants and batch control system. The standardization of terminology, models and functions does: Promotes optimum plant design and operation, Improves batch control, Increases applicability.
ISA-88.01 Physical Model

The ISA-88.01 presents a number of batch-process models including Physical Model. The following gure shows the relationship between Physical Model and VP Batch software.
Enterprise Site (factory) Area (plant) Process cell Unit Equipment module Control module
Production management
Recipe group/Train Unit (instrument) Operation Function block SEBOL block Sequence table block Logic chart block <VP Batch>
F020201.ai
Figure ISA-88.01 Physical Model & VP Batch
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The Physical Model divides physical resources of an enterprise into seven hierarchical levels the upper three levels (enterprise, site, area) have not been discussed in detail in ISA-88.01 because of their business-oriented nature. The lower four levels (process cell, unit, equipment module, control module) are provided by grouping devices or equipment through batch engineering. A process cell is composed of more than one train. A train is a group of units required to perform each batch operation. A unit executes a procedure such as reaction, recovery and drying. An equipment module executes an operation such as charging and measuring. The following gure shows the relationship between ISA-88.01 Control Activity Model and VP Batch software. The model illustrates the total image of batch control and inter-functional relationships various functions are required to perform batch-process operation, which are described in Chapters 4-6.
Recipe management (*1)
Production planing and scheduling
Production information management
Process management
Unit supervision (*2)

*1:
: Covered by the VP Batch software
Process control (function block)

*2:
The ISA-88.01 Recipe Management covers general, site, master, and control recipes, but the VP Batch software supports master and control recipes. The Unit Supervision has standard FCS functions. It runs by itself, without VP Batch Recipe Management and Process Managenent packages.
F020202.ai
Figure ISA-88.01 Control Activity Model & VP Batch
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3. Overview of VP Batch Software
3-1
3.
Overview of VP Batch Software

The VP Batch is designed to simplify installation of a batch program on the CENTUM VP system and implement full capabilities. The VP Batch is comprised of recipe management, process management, and unit supervision, as shown in Chapter 2. The following shows the ow of a typical batch operation and the relationship among the three parts.
General Purpose PC Recipe Creates a product recipe containing data and procedures. mgt. or HIS
1. Selecting a recipe for product. 2. Assigning unit and batch ID (setup). 3. Downloading a recipe to FCS and giving start Process command. HIS mgt. 4. Monitoring batch-process operation. 5. Receiving operationcompletion notification and collecting operation data. 6. Deleting a recipe.
1. Receiving batch ID, procedure, data, etc., by downloading a recipe. Unit 2. Starting specified unit upon FCS supervision receiving start command. 3. Notifying processmanagement of operationcompletion.
F030001.ai
Figure Flow of Batch-Process Operation
Some conventional batch packages permit programming variable data in recipes and downloading the data to the controller when the operator commands it. Unlike these packages, the VP Batch software control the entire function of batch-process operation. The software have the following features: They can modify procedures as well as formula. They have their own control data and algorithms. They have unied windows for batch-process operation. The VP Batch software show sequential function charts (SFC) as operation windows regardless of recipes with different procedures it is not easy to provide such exibility with graphically created windows. They comply with ISA-88.01. They are designed in modules and hierarchy. The ow of a batch-process operation is divided into four sections to cover VP Batch: Recipe structure Recipe setup and downloading Batch-operation monitoring Unit supervision
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3.1
A recipe is an entity that contains the minimum set of information that uniquely denes the manufacturing requirements for a specic product. The ISA-88.01 standard denes four types of recipes as shown below, according to the required actions, resources, and so on. Of these four, the VP Batch handles master recipes and control recipes. The Process Management Package mainly handles control recipes, while the Recipe Management Package primarily deals with master recipes.
General Recipe Product-specific processing information
Recipes
Site Recipe
Site-specific information
Master Recipe
Process cell-specific information
Control Recipe
Batch ID, batch size, in-process, operator-and/or system-generated information

F030101.ai
Figure Recipe Types
Master Recipe
The master recipe, which is derived from a general recipe or a site recipe, is the recipe level that is targeted to a specic process cell or a set of that process cells equipment. Generally, the amounts of raw materials are specied as relative values rather than absolute values. To derive a control recipe from a master recipe, execution parameters must be specied according to the set of process cell equipment for batch processes and the size of the batch being processed in that process cell.
Control Recipe
A control recipe contains information necessary to manufacture a particular batch of product. It has detailed information for plant operation. It may have been modied to account for actual raw material qualities and actual equipment to be utilized.
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3.2
The recipe generated by VP Batch Recipe Management has the following four items: Header: Contains the recipe version, the issue date and other administrative information Procedure: Contains a procedure to make a product. Formula: Contains parameters and recipe data to make a product. Equipment Requirements: Contains requirements of equipment required to make a product.
Recipe
Recipe Structure
Header
Procedure
Formula (recipe data)
Equipment requirements
F030201.ai
Figure Recipe Structure
Header
Contains the recipe name, the create date, the version and other administrative information.
Procedure
Contains two procedures to make a product: recipe procedure and unit recipe procedure. A recipe procedure describes the order of used units. For example, it denes how to use a mixing unit, a reactor, and a crystallization unit. A unit recipe procedure denes how processes are executed in each step described in a recipe procedure. The following gure shows the relationship between recipe procedure and unit recipe procedure.
1 1 2 3 Mixing Unit 1 Reactor 1 Crystallization 1 2 3 5 6 7 <Recipe Procedure> Initialize Charge Heat Reaction Cool Discharge 4 Mix
<Unit Recipe Procedure>

F030202.ai
Figure Recipe Procedure and Unit Recipe Procedure
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Formula
The formula (recipe data) is a category of information that includes process parameters to manufacture a product. It is stored in system-specic common block and user-denable common block. The system-specic common block contains the recipe name, batch ID, status and other data, while the user-denable common block contains the amount of raw materials, temperature set points, and data required for the batch process in the manufacture of a product.
Equipment requirements constrain the choice of the equipment that will be used to manufacture a product. For example, they may be expressed in a manner that species allowable equipment in each step of a recipe procedure. Procedures and formulas are the most important information among the four types, because they are downloaded to the FCS. A recipe does not include an execution program to turn on/off a valve. An execution program resides in the FCS. The unit recipe procedure denes the strategy of carrying out the execution program.
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3.3
A master recipe is a group of information. It must be changed to a control recipe and sent to the FCS to use in the FCS-resided execution program. Changing a master recipe to a control recipe is called setup, and sending it to the FCS is called recipe downloading. To set up a recipe, one has to dene the equipment of the FCS that will be used for the recipe at the initiation of the batch, which is called a unit assignment. The following gure shows that a recipe is assigned to the equipment 1a, 2b, and 3a. Next, one has to give a name to the product manufactured using the recipe in order to distinguish them from products which have been created at different time or by different equipment. The name is called batch ID. After unit assignment and addition of batch ID, a master recipe is changed to a control recipe. Now recipe setup is complete. A control recipe is divided into more than one unit recipe according to the number of equipment to be utilized, and downloaded to the FCSs, as shown below. The VP Batch is a batch package for a multi-path, multi-product process and a variablepath process. It allows recipe downloading for any combination of equipment as long as process requirements are met, when multiple equipment are required to manufacture a product.
Control Recipe Unit Recipe 1 1a 1b 1c
Recipe Setup and Downloading
Unit Recipe 2
2a
2b
2c
Unit Recipe 3
3a
3b
3c
<VP Batch>
<Processes>
F030301.ai
Figure Downloading a Recipe
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3.4
After a control recipe is downloaded to the FCS, actual batch operation starts in the FCS. The HIS is used as a human interface to monitor the operation. There are two approaches to monitor the operation. One is product-basis monitoring to monitor the progress of the entire operation, and the other is unit-basis monitoring to monitor the state of the currently-operated unit. For monitoring the entire batch processes, the Product Control View is used. The window displays the following items: Recipe group name/train name/path name Recipe name/comment Equipment requirements Recipe status Recipe description Production start and end times Planned production start and end times Batch ID Lot number and user codes Unit recipe status Unit names User-dened common block data, etc. This window shows by which unit a product is made, and how batch operation and each unit recipe are being operated. The Product Control View may be customized by graphics builder. Creating a graphic view to understand the status of a unit (device) that is executing the unit recipe enables the operation and monitoring of the device.
Batch-Operation Monitoring
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The unit supervision function controls the batch process according to the downloaded recipe. The structure of a unit and the downloading of a recipe are explained in this section.
Unit Supervision
Unit Structure
Units can reside independently in the FCS without being related to the control recipe. There are two types of units: a unit with or without a procedure. If a procedure does not reside in a unit, it is downloaded from a control recipe.
UNIT Unit procedure *1
Charge Heat React Discharge
Unit data Mode Status Operation start time Batch ID User-defined data Others
Step
Operation Charge ~ FIC100.LS=AUT drive[Valve_1=on] end ~

Initialize
program FeedA Phase
Operation procedure
Charge start Charge end
*1: When a procedure does not reside in a unit, it can be downloaded from a control recipe/process management.
F030401.ai
Figure Unit Structure (Unit with a Procedure)
As shown above, the unit contains the unit procedure, operation, and unit data. The unit procedure describes the execution order of phases in the unit using the SFC block. For example, the execution order of charge, heat, react, and discharge as one step is described. The operation, which is the sequence of each step started by the unit procedure, is realized using the SFC block and includes the operation procedure and phases. The phases are used in actual operation, for example, to turn valves on and off or change regulator settings, and described using the SEBOL, sequence table, or logic chart block. The unit data indicate the condition of the equipment under the unit supervision function and divided into unit-specic and user-dened data.
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Downloading a Recipe
Data and procedures are downloaded from the control recipe. The unit recipe procedure in a recipe is downloaded to the unit procedure, properly assigning operations to the units according to the steps used in the procedure. The formula (recipe data) is not downloaded to the data area of the unit and remains outside of the unit as common block data, which can be accessed from the phase.
Control Recipe Recipe procedure Unit recipe procedure Unit recipe procedure Unit recipe procedure Header Equipment requirements Formula Temperature Charging volume
Download
Download
Unit Unit recipe procedure Charge Heat Reaction Discharge Step Unit data Mode Status Execution time Batch ID User-defined data
Common block Data
Access from Phases

F030402.ai
Figure Unit Structure (Unit without a Procedure)
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4. Recipe Management Function
4-1
4.
Recipe Management Function

This chapter describes the recipe management function of the VP Batch software.
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4.1
The Recipe Management is positioned at the same level as production planning and scheduling, production information management. It primarily serves as an interface for process management. Recipes are classied into groups, which generate and save master recipes. This function independent from the builder can be used as separate application.
ISA-88.02 Structure
Overview of Recipe Management
Recipe management
Production planning and scheduling
Production planning and scheduling interface
OPC interface
Process management
Unit supervision
F040101.ai
Figure Positioning of Recipe Management
Features Recipe Management does: Managing master recipes Editing recipes Equalizing recipes Security Management function
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VP Batch recipes are managed by a recipe group. Master recipes and control recipes are managed by a recipe group. Any recipe is not managed by a few recipe groups. Recipes may be grouped by a physical layer such as area or production cell, or by product. Number of recipe groups: Recipe to be managed: Number of master recipes: Number of unit recipes: Number of path menus: Max. 16 groups/project Master recipe Max. 1,000 recipes/recipe group Max. 32 recipes/master recipe Max. 64 path menus/master recipe
Project
Recipe group 1
Recipe group 2
Recipe group 16
Master recipe
Control recipe
Master recipe
Control recipe
F040102.ai
Figure Conguration of Recipe Groups
One recipe managed by the Recipe Management consists of the following elements: Header: Contains the recipe version, the create date and other administrative information Procedure: Contains a procedure to make a product Formula: Contains parameters (recipe data) to make a product Equipment Requirements: Contains equipment requirements necessary to make a product
Recipe
Header
Procedure
Formula
F040103.ai
Figure Recipe Conguration
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A header contains administrative information, such as recipe name, version and issue date. These data are used for Recipe Management and Production Information Management. A headers elements are included in a control recipe, but elements excluding a recipe name, description, download mode and start mode cannot be displayed on the Operation and Monitoring Window. Neither can these elements be downloaded to the FCS.
Header
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A procedure is a series of steps which stipulate the order of actions for a batch process. The Recipe Management denes recipe procedure and unit recipe procedure. A recipe procedure shows the order of more than one unit procedure used in a recipe.
Master recipe Recipe procedure
Procedure
Unit recipe procedure
Operation
Operation
Unit supervision
Phase
Phase
Phase
Phase
F040301.ai
Figure Conguration of Procedure

Unit recipe #1 1A 1B Recipe procedure
1A
#2
2A
2B
2B
#3
3A
3B
3A
F040302.ai
Figure Example of Recipe Procedure
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The unit recipe procedure, which is described using the SFC (Sequencial Function Chart), denes the execution order of the operations dened in the unit recipe.
1 2 3 6 7 8 9 Initialize Charge Heat Branch Discharge Wash End
F040303.ai
Add
Agitate
Figure Example of Unit Recipe Procedure
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4.4
A formula (recipe data) is a set of parameters used to produce a product, such as charging volumes, temperature settings, and result data. It is divided into data values and attributes (data type, display format, item comments). A master recipe has data values only, so use a common block for dening formula data attributes.
Master recipe Formula (recipe data)
Formula
Common block name
Common block name
Common block name
Data item name
Data item name
Data value
Data value
Data attribute Definition using common block
Data attribute
F040401.ai
Figure Formula (Recipe Data) Structure
4.5
Equipment requirements show the conditions required to make a product.

Table Conguration of Equipment Requirements Description 64 at maximum of a combination of train-path E.g., Train 1-Path 1 Train 2-Path 3 Name of the units used for each unit recipe Remarks * (wild card) applicable Max. 16 - (dynamic unit assignment) applicable
Equipment Requirements
Requirements Train-path specication (*1) Unit menu specication
Used as dened information for process control

*1: Trains: Paths: Max 16/recipe group Max. 64/train
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Access Control Function of CENTUM VP is to protect systems and data from any breakins and to control individual operations by authenticating an operator, a system engineer, and a recipe engineer. By using this function, the management of a system engineer (System View/Builder) and a recipe engineer (Recipe Management Function) are ensured besides the conventional management for operators by User Name and Password enabled only in HIS Operation and Monitoring Function. This section covers the recipe engineer management (Recipe Management Function).
Access Control Function
Recipe Engineer Authentication and Authority Check

This veries identity and if the recipe engineer has the authority to perform the job.
Table The Authority Types Description Can start Recipe Builder/Procedure Builder and view recipes. Recipe View and Builder are Read Only. Can create and edit a recipe. Cannot delete and download a recipe. Cannot create; delete; edit a project and a recipe group. Can delete a recipe. Cannot download a recipe. Cannot create; delete; edit a project and a recipe group. Can download recipes from Recipe View/Builder. Cannot create; delete; edit a project and a recipe group. Can write in the recipe-approval person eld. Cannot create; delete; edit a project and a recipe group. Can create; delete; edit a project and a recipe group. Can start Recipe Builder/Procedure Builder and view recipes. Cannot create; edit; delete; download a recipe. The Authority Types Read (*1) Write
Delete Download Approve (future function) Engineering (*2)

*1: *2:
All recipe engineers are automatically entitled Read authority and cannot set the authority scope. Engineering authority can be used with Recipe-related authority (Read, Write, Delete, Download, and Approve (future function)). For instance, Engineering authority plus Download authority for one recipe engineer.
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5. Process Management Function
5-1
5.
Process Management Function

This chapter describes the process management function of the VP Batch software.
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5.1
The process management function controls the execution of batch operation. It implements:
Overview
Control recipe create

A control recipe can be created by copying a master recipe or a control recipe that has once been tuned.
Batch execution control

A batch operation is controlled according to the transition of recipe statuses.
Message generation
Messages are generated to notify the start and end of batch execution and status changes.
Execution data acquisition

The data resulted during batch execution are collected by a batch basis. The gure below shows the ow of a batch, from the creation of control recipes to their completion.
Master recipe
Recipe setup HIS
Control recipe (RESERVED)
Control recipe (LOG)
Completion of execution Control recipe (COMPLETE)
Downloading Start of Control recipe execution Control recipe (READY) (ACTIVE) FCS
Uploading Completion Control recipe of execution (LOG) Delation Control recipe (COMPLETE)
F050101.ai
Figure Flow of Batch
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In the process management, the control recipes for actual production are created from the master recipe generated using the recipe management function. This execution is called Control recipe setup. At control recipe setup for a batch, Control Recipe Copy function enables to reuse the batch formula data in another batch, which have achieved good production results.
Control Recipe Setup
5.2.1
Control Recipe Setup

A control recipe can be set up either by manual operations via the Product Overview or by a command in a program.
Setup Procedure
Follow the procedure below for the setup of a control recipe on the Product Overview.
Master recipe selection

Select the master recipe to be used on the Product Overview.
Unit assignment
Assign the unit or units to be executed for the selected master recipe.
Batch ID specication
Give a name to the batch to be executed for its identication.
Formula (recipe data) modication

Modify formula (recipe data) of the master recipe if any formulas need be adjusted to execute the batch.
Setting of Reference Batch ID

Specify a batch ID of a completed control recipe as a reference destination of reference trend display. Reference trend display is a function to display the trend of a completed batch for which a reference batch ID is specied on top of the real time trend of a batch being executed.
Control recipe setup

Execute instructions to set up the control recipe.
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Batch ID
Every batch must be named for its identication. A batch ID must be unique and composed of up to 16 alphanumeric characters including hyphens. The batch ID can be entered in either one of the following manners:
Manual Entry
Batch IDs can be entered manually using the recipe setup window.
Batch ID Descriptors
Batch IDs, which are unique in a group of recipes, are automatically attached using the systemdened descriptors shown below. A user-specied ID format may be used for each recipe group. System-dened batch-ID descriptors: %nG: Reserved recipe group number (n = 1 to 2 digits; no zero-suppression) %nY: Reserved date: YYMMDD (n = 1 to 6 digits) %nM: Reserved date: MMDD (n = 1 to 4 digits) %nD: Reserved date: DD (n = 1 to 2 digits) %nT: Reserved time (n = 1 to 4 digits) %nN[t]: Numeric value increment [reset time: 00 thru 23] (n = no. of digits; no zero suppression) Reset value: 1 %nS: Entered uppercase characters (n = no. of entered bytes) Characters: Fixed uppercase-character string (alphanumeric characters and hyphens only) Examples of user-specied batch-ID format: BA-%4N BA-0001 thru BA-9999 %6Y%2N 93103101 thru 93103199 %2G-%4N 01-0001 thru 01-9999 %2N-%4S 01-**** thru 99-****
Unit Assignment
Assigning a unit name to a unit recipe is called unit assignment. There are two ways to assign a unit to a unit recipe, Train-Path designation and Direct designation.
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5.2.2
Reuse of Control Recipe

The operator can modify the formula data of a control recipe set up based on a master recipe. After this, the operator can make a copy of that control recipe containing the modied formula data (control recipe copying function) to set it up for the next batch, or export the modied formula data and feed it back to the original master recipe.
Flow of Control Recipe Copying Function

This function copies one of control recipes as another new control recipe and sets it up. This control recipe set up is called Copied recipe, given the status RESERVED at rst. The source of copied recipe is called Original Recipe. While the most of formula data in the original recipe are copied to the copied recipe, some of formula data, such as Batch ID and Reserved date and time, are not copied, but are set newly. For formula data Origin Batch ID of the copied recipe, the batch ID of the original control recipe is set up.
Master Recipe Recipe Setup Original Recipe (Copied Recipe)
Downloading Control Recipe Start Execution Control Recipe End Execution Control Recipe (RESERVED) (ACTIVE) (COMPLETE)
Copy the initial parameters from master reicpe to control recipe Control Recipe copying function Copied Recipe Recipe Setup Control Recipe (RESERVED)
Duplicating
Downloading Start Execution Control Recipe End Execution Control Recipe (ACTIVE) (COMPLETE)
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Figure Flow of Control Recipe Copying Function
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Exporting Formulas
User can choose a formula and export the formula into a CSV format le. It is possible to export the formula of the control recipe selected by the user as a CSV format le. Formulas can be exported in two ways. The formulas can either be exported manually from the Product Overview, or they can be exported automatically when a batch is completed or the command to gather result data (GATHER) is issued.
Master Recipe Recipe Setup Control Recipe (RESERVED) HIS Downloading Start of Control Recipe execution Control Recipe (READY) (ACTIVE) FCS Uploading Control Recipe (LOG) Completion of execution Delation Control Recipe (COMPLETE) Control Recipe (LOG)
Completion of execution
Control Recipe (COMPLETE)
Run export (Exported manually)
Exported automatically
Exporting Formula
Exporting Formula
CSV Format File For general-purpose
CSV Format File For Recipe Builder
CSV Format File For general-purpose

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Figure Exporting Formula
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5.3
This section describes the execution and synchronization control of units used for a control recipe.
Batch Control
Recipe Statuses
The control recipe has Control Recipe Status indicating the state of the entire recipe and Unit Recipe Status showing the state of the unit recipe. The control recipe status changes in accordance with the status of the unit recipe contained in the control recipe.
Table Recipe Statuses Symbol RESERVED ASSIGNED NOASSIGN READY ACTIVE LOG COMPLETE ABORTED Description Reserved for execution. Units assigned. Units not assigned. Downloaded and standing by. Being executed. Data being acquired. Execution completed. Execution aborted. x x x x x Control Recipe Status x x x x x x x x Unit Recipe Status
Unit status: ACTIVE Unit recipe status 1: COMPLETE
Unit recipe status 2: ACTIVE
Unit recipe status 3: READY
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Figure Unit Status and Unit Recipe Statuses
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Control Recipe Status

Master Recipe Control Recipe Reserve END
RESERVED
LOAD
READY
START
ACTIVE
UP_LOAD
LOG
COMPLETE
ABORT ABORT ABORT DELETE
ABORTED
DELETE
DELETE DELETED
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Figure Transition Between Recipe Statuses Table Control Recipe Statuses Description Indicates that recipe setup ended successfully and the required recipe has been reserved. Upon reservation completion, the recipe is in the RESERVED state. The unit recipe status becomes ASSIGNED if units have already been assigned; the status becomes NO ASSIGN if units have not yet been assigned. Indicates that downloading has been completed and the downloaded recipe is waiting for execution (start). The recipe is in the READY state when the shared section of the recipe is downloaded successfully. Indicates that the recipe is running. A recipe is in the ACTIVE state when it is started. Indicates that result data are being uploaded (logged). A recipe is in this state if every unit recipe status is either LOG or COMPLETE and at least one unit recipe status becomes LOG. Indicates that all of the recipes have been executed successfully. A recipe is in this state if all of the unit recipe statuses become COMPLETE. Indicates that the recipe has been aborted. A recipe is in this state if every unit recipe status is either ABORTED or COMPLETE and at least one unit recipe status becomes ABORTED. Indicates that a control recipe has been deleted. Since the control recipe disappears, the recipe status does not exist. This status can take place only when the recipe status is either RESERVED, ABORTED or COMPLETE.
Notation RESERVED
READY
ACTIVE LOG COMPLETE ABORTED
(DELETED)
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Unit Recipe Status

Control Recipe END
UNIT LOAD NO- ASSIGN ASSIGNED ASSIGN
READY
START
ACTIVE
UP_LOAD
LOG
COMPLETE
CANCEL ABORT ABORT ABORT
ABORTED
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Figure Transition Between Unit Recipe Statuses Table Unit Recipe Statuses Description Indicates that units have not yet been assigned to a unit recipe. This status takes place if units have not yet been assigned, units are under dynamic (unit) assignment, the dynamic assignment abnormally ends, or any of the assigned units are canceled. Indicates that units have been assigned to a unit recipe. This status occurs when the assignment of units ends successfully. Indicates that unit recipes have been downloaded and are waiting for execution (start). This status takes place when the downloading of unit recipes ends successfully. Indicates that a unit recipe is running. This status takes place when a unit recipe is started. Indicates that the result data are being uploaded (logged). This status takes place when the execution of a unit recipe has been completed. Since no data is available for uploading at the LOG status of a unit recipe, this status takes place soon. Indicates that all of the unit recipes have been executed successfully. This status takes place when uploading is completed or a unit recipe ends successfully. Indicates that a unit recipe has been aborted. This status takes place if a unit recipe is aborted.
Notation NO ASSIGN
ASSIGNED READY ACTIVE
LOG
COMPLETE ABORTED
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Batch Modes
A control recipe has batch modes to show whether the DownLoading Modes and Starting Modes are carried out automatically or manually. Downloading Modes: Receives a download command for a control recipe. Starting Modes: Receives a start command for a recipe or a unit recipe.
Downloading Modes
Recipe (Common Part) Downloading Mode AUT (default): Automatically downloaded when the recipe has been reserved. TIME: Automatically downloaded at the specied time. MAN: Manually downloaded. Unit Recipe Downloading Mode AUT (default): Automatically downloaded as soon as the common part of the control recipe has been downloaded. TIME: Automatically downloaded at the specied time. MAN: Manually downloaded.
Starting Modes
Recipe (Common Part) Starting Mode AUT (default): Automatically starts as soon as a control recipe has been downloaded. TIME: Automatically starts at the specied time. MAN: Manually starts. Unit Recipe Starting Mode AUT (default): Automatically starts as soon as a unit recipe has been downloaded. TIME: Automatically starts at the specied time. MAN: Manually starts.
IMPORTANT
Change a batch mode during the recipe setup. You cannot change it after the recipe setup. If a unit, which has been assigned to a unit recipe, is in use by another batch process when the start mode of that unit recipe is either AUT or TIME, the START directive will result in an error. In this case, the user must issue the START directive on the Operation and Monitoring Window.
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Dynamic Unit Assignment

The dynamic assignment of units means to assign units to be run before a given unit recipe starts running.
Unit recipe #1 UNIT A1
#2
UNIT A2
#3
UNIT A3
#4
UNIT A4
UNIT B4
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Figure Example of Dynamic Assignment of Units
As seen in the above example, the UNIT A1 to UNIT A3 have already been assigned to unit recipes #1 to #3 at the time a given recipe is started. The dynamic assignment of units is useful when determining which unit to use for recipe #4, UNIT A4 or UNIT B4 during the running of UNIT A3. Using the Dynamic Unit Assignment to change the name of a unit already assigned, the information on the original unit name will be lost. The directive must be used for a unit recipe that is not yet started when: units to be assigned are not assigned (NOASSIGN); the name of a unit already assigned (ASSIGNED) needs to be changed; or the name of a unit for a unit recipe that has already been downloaded (READY) needs to be changed.
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The ASSIGN directive is valid only for unit recipes before starting. If the directive is issued through the Operation and Monitoring Window after downloading a unit recipe, the existing units are cancelled by the system so that the directive can take effect. The ASSIGN directive can be used to assign unit recipes within the same batch by SEBOL (urassign) as well as the Operation and Monitoring Window. To implement the dynamic assignment of units through the Operation and Monitoring Window (or Product Control View), type a unit name for separate specication of the unit name. A unit name can be designated using: Direct specication Selection from unit menu Selection from a list of usable unit names Select a method as specied in the Master Recipe Builder. However, there are some restrictions. No dynamic assignment of units is allowed for the starting unit recipe (unit recipe #1). If an error occurs when the ASSIGN directive is issued after downloading a recipe, a unit will be cancelled, resulting in the cancellation of downloaded unit recipes. If the ASSIGN directive is issued on the Operation and Monitoring Window (or Product Control View) after downloading a unit recipe, the system cancels original units, carries out dynamic assignment of units, and downloads the new units when the downloading modes of a recipe and a unit recipe are AUT.
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5.4
This section covers how the data recorded during batch execution are collected and saved.
Batch Results
Data Collection
The data recorded during batch execution is collected on a batch basis. Processes, setpoints, quality, calculation, manual input, and other data recorded during batch execution are collected and saved in the common block data area.
Collected data
Collecting means the FCS-resided common block data is collected at a station that manages processes, such as the HIS.
Manner of data collection

Data is collected at a time after recipe execution has been completed. The user copies process data to the common block data area of the FCS arbitrarily using the SEBOL block or other blocks. The copied data is to be collected on a batch (control recipe) basis.
Timing of data collection

Data is collected automatically (at the time of uploading) or arbitrarily. When data has been collected arbitrarily a number of times, or when data has been uploaded after it was collected arbitrarily, the data will be renewed by the latest data.
Table Data Collection Timing When GATHER is specied on the Product Control View When the unit or control recipe has been Uploaded Data Common block data Common block data Collection Arbitrarily Automatically
Control start and end time

The control start time (STRTIME) and control end time (ENDTIME) which have been dened for system-specic common block recipes and unit recipes are automatically dened for batch execution.
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Batch Related Trend Data Filing

By linking the process management of the batch management package and the trend recording functions of the HIS, trend data related to each batch and acquired by the HIS can be output to les upon the end of the batch or upon invocation of the batch result gathering (GATHER) command. These output les are referred to as batch-related trend les. Two kinds of les can be created, and whether to create one, the other or both of them can be specied using the corresponding Builder depending on the purpose.
CSV format les

Batch-related trend les in CSV format are useful for application to other systems. From the binary trend data that the trend recording functions of the HIS operation and monitoring functions store in trend data les, process management selectively extracts data related to the batch ID of a given batch for the time period corresponding to the execution time (runtime) of that batch, and saves it to CSV les.
Binary format les

Batch-related trend les in binary format are used to display the trend graphs of batch-related data using a trend window after the execution of each batch.
Process Management Function Batch Related Trend Data Filing (CSV file)
Batch Related Trend Data Filing (Binary file) Data Filing
Standard Operation and Monitoring Function

TG1001 Block:10 Group:01
1 2
102.3
82.3
FIC001.PV
62.3
42.3
Trend Data File

Gathering 13:34 05/10/2010 00:12:00 13:36 100% 13:38 13:40 05/10/2010 13:42 13:44
22.3
2.3
Tag Name 1 2 3 4 5 6 7 8 FIC001. PV FIC002. PV LIC100. PV TIC100. PV TIC200. PV
Tag Comment Inlet flow Outlet flow Level Temp A Temp B
Value 72.1 53.3 3.8 25.7 14.1
Unit M3/h M3/h M DEGC DEGC
Lower 0.0 0.0 0.0 0.0 0.0
Upper 100.0 100.0 100.0 100.0 100.0
Trend Data Acquisition
Trend View
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Message Gathering
The VP Batch gathers messages generated during batch execution as part of batch result data. Messages are stored in a historical le of the HIS upon receipt of the messages by Message Management Function. The gathered messages can be retrieved with a batch ID from a historical message report.
Process Report
The Process Report Function collects data regarding the state of system operation. The VP Batch allows the user to specify a batch ID as the search conditions. To use this function, the Process Management must have been installed.
Batch Journal
The VP Batch allows the user to access recorded data according to a batch ID, print it as a report and use it on application programs. The following data is recorded during batch execution: Historical messages Common block data Historical trend data These data may be printed as batch reports by arbitrary formats at the time of batch process end. To print them as batch reports, use the Report Package. Previous batch journal includes the function. With the Report Package, current tag data, tag attributes, closing data as well as the above data are collected and detailed batch reports are printed. For data reference on the Report Package, the Open Data Interface Package (Exaopc) for OPC must be installed.
Reference from Application Programs

With application programs, the user can access recorded data using a batch ID through OPC communications.
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5.5
This section describes the use of a number of HISs for operation and monitoring applying the process management function.
Server/Client Function Redundancy
Specifying Server and Client Stations

The Process Management Function can be used and monitored from a number of HISs. These HISs serve as server/client stations, so the user can operate and monitor the Process Management Function from any HIS. The server station can also be made redundant (master/ backup), suitable for mission-critical application. To dene server and client station names for each recipe group, use the Process Management Conguration Builder. Server station: Client station:
Ethernet
A station that processes requests of the client station Up to 2 server stations/recipe group A station that uses information of the server station Up to 14 client stations/recipe group
HIS 1 Server #1 Control bus FCS
HIS 2 Client
HIS 3 Server #2
General purpose PC
Recipe management (When the Server #1 is a master, the Server #2 serves as a backup and client server.)
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Figure Station Conguration
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Control Recipe Copy between Servers

Up to 2 HIS that can offer the server function can be specied for each recipe group. However, during execution of the process management function, one station becomes the master server and the other the backup server. When 2 candidate servers are specied, the following control recipe copy is performed between server stations. Control recipe is equalized for each recipe group. Control recipe copy is performed automatically upon completion of recipe setup and completion of execution. If the formula is modied between recipe setup completion and recipe downloading, control recipe is equalized at the timing at which each individual data was written. With a recipe status between READY and LOG (or between recipe downloading and recipe uploading upon completion of execution), the control recipe exists in the FCS and therefore its equalization is not necessary. Switching between the master server and backup server is performed manually for each recipe group.
HIS Backup Server
Control Recipe (RESERVED) HIS Master Server Equalize
Control Recipe (LOG) Equalize
End
Master Recipe
Recipe Setup
Control Recipe (RESERVED)
Control Recipe (LOG)
End
FCS
Download Control Recipe (READY) Start Control Recipe (ACTIVE)
Upload Delete Control Recipe (LOG) End Control Recipe (COMPLETE)

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Figure Control Recipe Transition
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5.6
Production Planning and Scheduling Interface

The schedule management function is used to plan the schedule of the process management function. The production planning and scheduling interface is used to exchange information between the schedule management function and the process management function. On the process management side, recipes are executed according to the schedule information le(*1) through the production planning and scheduling interface. The production planning and scheduling interface is included in the package of the process management function.
*1: Including the respective batch IDs, recipe names, formulas, and equipment requirements, but excluding the headers.
Production Planning and Scheduling Interface
Recipe management
Schedule management
Production planning and scheduling interface Process management
Unit supervision
Function block
Function described in this chapter

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Figure Positioning of Production Planning and Scheduling Interface
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Overview of Production Planning and Scheduling Interface Function

The following describes the overview of the production planning and scheduling interface function.
Schedule Expansion
The schedule expansion function makes it possible to expand the established schedule created by schedule management to the process management function. The process management function performs recipe setup automatically according to the recipe name, batch ID, and scheduled execution start time within the established schedule le and then executes the recipe.
Batch Progress Information

The batch journal showing the batch progress information can be collected through the OPC interface. The schedule management function also allows scheduling which reects messages collected from the batch journal.
System Conguration Including Schedule Management Function

The following shows the system conguration based on the combination of the schedule management function, production planning and scheduling interface, and process management function. The process management function registers the server station and client station for each recipe group. The schedule management function can communicate with either the server station or client station. To communication with multiple server stations and client stations, specify all the target HIS on the schedule management function side.
Host computer
Schedule management
Ethernet HIS Production planning and scheduling interface Process management HIS Production planning and scheduling interface Process management HIS Production planning and scheduling interface Process management
Server #1
Server #2
Client
Control bus
FCS
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Figure System Conguration Including Schedule Management Function
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6. Unit Supervision Function
6-1
6.
Unit Supervision Function

This chapter describes the Unit Supervision Function of the VP Batch software.
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6.1
A number of equipment used to control continuous or batch processes can be controlled as a unit. For example, a group of reactors in batch processes can be controlled as a unit. A unit represents a group of equipment, simplifying operation. Giving a command to a unit activates a group of equipment. The user does not need to use individual tag names. A unit has control algorithm and unit data to control equipment. The control algorithm is composed of unit procedures (SFC) showing the order of processes, operations (SFC and SEBOL) controlling respective action of each equipment, sequence table logic, and logic charts. There are two types of units: one where procedures reside and the other where they must be downloaded from control recipes. The unit data saves the tuning data for the entire equipment. Function blocks can be placed under a unit, and operator guide messages and alarms on the blocks can also be grouped as a unit.
Unit data SET_DATA=10 kg
Unit
Unit Procedure
1
Operation (SFC block)
Phase SEBOL Sequence table Logic chart
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Figure Conguration of Unit with Procedures
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6.2
Unit data is a group of data indicating the condition of the unit-controlled equipment. Data items are either unit-specic or user-dened.
Unit Data
Unit-Specic Data Items

There are unit-specic data item names, data names and data types.
User-Dened Data Items

Up to 256 data items can be user-dened. A default storage named BIDQUEUE[ ] is reserved in the user-dened data area to save the Process Management Function-dened batch ID to start recipes. Up to 16 bytes display label can be attached to each user-dened unit data item and displayed on the Operation and Monitoring Window.
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6.3
The unit procedure executes unit processes (procedures). It is described in SFC. To control the order of carrying out operations, a generic operation name or operation tag name is described in the action box of each step (In the following gure, charge, heat, and others).
1 2 3 6 7 9 10 Initialize Charge Heat Analyze Discharge Wash End
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Unit Procedure
Add
Agitate
Discharge 2
Figure Example of Unit Procedure
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6.3.1
SFC Language
The SFC language has the following three basic elements: Steps: Links: Description of actions. Linking steps and transitions. Transition: Description of transition conditions.
Basic Elements
Steps
Steps are expressed by putting numbers (step numbers) in squares. A step has active and inactive states. In the active state the step is being executed, and in the inactive state the step either has been executed or has not yet been executed. The rst step, which is called the initial step, is shown in double squares. The initial step is expressed differently, but the action of the initial step is the same as those of successive steps.
10
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For each step, the user denes an action in rectangles. When a step is active, the operation described in the rectangular action box starts. Upon completion of the operation, the step is inactive, moving to the next step. In the action box, a generic operation name or operation tag name is entered. A display label, if it is dened, is shown in the box using the SFC function display.
Transition
Transition from one step to another is indicated using lines. A logical expression called transition condition can be described for transition. Satisfying a transition condition moves to next step. The transition condition becomes active at previous step, and is examined upon completion of the operation in the action box.
5 6 7
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Links
Links between steps, between steps and transition are expressed using horizontal and vertical lines. They show the order (path) of carrying out steps.
3 4 5 <Regular linking> 5 6 7 <Looped linking> 10 11 12 <Selected linking>
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SFC Execution
The unit procedure is executed as follows: 1. 2. 3. 4. 5. When the unit procedure starts, the initial step is activated for execution. The activated step executes the operation described in the action box. The step is inactivated when the operation is completed. The next step linked to the current step is activated. If there is a transition, a transition condition will be examined. When the transition condition is proved true, the step following the transition will be activated for execution.
Complex Sequences
There are two types of complex sequences selective and parallel sequences.
Selective Sequence
The selective sequence is used when different step must be executed according to transition conditions.
5 6 9 10 <Example of Selective Sequence>
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In the example shown above, as Step 5 becomes inactive, three transition conditions connected to the step are examined from the left. The step of which the condition has been proved true will be activated. If more than one transition condition have been proved true, priority is given to the step on the left. If none of transition conditions is proved true, their conditions will be examined repeatedly until one is proved true. Up to eight selective sequences can be described.
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Parallel Sequence
The parallel sequence is used when a number of sequences must be executed at the same time. A parallel sequence is indicated using double horizontal lines. Steps connected to the line become active and executed at the same time. Drawing double horizontal lines at the end of parallel sequences returns to its original path.
5
6 9 10
<Example of Parallel Sequence>

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Up to eight steps can be executed at the same time in a parallel sequence. Up to 32 steps can be executed at the same time if parallel sequences are included within parallel sequences (they can be nested up to three levels in one sequence).
Table SFC Elements Name Initial step Steps Step Wait step Transition Transition Branch Join Parallel branch Parallel join Loop out Links Loop in Jump up Jump down Jump in Link
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Class
Symbol
Jnn Jnn Jnn
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Transition Condition
As a transition condition, one line can be described using a simple logical expression in the following format: Left operand Operator Right operand One item can be described as the left operand, such as unit data or function block data of the present station. For the operator, either one of =, <>, <, >, <=, or >= can be entered. For the right operand, one item can be described, such as unit data, function block data of the present station, or a constant. With the Process Management Function, the common block data of the recipe being executed on relevant unit can be described as the left operand.
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6.4
An operation is a series of control steps executed in the unit-controlled device. It is an independent process in a series of production processes assigned to the device. Each operation corresponds to one step of a unit procedure. When the user tries to execute a unit procedure by a unit, operations are executed according to the progress of the unit procedure processing. When the user tries to execute multiple steps at the same time in the unit procedure, multiple operations are executed at appropriate timing.
Operation (OPSFC) Unit Unit procedure (SFC) Initialize Charge Initial step Charge 1 Agitation Charge 2 Heat Operation (OPSBL) SEBOL or Logic chart Terminate or Sequence table Y N SEBOL
Operation
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Figure Positioning of Operation
The operation has functions that are equivalent to those of the SFC block. You may think that we call the unit-started SFC block an operation. The major difference between them is that the operation can use additional functions such as access to activated units and formulas (recipe data). Other differences are described below: Present unit data can be accessed by data item %%. from the operation, while it can be accessed by data item format unit name. from the SFC block. The operation can be started by a unit only. The user cannot start the operation by themselves. With the Process Management Function, the common block data of the recipe can be accessed from the operation, but not from the SFC block. The operation can control the start and termination of the unit procedure for another unit in the same recipe. The operation can request the downloading of the unit procedure for another unit in the same recipe. The operation can reserve (or dynamically assign) the unit to be executed by the unit procedure for another unit in the same recipe.
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Operation Data Items

Only system-specic data items are available for operations. The user cannot specify userspecic data items.
Operation SFC
The differences between operation SFC and unit procedure SFC are shown below.
Table Operation SFC vs. Unit Procedure SFC Item Transition condition Action Operation SFC Available. Unit-specic logical expression. Unit Procedure SFC
Parallel sequence Not available. SEBOL expression.
Description using SEBOL, etc. Description of name of operation to be started.
Operation Mode and Status

The operation is a function block with a tag name, and has its block mode and block status like other function blocks. The block mode indicates the state of operation control and the block status indicates the state of operation. The operation is normally executed under the control of a unit, which cannot be started by operators.
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6.5
The user can send a status change directive to a unit, such as operation from the Operation and Monitoring Function, or emergency stop due to failure. The unit also has modes to order the actions of unit procedures and operations. The mode change directive can also be sent from the Operation and Monitoring Function.
Unit Mode and Status
Unit Modes
Like function blocks, units have modes indicating the control state of a unit. The modes can be changed by a mode change directive from the Operation and Monitoring Function.
Table O/S MAN SEMI AUT Unit Modes Name Out-of-service mode Manual mode Semi-automatic mode Automatic mode Description All unit functions are stopped. The unit can be manually operated. The unit procedure cannot be activated, however. Inter-step transition can be manually operated but the step itself is automatically controlled. All unit functions are automatically controlled. Symbol
Unit Statuses
The unit status indicates the operation condition of a unit (a unit procedure). The combination of statuses and modes expresses the overall operation condition of a unit. There are operation statuses indicating the state of operation and internal statuses indicating internal detailed condition.
Operation Statuses
The operation statuses of the unit are described below.
Table END ABORTED RUNNING SUSPEND PAUSED Operation Statuses Name Completion Abnormal termination Execution Procedure suspension Sequence suspension Description The unit procedure has been executed. The unit procedure has been abnormally aborted. The unit procedure is being executed. The unit procedure is being suspended at the start of a step. The operation sequence is being suspended at the start of a phase. Symbol
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Internal Statuses
The internal statuses show detailed internal conditions of operation statuses.
Table Internal Statuses Status Code CNCT NOCNCT INIT INTR USER SYSTEM INTR INTRCKTR INTR Description The unit procedure is standing by for execution. There is not unit procedure to execute. The initialization operation sequence is being eecuted. An interruption process is being executed. The unit procedure has been aborted by the user. The unit procedure has been aborted due to a system-detected error. An interruption process is being executed. An interruption process is being executed. The transition condition is being examined. An interruption process is being executed. Symbol END
ABORTED RUNNING SUSPEND PAUSED
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6.6
The unit executes initialization and monitoring operations in addition to unit procedures and operations.
Initialization and Monitoring Operation
Initialization Operation
The initialization operation starts one time at system startup before a unit starts. It initializes processes.
Monitoring Operation
The monitoring operation is used for monitoring a unit. It runs regardless of the unit status. It is used when equipment must be monitored all the time, though unit procedures do not run.
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6.7
To use FCS memory effectively and improve engineering productivity, a generic name can be used, and units, unit procedures and operations which have the same function can be shared.
Using Generic Name and Sharing Resources
Using Generic Name for Units

A generic name is a variable name used in a program within operation, instead of a tag name. For units, the relationship between a generic name and a tag name can be dened. With a generic name, a program can be described without a tag name.
Sharing Unit Denition

Unit denitions, such as unit data denitions, can be shared among units.
Sharing Unit Procedure

The same unit procedure (SFC) can be shared among multiple units. Entering a generic name of operation in the SFC action box and starting as unit SFC starts corresponding operation.
Sharing Operation
To share the same operation, the function blocks and units accessed in a program can be described by their generic names. The relationship among generic name, tag name and unit name can be registered in the unit.
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6.8
The status transition matrix determines actions for unit mode/status change commands. A unit changes unit mode/status according to the status transition matrix.
Status Transition Matrix
Status Transition
A unit mode shows the control status of a unit and a unit status shows its operation status. Status transition means the change of the unit mode and unit status. It is executed by unit mode/status change command. When the unit instrument receives the change command, it shifts to a new unit mode and unit status according to the state transition matrix and, at the same time, transmits operation commands to control the control status and operation status of the unit instrument and operation. The state transition matrix can be customized by the user. (*1)
*1: Planned to be customized in future.
Status Transition at the AUT Mode

END RUNNING PSTART ABORT PAUSE SUSPEND RESTART RESTART END END
PAUSED
SUSPEND
SUSPEND
ABORT
ABORT RESET
ABORTED
F060801.ai
Figure Status Transition at the AUT Mode
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Status Transition at the SEMI Mode

END RUNNING PSTART ABORT PAUSE END
At start of step execution or SUSPEND RESTART END
RESTART
PAUSED
SUSPEND
SUSPEND
ABORT
ABORT RESET
ABORTED
F060802.ai
Figure Status Transition at the SEMI Mode
6.9
While the common blocks are usually used commonly among all recipes, it is also possible to use some common blocks only for some units or some operations. This link between common blocks and units/operation is congured, as users like. Thus, by closely link between each unit/phase and formula data contributes to much more efcient conguration and to improvement plant operation and monitoring.
The denition of link between Common Block & Operation
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7. VP Batch Operation and Monitoring Windows
7-1
7.
VP Batch Operation and Monitoring Windows

This chapter describes operation and monitoring windows of the VP Batch software. The VP Batch has various standard windows, permitting consistent operation and reducing engineering steps. The user does not need to create graphic windows for batch control. The operation and monitoring windows are supplied as the human-machine interface of VP Batch. They are classied into a window switching from Product overview and a window switching from Product Control view. Windows that can be opened from the Product Overview are shown below.
Product Overview
Recipe List Operator Guide View (*1)

Historical Message Report Window (*2)
Recipe Procedure View Formula Dialog Box Trend Selection Dialog Box Trend View
Unit Recipe List Operator Guide View (*1)

Historical Message Report Window (*2)
Unit Recipe Procedure View (or Unit-SFC View) Unit Formula Dialog Box Trend Selection Dialog Box Trend View
Operation List
Operator Guide View (*1) Historical Message Report Window (*2) Operation-SFC View Operation Formula Dialog Box Faceplate
Phase List
Operator Guide View (*1) Historical Message Report Window (*2) Phase-SFC View (or SEBOL/Logic Chart/Sequence Table View)
Recipe Header Dialog Box Faceplate Operator Memo Dialog Box Product Control View
F070001.ai
*1: *2:
The CAMS for HIS Message Monitor is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled and operator guide messages are integrated. The CAMS for HIS Historical Viewer is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled.
Figure Windows Opened from the Product Overview (Windows for Information Display)
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Product Overview Recipe List Recipe List Dialog Box Control Recipe Copy Dialog Box Server Switch Dialog Box Formula Export Dialog Box Train Selection Dialog Box
F070002.ai
Unit Recipe List Recipe Setup Dialog Box Dynamic Unit Assign Dialog Box
Figure Windows Opened from the Product Overview (Windows for Operations)
Windows that can be opened from the Product Control View are shown below.
Product Control View Operator Guide View (*1) Process Alarm View (*2) Historical Message Report Window (*3) Unit Recipe Procedure View Unit Formula Dialog Box Recipe Header Dialog Box Operator Memo Dialog Box Equipment Requirement Dialog Box Product Overview
F070003.ai
Operation-SFC View Operation Formula Dialog Box
Phase-SFC View (or SEBOL/Logic Chart/Sequence Table View)
Dynamic Unit Assign Dialog Box
*1: *2: *3:
The CAMS for HIS Message Monitor is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled and operator guide messages are integrated. The CAMS for HIS Message Monitor is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled. The CAMS for HIS Historical Viewer is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled.
Figure Windows Opened from the Product Control View

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Recipe-related Views and Dialog Boxes Product Overview Displays batch status for each recipe group/train. Product Control View Displays the status of each batch. The operation of all batches or individual unit recipes can be carried out. The window is customized by the graphic builder. Recipe Procedure View Displays the recipe procedure (SFC) and unit recipe procedure (SFC) of the specied control recipe. Unit Recipe Procedure View Displays the unit recipe procedures of a selected control recipe. Operation Formula dialog box Displays and allows the user to change the formula applied to a selected operation. Unit Formula dialog box Displays and allows the user to change the formula commonly applied to a selected unit. Formula dialog box Denes and displays the formula of the specied control recipe. Recipe Header dialog box Displays the recipe header of the specied control recipe. Recipe List dialog box Displays a list of master recipes for each recipe group/train. Recipe Setup dialog box The master recipe selected from the Recipe Overview Dialogue is converted into a control recipe by adding a batch ID, assigning a unit and setting actual volumes. Control Recipe Copy dialog box Used to make a copy of a selected control recipe to create a new control recipe. Server Switch dialog box Sends a command to switch server stations according to recipe group. Formula Export dialog box Used to export formula data for a selected control recipe to a comma-separated value (CSV) text le. Train Selection dialog box Used to change the trains within the recipe group. Operator Memo dialog box Enters memo of the specied control recipe for operators. Equipment Requirement dialog box Denes and displays the equipment requirement of the specied control recipe.
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7-4
Follow the procedure below to use the operation and monitoring windows: 1. 2. Select a recipe to be formulated on the Recipe Overview. Set up a recipe (convert from a master recipe to a control recipe) on the Recipe Setup dialog box.
Specify a batch ID. Assign a unit to be utilized. 3. 4. Send the Load and Start commands to the FCS to download and start the recipe on the same window (When the automatic starting mode is specied, the system automatically executes the downloading and starting of the recipe upon completion of the recipe setup.) After the operation has started,
the batch operation is monitored on the Product Overview or Product Control View and the unit operation is monitored on the Graphic View.
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8. FDA : 21 CFR Part 11 Compliant
8-1
8.
FDA : 21 CFR Part 11 Compliant

Supporting FDA : 21 CFR Part 11 compliant functions. The management of recipe engineer (Recipe Management Function) includes Access Control Function and Audit Trail Management Function that meet the regulations in FDA : 21 CFR Part 11. CENTUM VP achieves comprehensive FDA : 21 CFR Part 11 compliant by supporting the management of an operator (Operation and Monitoring Function) and a system engineer (System View/Builder) besides a recipe engineer (Recipe Management Function).
SEE
ALSO
For details of FDA : 21 CFR Part 11, see following TI: Achieving 21 CFR Part 11 Compliance Using CENTUM VP Authored by Stelex (TI 33M01A62-40E)
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9. Glossary
9-1
9.
area
Glossary
This chapter gives denitions of terms used in this manual. An element in a batch process plant physically, geographically, or logically divided. An area is a component of hierarchical plant information and contains process cells, process units, equipment modules, and control modules. Area in this sense is different from that used in controlled area. (See control module, equipment module, process cell, unit.)
batch
A unit of nished or half-nished products of the same kind that is processed using more than one manufacturing unit. The term is used to identify resources and recipes used in processing each kind of products. (See recipe.)
batch journal
Batch data recorded during batch operation. It includes operator input, mode change, operation command, data entry, status change notication and operator guide messages.
batch message
Batch process messages from the FCS and batch history messages from the Operation and Monitoring Function during batch operation. It includes messages from currently operating units and function blocks under the control of units.
batch process
A process of manufacturing a limited quantity of products by using more than one manufacturing unit in order of the dened procedure. (See batch.)
common block data

Data that can be shared among unit recipes. The term, common block, is used as a means of implementing recipe data.
control module
A unit that combines a regulating device and a state-transition control device for a combined operation. An example is a single-loop controller.
control recipe
A recipe that contains information for manufacturing one specic batch of a product. The information denes all the details required for the production. More than one unit recipes comprise one control recipe. (See batch, unit recipe.)
equipment module
A unit of functions to control specic and limited minor process activities, such as measuring and material additions. An example is process equipment such as tanks and heaters.
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9. Glossary
9-2
equipment requirement
A requirement for the unit or equipment used in manufacturing products.
formula
A set of recipe data that separates procedure-dened products from other products. A formula include the product grade, quality specication, process variables, material type and quantity. (See procedure.)
ISA-88.01
Instrument Society of America (ISA)s SP (Standards&Practices)88 Committee has been working on batch process standardization and modelling. It released Batch Control Part 1: models and terminology as ISA-88.01 in 1995.
master recipe
A recipe that is prepared in accordance with specic manufacturing equipment. A master recipe contains the information for manufacturing a batch of a product. (See batch, recipe.)
operation (sequence)
A sequence of steps in operation of a process unit or a sequence of phases in an independent major process contained in the procedure. (See procedure, unit.)
path
A group of process units that are congured in series or parallel and used, or planned to be used, in a batch production operation. (See batch, unit.)
phase
Processing or action that is related to the process in an operation sequence. (See operation.)
procedure
A series of actions taken to accomplish a specied purpose or that denes the order manufacturing steps and the control method for a batch production operation. The term is also applied to the order of executing a unit recipe. (See unit recipe.)
process
A series of chemical, physical, or biological activities for the conversion, transportation, or storage of material or energy excluding computers, controls, and monitors. An example is the distillation process of a renery.
process cell
A concentrated group of equipment involved in the production of batches. A cell is a component of hierarchical plant information and logically controls an entire set of process equipment in an area. (See area, batch, process.)
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9. Glossary
9-3
recipe
A recipe is a set of information that denes control requirements for the production of a batch specifying steps, methods, and parameters. Each recipe is composed of a recipe header, equipment requirements, a formula, and a procedure. Recipes are created in four levels, namely, general recipe, site recipe, master recipe, and control recipe. (See batch, control recipe, equipment requirement, formula, master recipe, procedure, recipe header, unit recipe.)
recipe group
A group of master recipes classied by plant and product line. (See master recipe.)
recipe header
A set of information given to each recipe, including recipe and product identications, version of the recipe, and originator and originated data. (See recipe.)
recipe setup
The procedure for generating a control recipe from a master recipe by setting parameters, batch identication, and so on and assigning process units that are to be executed by the recipe. (See batch, control recipe, master recipe, unit.)
SEBOL (Sequence and Batch Oriented Language)

A text language used to describe sequential control and batch control. (See SFC.)
SFC (sequential function chart)

A graphical language used to describe the sequential control function. (See SEBOL.)
SFC block
A function block that executes the SFC-described control function, which controls SEBOL, sequence tables and logic charts. (See SFC.)
site
An element in a batch production enterprise physically, geographically, or logically divided. A site is a component of hierarchical plant information and contains areas, process cells, process units, equipment modules, control modules. (See area, control module, equipment module, process cell, unit.)
train
A group of process units that are planned to be used in manufacturing a batch of products nished or half-nished. (See batch, unit.)
unit (unit instrument)

An instrument having a function to execute part of a specic batch and manage the data and procedure for the purpose. It actually executes a unit procedure that describes the order of manufacturing steps and the control method for reaction, crystallization, dissolution, and so on. It is also a group of control modules or equipment modules. (See batch, control module, equipment module, unit procedure.)
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9. Glossary
9-4
unit procedure
A sequence of operation steps or phases completed within one unit. A procedure in a unit recipe is called unit recipe procedure. (See operation, phase, procedure, recipe.)
unit recipe
A recipe that denes a unit for operation. (See unit.)
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TI 33M05L10-40E 1st Edition
INDEX
A
Access Control Function ....................................... 4-8 Adaptability............................................................ 1-3 area ...................................................................... 9-1
D
Data Collection ....................................................5-13 Downloading a Recipe .......................................... 3-8 Downloading Modes ...........................................5-10 Dynamic Unit Assignment ................................... 5-11
B
Basic Elements ..................................................... 6-5 batch ..................................................................... 9-1 Batch-Operation Monitoring.................................. 3-6 Batch Control ........................................................ 5-7 Batch execution control......................................... 5-2 Batch ID ................................................................ 5-4 Batch ID Descriptors ............................................. 5-4 Batch ID specication ........................................... 5-3 Batch Journal ...............................................5-15, 9-1 batch message...................................................... 9-1 Batch Modes .......................................................5-10 Batch Process ....................................................... 1-1 Batch Processes ............................................1-1, 9-1 Batch Progress Information ................................5-19 Batch Related Trend Data Filing .........................5-14 Batch Results ......................................................5-13 Binary format les ...............................................5-14
E
Easy Operation ..................................................... 1-3 equipment module ................................................ 9-1 Equipment Requirements .......................3-4, 4-7, 9-2 Execution data acquisition .................................... 5-2 Exporting Formulas ............................................... 5-6
F
FDA : 21 CFR Part 11 Compliant .......................... 8-1 Flow of Control Recipe Copying Function ............ 5-5 Formula ...................................................3-4, 4-7, 9-2 Formula (recipe data) modication ....................... 5-3
G
Glossary ................................................................ 9-1
H
Header ...........................................................3-3, 4-4 Higher Engineering Efciency .............................. 1-4
C
Collected data .....................................................5-13 common block data ............................................... 9-1 Complex Sequences............................................. 6-6 Compliance with International Standard (ISA-88.01 and 21 CFR Part 11) .................. 1-3 control module ...................................................... 9-1 Control Recipe ...............................................3-2, 9-1 Control Recipe Copy between Servers ..............5-17 Control recipe create............................................. 5-2 Control Recipe Setup ............................................ 5-3 Control Recipe Status ........................................... 5-8 Control start and end time ...................................5-13 CSV format les ..................................................5-14
I
Initialization and Monitoring Operation ...............6-13 Initialization Operation ........................................6-13 Internal Statuses .................................................6-12 ISA-88 ................................................................... 2-1 ISA-88.01 .............................................................. 9-2 ISA-88.01 Physical Model..................................... 2-1 ISA-88 compliant VP Batch................................... 2-1
L
Links ...................................................................... 6-5
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M
Manner of data collection ....................................5-13 Manual Entry ......................................................... 5-4 Master Recipe ................................................3-2, 9-2 Master recipe selection ......................................... 5-3 Message Gathering ............................................5-15 Message generation ............................................. 5-2 Monitoring Operation ..........................................6-13
S
Schedule Expansion ...........................................5-19 SEBOL .................................................................. 9-3 Selective Sequence .............................................. 6-6 Server/Client Function Redundancy...................5-16 Setting of Reference Batch ID .............................. 5-3 Setup Procedure ................................................... 5-3 SFC ...................................................................... 9-3 SFC block.............................................................. 9-3 SFC Execution ...................................................... 6-6 SFC Language ...................................................... 6-5 Sharing Operation ...............................................6-14 Sharing Unit Denition ........................................6-14 Sharing Unit Procedure ......................................6-14 site ...................................................................... 9-3 Specifying Server and Client Stations ................5-16 Starting Modes ....................................................5-10 Status Transition .................................................6-15 Status Transition at the AUT Mode .....................6-15 Status Transition at the SEMI Mode ...................6-16 Status Transition Matrix ......................................6-15 Steps ..................................................................... 6-5 System Conguration Including Schedule Management Function ................................5-19
O
Open Environment ................................................ 1-3 Operation .......................................................6-9, 9-2 Operation Data Items ..........................................6-10 Operation Mode and Status ................................6-10 Operation SFC ....................................................6-10 Operation Statuses ............................................. 6-11 Overview ............................................................... 5-2 Overview of Production Planning and Scheduling Interface Function ........................................5-19 Overview of Recipe Management ........................ 4-2 Overview of VP Batch Software ............................ 3-1
P
Parallel Sequence ................................................. 6-7 path ...................................................................... 9-2 phase .................................................................... 9-2 Procedure ...............................................3-3, 4-5, 9-2 process.................................................................. 9-2 process cell ........................................................... 9-2 Process Management Function ............................ 5-1 Process Report ...................................................5-15 Production Planning and Scheduling Interface .......................................................5-18
T
The denition of link between Common Block & Operation .....................................................6-16 Timing of data collection .....................................5-13 train ...................................................................... 9-3 Transition............................................................... 6-5 Transition Condition .............................................. 6-8
U
unit ...............................................................6-2, 9-3 Unit-Specic Data Items ....................................... 6-3 Unit Assignment .............................................5-3, 5-4 Unit Data ............................................................... 6-3 Unit Modes .......................................................... 6-11 Unit Mode and Status ......................................... 6-11 Unit Procedure ...............................................6-4, 9-4 unit recipe .............................................................. 9-4 Unit Recipe Status ................................................ 5-9 Unit Statuses ....................................................... 6-11 Unit Structure ........................................................ 3-7 Unit Supervision .................................................... 3-7 Unit Supervision Function ..................................... 6-1 User-Dened Data Items ...................................... 6-3
R
Recipe ................................................................... 3-2 recipe .................................................................... 9-3 Recipe Engineer Authentication and Authority Check ............................................. 4-8 recipe group .......................................................... 9-3 recipe header ........................................................ 9-3 Recipe Management Function.............................. 4-1 recipe setup........................................................... 9-3 Recipe Setup and Downloading ........................... 3-5 Recipe Statuses .................................................... 5-7 Recipe Structure ................................................... 3-3 Reference from Application Programs ................5-15 Requirements for DCS Manufacturers ................. 1-3 Reuse of Control Recipe ....................................... 5-5
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Using Generic Name and Sharing Resources ...6-14 Using Generic Name for Units ............................6-14
V
VP Batch Operation and Monitoring Windows ..... 7-1
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Blank Page
Revision Information
Title Manual No. : VP Batch Batch Management Package : TI 33M05L10-40E Oct. 2010/1st Edition Newly published
TI 33M05L10-40E
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Written by
Published by
Product Marketing Dept. Industrial Automation Systems Business Division Yokogawa Electric Corporation Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN
Subject to change without notice.

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VP Batch Batch Management Package

All Rights Reserved Copyright 2010, Yokogawa Electric Corporation

Oct. 29, 2010-00

VP Batch Batch Management Package

Recipe Management Function ................................................................ 4-1

Process Management Function.............................................................. 5-1

Unit Supervision Function ...................................................................... 6-1

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Figure Single-Path, Single-Product Process

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Figure Multi-Path, Single-Product Process

Figure Single-Path, Multi-Product Process

Figure Variable-path Process

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Requirements for DCS Manufacturers

Compliance with International Standard (ISA-88.01 and 21 CFR Part 11)

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Higher Engineering Efciency

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2. ISA-88 compliant VP Batch

ISA-88 compliant VP Batch

ISA-88.01 Physical Model

Figure ISA-88.01 Physical Model & VP Batch

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2. ISA-88 compliant VP Batch

Recipe management (*1)

Production planing and scheduling

Production information management

Unit supervision (*2)

: Covered by the VP Batch software

Process control (function block)

Figure ISA-88.01 Control Activity Model & VP Batch

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3. Overview of VP Batch Software

Overview of VP Batch Software

Figure Flow of Batch-Process Operation

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3. Overview of VP Batch Software

Process cell-specific information

Batch ID, batch size, in-process, operator-and/or system-generated information

Figure Recipe Types

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3. Overview of VP Batch Software

Formula (recipe data)

Figure Recipe Structure

<Unit Recipe Procedure>

Figure Recipe Procedure and Unit Recipe Procedure

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3. Overview of VP Batch Software

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3. Overview of VP Batch Software

Recipe Setup and Downloading

Figure Downloading a Recipe

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3. Overview of VP Batch Software

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3. Overview of VP Batch Software

Operation Charge ~ FIC100.LS=AUT drive[Valve_1=on] end ~

program FeedA Phase

Charge start Charge end

Figure Unit Structure (Unit with a Procedure)

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