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6724-2.1, PLC-Based Batch/Process Control System, System

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1. Oooocoooocoocooooococooooooc Oo0oco0oocoooooocooooocoooococo OOoOoocoocooooooooocooooococo Sc o o oO OoOo Oo eneo n eo Oo eO Oo oo o OoOo OoOo oO OoOo P HP P P HP HP Bp P P H B Bp p PP B p p HP HB Figure 2 8 Alarm Log DD1000 FLTALM DD1001 FLTALM DD1002 FLTALM DD1003 FLTALM DD1004 FLTALM DD1005 FLTALM DD1006 FLTALM DD1007 FLTALM DD1008 FLTALM DD1010 FLTALM DD1011 FLTALM DD1013 FLTALM LOOP101 PVSCALED LOOP101 PVSCALED LOOP101 PVSCALED LOOP101 PVSCALED DEMO MANWTALM DEMO MANWTALM DEMO MANWTALM LOOP101 PVSCALED Hardware Products Chapter 2 Becoming Familiar with Batch Process Control Products Reporting function The Reporting option 6190 REP lets you generate reports that combine real time or historical data with free form text You can define a template for each report specifying exactly what data is to be extracted and in what format it is to appear Reports can be viewed on screen or printed on a local or a network printer Data from any of the four log files described in the previous pages can be combined with Report Writer to generate a report Figure 2 9 Figure 2 9 Data Flow from Log Files through Report Writer Activity Log Data Log Batch Log Reporting Production Batch Option Report Batch Process Control hardware consists of several modular products Each hardware package listed below is available separately through our FlexFactory Group This hardware ha
2. BATCH COOKIE ID 2 STATE PENDING RECIPE CHOC CHIP HE APPROVAL MODE MASTER SEQUENCING MODE SCHEDULE AUTO AUTO now HW1 1 OCT 12 08 16 20 Figure 3 5 Formula Detail Screen Formula Detail INT Form Dtl BIN Form Dtl FLOAT Form Dtl Modify Batch COOKIE 1 ID 18 State PENDING Recipe CHOCOLAT Blk 120 Op Name State PENDING FV Type FLOATING POINT Work Value Eng Unit Default Value Min Value INGREDIENT E LBS 3750 000 2500 000 5000 000 INGREDIENT I 2500 000 0 000000 5000 000 COOL TEMP igo 00 80 00000 60 00000 100 0000 HW1 1 OCT 12 08 16 20 3 5 Chapter 3 Understanding Batch Process Control Operations Monitoring Batches Once a batch is started you can monitor the execution of the procedure operations and even phases that comprise the batch From this screen Figure 3 6 information pertaining to the state of the selected batch is available It also provides information about the procedure contained in the recipe such as which unit s are assigned to run the operations and the selected mode This screen allows you with the proper security level to select some batch oriented functions that may be executed such as aborting or modifying an operation Figure 3 6 Batch Detail Screen Batch Detail INT Dt BIN Dti FLOAT Dtl Op Dt Op Abort Mdfy Mode Batch COOKIE 1 ID 18 State ACTIVE Recipe CHOCOLAT Bik Bik Name Seq Mode unit Assign State
3. DUERUII ees TO ST9 RRGE FL LEGEND The PLC processor controls the actual batch process equipment You enter control into the PLC processor as ladder code This code is segmented into subroutines which correspond to either operations or phases Since Control View uses recipes to provide both the order of execution for these subroutines and the formula data it can be used to manage the batch execution and provide data for operators to interact with the system It also controls and coordinates the data flow between the industrial workstation and the PLC processors Batch Management combined with Control View and Process Configuration and Operation software provides all the functions needed for batch processing including recipe execution log creation and management and unit management and control of the process The actual control of a batch is functionally partitioned into the PLC code Therefore process interfaces and specific control requirements need to be incorporated into the PLC processor and any special operation interfaces need to be developed for Panel View or Control View 3 9 Chapter 3 Understanding Batch Process Control Operations Controlling Lots A common requirement in batch process control applications is the ability to run several batches of the same product one right after the other This is done for example when the amount of product desired exceeds the equipment capacity Batch Management softw
4. Phase state file provide messages that tell the operator the status of a phase in an operation Customizing Your Operator Interface for Data Collection amp Batch Management ControlView software provides you with various tools to create a truly customized system for your batch process control application You can create custom graphics for the operator interface to give your operators more useful and meaningful information about your process Some of the Ways you can customize your operator interface are described on the following pages Generate custom graphic screens By using the tag database you can associate graphics with specific locations in the batch process controller memory which in turn hold information from devices and loops in your process You can use this feature to animate graphic screens Redefine keys on the Batch Process Control keyboard If you want a key to perform a non standard application specific function you can modify an existing definition of a key or create a new definition for a previously unused key 5 7 Chapter 5 Configuring Your Batch Process Control System 5 8 Configure security You can use the operator interface to control access to the system and keep track of the operators using the system Configure alarms In addition to setting alarm tags in the database you can configure alarms that are specific to your application You can specify alarm thresholds as constants or
5. The typical characteristics of a complex batch process control application are multistream multiple line capability multiple batches running simultaneously on same or different lines m many recipes or recipes are changed frequently m numerous procedures or the sequence of production changes m many process units m operator interaction is an exception m much data collection is required for validation etc Figure 4 4 is a diagram of a complex batch process control system and shows how to configure a control system by using the following products BatchMaster Batch Process Controller and or PLC processors BatchView Operator Console or industrial workstation ControlView and Batch Management Option To expand your existing medium scale system you may only need to add new recipes or a plant computer system to manage the recipes This assumes that the control system was developed using the Allen Bradley structured approach 4 5 Chapter 4 Building Your Own Batch Process Control System Storage Tank Steam Figure 4 4 Example of a Complex Batch Process Control System m ww om x Drain Control System Inputs Outputs Mixer Agitator Control PI Transfer Pump Motor 2 x lt lt lt lt c ooo we Product This complex batch process application solution utilizes all of the functions o
6. ALLEN BRADLEY AROCKWELLINTERNATIONAL COMPANY With offices in major cities worldwide WORLD EUROPE MIDDLE HEADQUARTERS EAST AFRICA Allen Bradley HEADQUARTERS 1201 South Second Street Allen Bradley Europe B V Milwaukee WI 53204 USA Amsterdamseweg 15 Tel 1 414 382 2000 1422 AC Uithoorn Telex 43 11 016 The Netherlands FAX 1 414 382 4444 Tel 31 2975 43500 Telex 844 18042 FAX 31 2975 60222 Publication 6724 2 1 September 1992 Supersedes Publication 6724 2 1 October 1989 As a subsidiary of Rockwell International one of the world s largest technology companies Allen Bradley meets today s challenges of industrial automation with over 85 years of practical plant floor experience More than 11 000 employees throughout the world design manufacture and apply a wide range of control and automation products and supporting services to help our customers continuously improve quality productivity and time to market These products and services not only control individual machines but integrate the manufacturing process while providing access to vital plant floor data that can be used to support decision making throughout the enterprise ASIA PACIFIC CANADA LATIN AMERICA HEADQUARTERS HEADQUARTERS HEADQUARTERS Allen Bradley Hong Kong Allen Bradley Canada Allen Bradley Limited Limited 1201 South Second Street Room 1006 Block B Sea 135 Dundas Street Milwaukee WI 53204 USA View Estate Cambridge O
7. PLC Based Batch Process Control System System Overview ALLEN BRADLEY Important User Information Because of the variety of uses for this product and because of the differences between solid state products and electromechanical products those responsible for applying and using this product must satisfy themselves as to the acceptability of each application and use of this product For more information refer to publication SGI 1 1 Safety Guidelines For The Application Installation and Maintenance of Solid State Control The illustrations charts and layout examples shown in this manual are intended solely to illustrate the text of this manual Because of the many variables and requirements associated with any particular installation Allen Bradley Company cannot assume responsibility or liability for actual use based upon the illustrative uses and applications No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this text Reproduction of the contents of this manual in whole or in part without written permission of the Allen Bradley Company is prohibited Throughout this manual we make notes to alert you to possible injury to people or damage to equipment under specific circumstances circumstances that can lead to personal injury or death property ATTENTION Identifies information about practices or damage or economic loss Attentio
8. products thus maintaining flexibility but reducing your implementation effort considerably A Building Block Approach To build a process control system that s right for you you need only utilize the specific products required to achieve the desired level of functionality Then as your needs grow you can expand the capability of your batch process control system in building block fashion as shown in Figure 1 1 Batch Process Control software building blocks include m operator interface software Control or Panel View m process control software Process Configuration and Operation Option m batch management software Batch Management Option m recipe creation software Y Batch Process Control hardware building blocks include m programmable controllers m a batch specific keyboard industrial workstations Simple Batch Process Control System Process Interface PLC 5 with Process Controller Chapter 1 The Allen Bradley Batch Process Control Advantage Figure 1 1 Batch Process Control Products Building Blocks Local Operator Interface If the controlled process is simple such as a mixing tank that requires little automation and has few regulatory control loops our Process Control J PanelView standard Allen Bradley products can Software provide a cost effective solution Plant Floor Devices Medium Scale Batch Process Control System Operator Interface Data Highway As complexity
9. graphics oriented environment that integrates data collection real time operator interface and supervisory control of a batch process control system Graphics editor The pixel based Mouse GRAFIX editor 6190 GFX lets you create high resolution graphic screens for process monitoring Figure 2 4 The screens are linked to the process through the tag database You can animate the screens by configuring specific points to be updated by reading the current status of one or more tags Multi level security capabilities To guard against unauthorized use and or tampering we provide multiple security levels You can restrict access to information control and graphic screens by assigning an appropriate level of security to each authorized user Chapter 2 Becoming Familiar with Batch Process Control Products Figure 2 4 Graphics Screen IL COLORI HZ 1 paene Carbonalion E Eel tzer i Tank dina Bi pence On line help windows You can develop your own customized help windows The user defined help window function supports window positioning choice of color and multiple levels including menus 2 7 Chapter 2 Becoming Familiar with Batch Process Control Product Alarm functions Using the values in the tag database the Alarming option 6190 ALM enables alarming for both analog and digital points When a point trips the alarm banner appears at the bottom of the displayed screen Figure
10. Start Time COMPLETED COMPLETED ACTIVE 10 12 08 13 ACTIVE 10 12 08 13 ACTIVE 10 12 08 13 PENDING PENDING HW1 1 OCT 12 08 16 20 3 6 Chapter 3 Understanding Batch Process Control Operations Each operation contains a series of control actions These control actions can be called phases The Operation Detail screen Figure 3 7 allows you to monitor all phases associated with the selected operation i e the collection of control functions in the batch process You access the Operation Detail screen from the Batch Detail screen Figure 3 7 Operation Detail Screen Operation Detail Batch COOKIE 1 ID 18 State ACTIVE Recipe CHOCOLAT Bik 4 110 Op Name PW1 State ACTIVE Unit UNIT 1 COMPLETED 10 12 08 13 10 12 08 15 COMPLETED 10 12 08 15 10 12 08 16 ACTIVE 10 12 08 16 PENDING PENDING PENDING HW1 1 OCT 12 08 16 20 3 7 Chapter 3 Understanding Batch Process Control Operations Monitoring Units Once the batch process has been segmented into process units a method to view monitor each unit is needed The Unit Summary screen carries the unit concept from the design to the operator and allow users to monitor the status of all configured units and the activities occurring within each Figure 3 8 You can access the Unit Summary screen from the Runtime menu or directly from the batch process control keyboard The Unit Summary screen displays configured process units and the stat
11. You can use Recipe Builder in the DOS window on the operator s interface terminal Off line it can be run on any suitable personal computer Since Recipe Builder is designed for use off line you can create and store your confidential recipe files on a top level plant computer located in a secure environment connected via local area network This provides an additional level of security for your recipe files Chapter 2 Becoming Familiar with Batch Process Control Product 2 6 In addition Recipe Builder lets you create recipes for product variations easily Simply modify the existing formula files and use Recipe Builder again to create new recipes Once Recipe Builder compiles the ASCII text files the resultant recipe can be edited using the Batch Management screens with proper security level protection at the operator interface To change the master recipe the original data files stored on the supervisory or plant computer can be modified and a new recipe made The master recipe can be modified at batch execution time with particular batch values at the operator interface terminal and saved as a new recipe But again only with proper security Recipe Builder performs extensive error checking while compiling a recipe This insures that all required information is provided before you run a batch ControlView Software Control View software is the industrial workstation based component that provides a multi tasking multi windowed
12. automatically monitor and collect batch production data Batch Management software includes Batch specific operator displays Summary and monitor screens Figure 2 2 provide detailed information about batches process units and procedures System Summary summary of all batches scheduled and current status Batch Detail a detailed look at the sequence of operations for a batch and the current status Formula Detail a screen that enables the modification of a recipe formula Unit Summary provides an overview of all batch units and their status Operator Action a listing of information and actions an operator may need for running a batch These screens are used in conjunction with ControlView custom graphics created using the Mouse GRAFIX package to provide a single window into the process Figure 2 2 Sample Batch specific Screen mee e ines c eet e s Del ECT EE sn Stop Time 10 12 07 59 10 12 06 45 10 12 07 23 10 12 08 10 Chapter 2 Becoming Familiar with Batch Process Control Products Batch log generation Batch Management creates a batch log for each batch started This log is unique to each batch and used in the batch report refer to Figure 2 3 Figure 2 3 Batch Log 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 15 56 49 15 56 49 15 56 49 15 56 49 15 56 49 1 TEST1 ABSOUP ABSOUP VERSION 1 001 2 22 91 APPROVAL MODE AUTO D
13. increases with more process EL ControlView loops the addition of process control y md Batch Management software 6190 PCO will provide a level of ocal Process Interface Process Controller Operator Interface configurable regulatory control Coupled with ControlView as a supervisory MMI and Batch Management software this can meet u je many of the needs of more complex 3 f wi 1 Iti unit systems E Process Control lt gt PanelView multi unit systems Software Plant Floor Devices Complex Batch Process Control System Supervisory Plant Operator Interface Computer RON Data Highway Scheduling y tacai ControlView Batch Tracking Process Interface Process Control Operator Interface Batch Management PLC 5 lt gt with I S _ Process Control lt gt PanelView Software v se ControlView Batch Management PLC 5 PanelView Software Process Control Plant Floor Devices Recipe Builder By adding networking with multiple ControlView systems plant wide control can be achieved The individual process units or lines can be managed from a facility level system that can interact with the ControlView Batch 1 3 Chapter 1 The Allen Bradley Batch Process Control Advantage Benefits In addition all batch specific products are fully compatible with other Allen Bradley hardware and software products Whether you are
14. is to Procedure dictate the order of operations in your batch process and coordinate the batch controller s execution of operation logic Operation identify operation parameters such as the formula and phases which are used by the personal computer Formula give actual values to formula parameters for each operation Recipe Builder combines this file with the procedure and operation files to form a recipe Appendix A Glossary batch 1 The product produced by one execution of a control recipe 2 the term used to identify the entity that uses a control recipe and other resources to produce a product batch management The activity that m selects a master recipe and transforms it into a control recipe m manages resources necessary for batch execution m initiates and supervises the execution of the batch and m collects and manages batch data batch process A process that manufactures a finite quantity of material by subjecting measured quantities of raw materials to a sequential order of processing actions using one or more pieces of equipment batch reports Reports containing process and user supplied information collected manually or automatically before during and after completing the batch C control module This is either a loop or a device A control module is the union of the definitions of loops and devices It refers to both devices and loops but it does not constitute another level above them i
15. process control stations as well as with the business systems An industrial workstation and a PLC processor share the responsibilities of controlling the process equipment The computer performs all file 1 7 Chapter 1 The Allen Bradley Batch Process Control Advantage management and data processing functions supervisory operator interface The PLC processor performs all control operation logic including input output interface functions This method of partitioning the data management independent of the control for a batch process control system provides the best combination of resources It retains the inherent reliability and maintainability of true PLC based control while providing a great deal of operational flexibility or recipe data management In addition the Allen Bradley approach allows the operator interface Control View to monitor and control not only the batch process but other PLC processors on the controller network thus providing a very versatile system Product Recipes The Allen Bradley approach to batch process control is based on managing the process as dictated by recipes This allows you to define the control by product requirements without engineering intensive programming normally required in a PLC based batch system Batches are controlled by recipes Using Recipe Builder software you create recipes from procedure formula and operation files Figure 1 3 The procedure formula and operati
16. solutions see your Allen Bradley systems integrator distributor or local Allen Bradley sales representative The most simple Batch Process application is one in which ingredients are being mixed or blended for use by other equipment These are normally stand alone units Typical characteristics of a simple batch processing application are m single stream used to produce a single product one batch at a time m small number of recipe changes in formula values m a procedure that rarely changes m system usually consists of one process unit m operator interaction is a normal activity m data collection is manual Figure 4 1 is a block diagram of a simple batch process control system In this example ingredient A and ingredient B will be added to the mixer Each ingredient will be added individually based on its weight The mixer will combine both ingredients and the valve will open to dispense the product Chapter 4 Building Your Own Batch Process Control System Figure 4 1 Example of a Simple Batch Process Control Application Solution Storage tank Ingd Storage tank B E tm a a ww om ow Control System 1 Load cell m m mmm Load cell w a a u x a Aw Control Valve Control System t Input Output Product Figure 4 2 shows how you can configure a control system using the following Allen Bradley products a PLC 5 family processor Process Configuration a
17. tags Also you can configure alarm priority and the system response to alarm occurrences at each priority level Configure logging functions to suit your application Information to be logged as well as its destination is configurable You can configure logs that show error messages changing tag values typed in operator commands and operator remarks Configure messages for your operators You can configure custom help messages which aid your operators as well as other plant personnel Also you can configure how the system displays graphics and other functions to the operator and which displays appear on the screen in a power up condition All tasks for configuring and starting up a control system using batch process software options are described in detail in the the user manual for that software option Developing Recipes Your recipes are created using a configuration process by assembling the information needed to run a batch into three ASCII files Using any word processing or database software that exports ASCII files you create file s for procedures operations and formulas Using Recipe Builder software you compile these files into Allen Bradley basic recipes This approach was designed so a system integrator using standard tools can tailor an operator interface to meet the customer s needs Table 5 B shows the purpose of each file Table 5 B Recipe Builder Configuration Files Configuration File Purpose of this file
18. 2 5 The alarm banner shows one alarm at a time with the most severe most recent unacknowledged alarm first In addition an alarm summary screen provides detailed listing of all current alarms You can acknowledge alarms from any screen There is also an alarm log that can be used with the Reporting package Figure 2 5 Alarm Summary Screen with Alarm Banner and Status Display Alarm Summary Acknowledge Alarm Acknowledge Page Alarm Identify Time Tag Description Threshold Units Label 18 40 35 Salad mixer total flow in 80 l min too fast 18 39 44 Salad mixer tank valve ON flow stuck 18 33 37 Bulk vinegar tank level 80 litres too high 18 33 37 Bulk vinegar tank valve ON flow problem g MIXER INFLOW Value 81 Ack Time Nov 09 18 40 49 Alarm Banner 18 33 37 Bulk vinegar tank level 80 litres too high on all screens Alm 1 2 8 Chapter 2 Becoming Familiar with Batch Process Control Products Log functions Control View and Batch Management option The four types of configurable log functions are listed below The logging function has the capability of printing logs to a printer or sending logs to a file Logs included are Activity log records all system and operator activities Figure 2 6 Data log records user defined data values Figure 2 7 Alarm log records all alarms Figure 2 8 Batch log records events specific to a batch that occurred while the batch was runni
19. Configuring Your Batch Process Control System 5 4 You can program your system to recognize up to 16 independent batch process control units You can distribute these process control units in any combination between one or several batch process controllers PLC processor as long as all I O associated with a particular process control unit resides in the same batch process controller PLC processor The ability to recognize multiple units allows the batch process control system to monitor manage and control more than one batch at a time Once defined the process control unit becomes the plant floor reference for information transfer between the process and the industrial workstation The workstation reads and writes all batch information through unit based files called unit tables located in the controller Figure 1 4 provides an example of defining process units Process Units Guidelines A process unit is a group of equipment modules that operate together to complete an operation For example if you have a tank for mixing all the valves pumps and weighing systems associated with that tank become a unit When you define process control units for your application the following guidelines can be used m Group associated process equipment together when they are required to execute a complete operation If your process control equipment is required to process multiple batches or products simultaneously you must group the process
20. EF 15 56 49 MASTER SEQ MODE AUTO DEF 15 56 49 BATCH STATE ACTIVE 15 56 49 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 91 10 12 15 56 50 15 56 56 15 56 56 15 56 56 15 56 56 15 56 56 15 56 56 15 56 57 15 56 57 15 56 57 15 56 57 15 56 57 15 56 57 15 56 57 15 56 57 15 56 57 15 56 57 15 56 57 PW1 OP_ID 110 0 PW1 1 PW1 2 PW1 PW2 OP ID 120 0 PW2 1 PW2 MASTER OP_ID 130 0 MASTER MASTER MASTER MASTER MASTER MASTER MASTER MASTER ACTIVE PW1 PREWEIGH 1 INGREDIENT C I LBS INGREDIENT D I LBS INGREDIENT E I LBS PREWEIGH 2 INGREDIENT H I LBS INGREDIENT I I LBS INGREDIENT A INGREDIENT B INGREDIENT F INGREDIENT G INGREDIENT J DUMP PW1 151 HEAT TEMP COOL TEMP tH m UU H H H H 15 56 57 MASTER_BLEND LBS LBS GAL GAL LBS YES NO DEG F DEG F VER PW1 RDY COMPLETE PREWEIGH 1 900 600 200 PREWEIGH 2 600 200 MASTER BLEND 2500 1100 75 60 50 1 1 500000E 002 8 000000E 001 15 56 57 900 600 200 600 200 2500 1100 75 60 50 1 1 500000E 002 8 000000E 001 a Recipe Builder Recipe Builder software is the tool you use to create recipes Allen Bradley supplies a basic recipe editor designed so that the system integrator using standard tools can tailor a recipe creation screen s to best meet the customer s needs
21. How Does a Batch Process Control System Work Related Publications len le le le le 45 la no lo lo lo le le lo le Becoming Familiar with Batch Process Control Products Introduction 2 l iseen apia Q aa Sasha su Qusa sun w Software Products Analog I O configuration Configurable loop control PLC Processor ControlView data table and database Batch specific operator Batch log generation Recipe Builder _ Graphics deeb awe PERO us SEEMS Multi level security capabilities _ On line help windows Alarm functions Log functions E Reporting function Hardware Products ko loo IN lo lo le le le le loo Table of Contents Understanding Batch Process Control Operations Introduction s a sas eee teens Using the Batch Interface Managing Recipes Setting Up Batches Modifying Batches _ Monit
22. Operator Screens User Developed Operation Logic Ladder Code Unit 1 Configuring Your Operator Interface for Batch Process Control Once the operation logic is developed and in the PLC you can now configure the operator interface for the proper interaction with the controllers This is done by configuring the unit tables 5 6 Chapter 5 Configuring Your Batch Process Control System Configuring Unit Tables Each process unit in your system has a corresponding unit table in PLC processor memory These tables are memory areas used for communication between the batch process controller and the industrial workstation The Batch Management option downloads recipe data to unit tables where it is accessed by your ladder program in order to execute operations The operation logic can also place production data into the table for collection to be placed in the batch log You configure unit tables by editing configuration files for units operation states and phase states These files contain information to control the passing of information to and from the batch controller Table 5 A lists the files you configure and the purpose of each Table 5 A Purpose of Configuration Files Configuration File Purpose of file is to associate unit numbers with a name and specify in which controller the unit is located Unit configuration file Operation state file provide messages that tell the operator the status of the operation
23. Time 10 12 07 59 10 12 06 45 10 12 07 23 10 12 08 10 All batches require a master product recipe You normally create this using the recipe creation package and load it into the batch system Following the proposed concepts from ISA SP 88 standards you do not run a batch from a master recipe but a copy called the working recipe This working recipe becomes the recipe that can be modified by the operator at the operator interface level This protects the original so that each batch starts from the same data Modification may be needed to make a change in the raw material or the product Therefore the Batch Management software has utilities that your plant floor operator can easily use to change and save recipes These functions include a load recipes from the recipe library m save modified recipes with a new filename m delete recipes not linked to a batch Using Recipe Builder software on a personal computer or the BatchView Operator s Console when it is off line you can also create new recipes and add them to the batch database If you modified formula values while a batch was running and want to save the revised recipe you simply save it with a new name It is available to be used again 3 3 Chapter 3 Understanding Batch Process Control Operations Setting Up Batches The act of selecting a recipe and scheduling it to run is called set up This is done by giving the batch a name selec
24. a system integrator or an end user familiar with automated process control you can assemble complete batch process control systems from Allen Bradley products that provide you with connectivity to a wide range of third party products Based on your application needs you can choose any degree of sophistication from a general purpose operator interface through a bundled turn key system Allen Bradley Batch Process Control products are the solution to your batch process control needs Provide a cost effective solution Using modular batch process control products as a foundation you can build a batch process control system tailored to your specific requirements Whether you have fewer than 10 or more than 10 000 I O points Batch Process Control products provide a cost effective process control solution Provide better recipe management Recipe Builder software lets you create recipes off line using a personal computer or LAN connected plant computer This gives you the security of having your confidential data files on a supervisory computer instead of leaving them accessible to every operator interface station After the recipe is compiled the file is downloaded to the operator interface terminal for execution Improve Design and Simplify Your Installation Reduce integration engineering requirements Tag assignments for status and alarm functions and data transfers are predefined and documented You can tailor the monitoring capability by crea
25. are lets you setup and start a group of identical batches called a lot in one step A lot can have up to 99 batches all using the same recipe Once the you set up and start the lot the software steps through the individual batches without further operator intervention Batch Management software contains several screens and commands to manage lot creation operation and monitoring It is also possible to chain lots together so that the completion of one lot triggers the start of another This makes it possible to setup an entire day s or more production at one time Introduction A Simple Batch Application Solution Chapter 4 Building Your Own Batch Process Control System Now that you have become familiar with the products that make up a batch system and are somewhat familiar with the operation of the software let s build a system for your application All batch applications have at least three common control functions They are m recipe management m batch management m unit management process unit control As the control becomes more complex the application of these functions changes This chapter describes three levels of solutions to batch process control applications Each example shows how you can use Allen Bradley products to build a batch process control system to meet your specific needs Note that the examples shown in this chapter are samples of possible solutions For additional suggestions and alternative
26. batch process control units These units are groups of process control equipment associated with required processing activities You can then create specific relay ladder logic subroutines libraries in the PLC processor to perform the actions required of each unit to produce a product Such subroutines can add ingredients to the tank wm heat the tank m cool the tank This then establishes the base from which you can build the batch process control system An Example Figure 1 4 shows an example of how a batch process control system operates This system has been divided into five process units Two preweigh tanks process unit 1 process unit 2 weigh out several ingredients and then dump the ingredients into the mixing tank process unit 3 The mixing tank also weighs out an ingredient agitates the mixture undergoes a heat cycle and dumps out the finished product which is then stored in storage tank 1 or 2 Once you define units it is a simple step to establish the control required for operation subroutines For example unit 1 preweigh tank 1 could have operations such as add ingredients mix ingredients transfer ingredients Or these can be phases of a single operation Units 2 and 3 would follow the same approach Unlike traditional PLC based batch processing systems which have procedures operations and formulas programmed in the controller memory the Allen Bradley Batch Process Control system stores only basic op
27. cipe type of recipe which accounts for specific equipment capabilities and train configurations 0 operation An independent production activity within a procedure consisting of phases which is carried to completion in a single unit Appendix A Glossary P phase An independent process oriented action with an operation The phase is defined by boundaries that constitute safe or logical points where processing can be interrupted procedure The part of a recipe that defines the generic strategy for producing a batch of product R recipe A complete set of information that specifies the control requirements for manufacturing a batch of a particular product recipe management The activity that includes creating editing storing and retrieving general site and master recipes and interfaces with the production scheduling and batch management activities regulatory control Maintaining the outputs of a process as close as possible to their respective set point values despite the influences of set point changes and disturbances S sequential control A class of industrial process control functions in which the objective is to sequence the process through a series of distinct states e g open close or on off U unit A collection of associated Elements Control Modules and Equipment Modules that performs a coordinated function Units operate relatively independently of one another A Unit includes both physical
28. ecipe utility software enables you to manage recipes at the operator interface It allows you to save modified recipes on line so you can continue to run your process Decrease response time for process and equipment contingencies Batch Management software in conjunction with ControlView lets you fine tune the formula and certain procedural parameters while the batch is running This gives you an opportunity to optimize the process and or compensate for unexpected conditions Provide information about batch status Batch Management software provides pre defined monitoring and summary screens so you can see the status of procedures operations phases and process control unit allocations for each batch Menu screens guide you through the summaries Reduce product changeover time Short runs with frequent and rapid product changeover are the nature of batch processing Batch Process Control software lets you run multiple batches simultaneously You can track one product and test another while continuing to make other products Changing to run a new product means changing only the recipe not redesigning the control system Using the recipes on multiple production paths can be defined prior to execution Use consistent basic operator interface All Batch Process Control software screens communicate information to the operator in ordinary batch language terminology These terms such as procedure operation formula and phase conform to the eme
29. edium scale batch process control application are m single stream is used to produce products one batch at a time may be parallel lines m large number of product recipes multiple procedures required to produce product variations m moderate operator interaction is required as system is automated m data collection is moderate The main feature differentiating this application from the simple application example is the need for greater flexibility because of the production of a greater variety of products with different recipes The diagram shown in Figure 4 1 could still apply However Figure 4 3 shows how you can enhance the capability of the simple control system by adding the following control products m batch process control industrial workstation m ControlView software with Batch Management Option m batch process keyboard to enable operator easy interaction with process optional 4 3 Chapter 4 Building Your Own Batch Process Control System Figure 4 3 Batch Process Control for a Medium to Complex Application I el S 8 ElS sisi ol ControlView als 2l2lsls8 Options E S 8 a including a Batch _2 2 ControlView SS Database ControlView Operator Intertace Industrial Worskation ar witout Based Operator s Station atch Option i x ae Table Operator Terminal L
30. equipment in such a manner to allow for the most complex or flexible batch m The more batch units you use the more flexible the system can be However you must remember that a unit has to be capable of completing the entire operation Shared Resources Any device or loop that might be used by more than one operation or more than one unit is referred to as a shared resource Shared resources are generally not part of any one process unit but may be used by several units They can be treated as a unit or included in one or more defined units This can only be determined by the application Each approach has its value When using a device as a shared resource you verify the availability of a device by including interlocks in your operation logic Figure 5 3 illustrates shared resources The pump valve 1 and valve 2 are not defined as part of a unit However because they are used by unit 4 and unit 5 they are shared resources Chapter 5 Configuring Your Batch Process Control System Figure 5 3 Unit Arrangement with Valve as a Shared Resource Unit 3 Mixing Tank Storage Storage Tank 1 Tank 2 J 17676 Configure Program the Controller You can use the standard PLC tools programming software to configure and assign the I O You can also accomplish this with the Process Configuration and Operation option which provides loops device drivers and configurable analog I O functions Once the discr
31. eration logic subroutines in PLC processor memory This is a significant advantage because it substantially reduces the amount of controller code necessary to run batches by eliminating most of the interlocks between the control operations It also provides more flexibility for the operator to interact during batch operation Chapter 1 The Allen Bradley Batch Process Control Advantage Figure 1 4 A Mixing System with 5 Batch Units hit 1 Flavor Flavor B Flavor C CN Pre weigh Tank lu X Heati wo Pump N 5 X coe cJ Storage Storage Tank 1 Tank 2 LM LM ee To produce a batch you access the recipe library on a local hard disk or remote file server select a product recipe using the operator screens assign it to a particular batch by adding the batch name and then start the batch While batches are running the operator interface software provides system status information and a window to the control which is displayed on the operator interface screen at the operator s console to keep operators informed and enable them to fine tune the process In addition the operator interface provides alarm monitoring and logging functions To learn more about the hardware and software capabilities of batch process systems turn to the next chapter Becoming Familiar with Batch Process Control Products 1 11 Chapter 1 The Allen Bradley Batch Proce
32. eric vacuum fluorescent display m Single Loop controller The Single Loop controller provides dedicated control of individual PID loops Single loop controllers interface to PLC processors over RS 422 serial links Chapter 2 Becoming Familiar with Batch Process Control Products Beyond Allen Bradley Products Your custom batch process control system may require products that are manufactured by Allen Bradley s partners Through the Pyramid Solutions Program PSP we can help you assess those needs Consult your local Allen Bradley sales representative for complete information on PSP programs Typical Batch Process Control System Figure 2 10 shows a typical batch process control system architecture based on applying the complete line of Allen Bradley products Figure 2 10 Typical Batch Process Control System Plant Computer System T60 Operator Console with ControlView Batch Management and 6200 Series software Batch Process Controller with Process Configuration and Operation software 17234 2 13 Introduction Using the Batch Interface Chapter 3 Understanding Batch Process Control Operations This section describes some of the tools available to operate and interact with a batch process control system You can manage the batch or control the process from the operator interface using standard Allen Bradley operator interface software and the batch process control keyboard Batch Mana
33. ete and analog I O assignment is complete and any regulatory control loops configured you can develop the operation logic to control your process control equipment The batch controller controls the process The relay ladder logic is segmented or structured into specific control actions called operations This operation logic is developed for each unit that has control and for every type of control required for a unit 5 5 Chapter 5 Configuring Your Batch Process Control System To read and act on recipe data the operation logic utilizes the unit table files This data includes commands to execute operations and provides formula parameters and other information required to execute the programmed unit logic The operation logic also can pass production values generated during the operation back to the industrial workstation for entry into the batch log through the unit tables Figure 5 4 shows the logic layout of the batch controller the operator interface and the flow of batch related information Figure 5 4 Batch Process Controller Logic Layout Operator Interface Batch Controller Recipe Procedure and Formula PE Unit Tables UN16 N UN3 UN2 EL Jew Operation Formula UN1 s kd s li rc E Operation ID Process data Formula Files and status cC Production Files t Status Batch Log Subroutine 1 Subroutine2 Subroutine3 Subroutine X D Operator Interaction Batch Summary ME
34. f the medium scale solution is more concerned with process unit identification and requires Recipe Management Recipe Management provides the following functions Function Application Method Recipe development procedure and formula on a plant computer Recipe editing recipe selection and scheduling Recipe Management Introduction Understanding Batch Process Control Component Relationships Plant Computer Operator Interface ControlView Builds recipes Manages recipes and provides data to the process logs data from the process Chapter 5 Configuring Your Batch Process Control System This chapter provides an overview of tasks you can use to define your batch process control system assuming you have the appropriate batch hardware along with ControlView Batch Management and Process Configuration and Operation software For more detailed information refer to the the Control View Batch Management User Manual or the Process Configuration and Operation User Manual No two batch processes are alike However a consistent approach to defining a batch control system that is flexible and utilizes emerging industry standards ISA SP 88 can reduce your implementation efforts The following is a summary of the methodology used by Allen Bradley to define and implement a PLC based batch process control system Figure 5 1 shows how the operator interface batch controller and process equipment interact with one another A br
35. gement software provides a variety of menus and screens that let you easily access all batch functions These screens are used in conjunction with the custom screens developed using the ControlView Mouse GRAFIX package and the process control screens provided by the Process Control and Operation software Using these operator interface packages you can perform many tasks such as loading recipes from storage controlling the miscellaneous devices and control loops in your process and monitoring alarms loops tags and devices We describe the tools you can use to perform the following tasks in this chapter m managing recipes m setting up batches m modifying batches m monitoring batches m monitoring units m controlling batches Batch Management software has a hierarchical display screen structure to help you monitor and adjust the batch process control Menu screens are provided to guide you through the displays Figure 3 1 shows how Batch Management menus and custom screens are organized The following pages show some of these screens with typical data displayed These screens highlight only a few of the features available Along with the accessibility to the data these screens establish a consistent way of interacting with your batch process control system This reduces the engineering time required by a system integrator to build your system A consistent approach makes it easier for operators to move from line to line since each system
36. gn I O to the process control devices Configure discrete device interfaces Program or configure regulatory loop Develop the process control units operation control logic using ladder diagram Configure Program The Controller e Enter data into the PLC device configuration Configure Your screens Process Configuration and Operation Operator Interface e Configure unit tables e Configure tag data base e Configure process function e Generate custom graphics tags custom help Customize Your messages etc Operator Interface e Configure logging functions alarms security etc e Build and load recipes Develop Your Operating Recipes Defining Your Process Control Units Following the recommended approach and using the Allen Bradley batch products the batch controller will be used to control the process equipment in groups called process control units Each process control unit consists of process equipment associated with a major batch process control operation such as mixing or blending Depending on the nature of the product the process may require one or more process control units Although a process control unit is defined as a collection of related process control equipment the real significance is how to segment the equipment to obtain the best utilization in the production process The more units there are the more flexible the system with respect to running multiple batches and products 5 3 Chapter 5
37. ief explanation follows the figure Figure 5 1 Functions of Operator Interface Batch Controller and Process Control Equipment Ez LL 151 Process Equipment Batch Controller PLC amp I O Lets operators monitor and Controls process equipment control batches and plant based on data from operator equipment using standard and interface and operation logic custom screens Returns production values to the operator interface for monitoring and data collection batch logging Chapter 5 Configuring Your Batch Process Control System Your Design Responsibilities 5 2 You define your batch process control system so that your operator interface batch controller and process equipment interact with one another to control the process The functional partitioning achieved by using a control system based on Allen Bradley batch specific components provides the proven reliability of PLC processor control along with the computing and display capabilities of an industrial workstation required for today s flexible batch process control system The operator interface which uses ControlView Batch Management software is a multi unit supervisory system that manages recipes and batch functions including interaction with an MIS system To develop your batch process control system you create product recipes using configuration files specifying formulas and procedures Recipe Builder software takes these files builds them in
38. interface is similar Chapter 3 Understanding Batch Process Control Operations Figure 3 1 Map of Batch Management Menus and Screens Runtime Menu Operator Actions Select Operation Detail Group Display Custom Graphics Phase Monitor Formula Detail Operation Detail You can use these screens to perform a variety of different tasks associated with batch processing The following pages describe these tasks and how they can be used in an application Most commands that control batch processing functions are issued from the Batch screens However you can implement custom control using advanced control functions such as macros or C programming tasks The System Summary screen Figure 3 2 displays current batch activity It shows batch name state start time and completion time By selecting one of the fields at the top of the screen you can access other screens or windows or perform the batch processing task indicated 3 2 Managing Recipes Chapter 3 Understanding Batch Process Control Operations Figure 3 2 System Summary Screen System Summary Setup start Detail Modify Suspend Continue Abort Appr Dei Schedule 101 ACTIVE CHOCOLAT START AT 8AM 2600 PENDING CHOC_CHIP START AT 9AM 1500 COMPLETE ANGEL SEE SUPR 27 PENDING LEMON SEE SUPR 148 ACTIVE VANILLA ANY TIME ID State Recipe Start Time Stop
39. monitor the status of analog functions Configurable loop control You can load each system controller with batch process control logic for regulatory loop control From the loop configuration display you can configure the control logic in multiple controllers for the loops to control the process This also includes control faceplates for ControlView and PanelView as we as tuning screens to be used with Control View PLC Processor ControlView data table and database The data mapping and communications between the PLC processor and the industrial workstation are provided as part of the system software This approach is unique in that although the tags are structured they can be modified using the standard Control View 6200 Series software tools so you can create your own custom screens and tags as required You load the software into the PLC processor using standard PLC programming software You configure it by filling in the needed data using the PLC programming software or configuration interface screens on Control View 2 3 Chapter 2 Becoming Familiar with Batch Process Control Product 2 4 Batch Management Software When added to Control View Batch Management software provides effective management of batch execution based on the selected product recipes Using this software your system can run multiple batches using multiple batch controllers and process units easily change the production procedure or products and
40. n helps you Identify a hazard Avoid the hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product 1992 Allen Bradley Company Inc PLC is a registered trademark of Allen Bradley Company Inc BatchMaster Batch View ControlView Dataliner Panel View and PLC 5 are trademarks of Allen Bradley Company Inc GRAFIX is a registered trademark of Dynapro Systems Inc Table of Contents The Allen Bradley Batch Process Control Advantage What Is an Allen Bradley Batch Process Control System Lp MERCEDE Provide a cost effective solution _ Provide better recipe management Reduce integration engineering requirements Reduce equipment setup time Provide flexible batch process control Increase production Optimize use of process control equipment Manage recipe changes on the plant floor Decrease response time for process and equipment contingencies Provide information about batch status Reduce product changeover time Use consistent basic operator interface Use traditional programmable control Rely on Allen Bradley support and service
41. n the Physical Model It does not contain both loops and devices it contains either one or the other This 1s similar to the use of element to refer to both sensors and actuators control recipe A master recipe with a specific batch ID which through its execution coordinates the production of a single batch of the specified product It may contain operator and or system generated information Appendix A Glossary E equipment module One functional group of equipment typically centered around a piece of process equipment such as a vessel heat exchanger filter scale etc including Control Modules and Elements that accomplishes a task in the process using a combination of Sequential Control Regulatory Control and Discrete Control Equipment Modules include both physical equipment and all associated control functions F formula A set of parameters that distinguish the products defined by procedures It may include types and quantities of ingredients along with information such as the magnitude of process variables It may affect procedures G general recipe A type of recipe that is generic and transportable L loop A combination of elements and control functions arranged so that signals pass from one to another for the purpose of measurement and or control of a process variable A loop may contain some discrete components lot One or more batches made with the same recipe all having a common trait master re
42. nd Operation software PanelView This solution can reduce the PLC development engineering effort to the following functions Function Application Method Programmed Formula Changes via Parameter Download from PanelView Recipe Management Batch Management Programmed operator interface in PanelView Programmed procedures sequences in PLC processor Programmed data collection in PLC processor ControlView compatible batch structured ControlView compatible PLC data table unit table process control interfaces Process Unit Control Configurable regulatory loop control Programmable sequential control PID logic and interfaces for faceplate and tuning display Configurable analog I O Configurable device drivers logic with faceplate interfaces A Medium Scale Batch Application Solution Chapter 4 Building Your Own Batch Process Control System The concept of using a structured PLC based process unit control is critical to establishing a manageable system Once this is accepted maintenance and upgrades become easy Figure 4 2 Batch Process Control for a Simple Application with Local Operator Interface e Q PanelView PE S 2 Data Operator Terminal 58 n Table Control Functions Unit Operations Unit Operations Unit Operations Process Interface Process Unit Local Interface Control Program developed using Process Control software and a PLC 5 Typical characteristics of a m
43. ng Figure 2 3 A new batch log is created each time a batch is started This helps ensure that all information for a batch is collected and identified Figure 2 6 Activity Log 91 03 26 comstatus 91 03 26 15 48 37 CMD time x634 91 03 26 15 48 37 CMD bkbon 91 03 26 15 48 38 CMD batchon 91 03 26 15 48 38 CMD LOAD BWD1102 91 03 26 15 52 43 CMD KEY DEMO 91 03 26 15 52 47 CMD ALARMON 91 03 26 15 52 47 CMD HANDSHAKEON 91 03 26 15 52 47 CMD EVENTON 91 03 26 15 52 47 CMD DATALOGON DEMOLOG 91 03 26 15 52 48 CMD HELLO X 91 03 26 15 52 49 APPLC LOGON DEFAULT 91 03 26 15 52 49 APPLC LOGIN X 91 03 26 15 52 49 CMD Toplevel 91 03 26 15 52 49 CMD menu 91 03 26 15 52 50 CMD ACKNOWLEDGE DEMO MANWTALM 91 03 26 15 52 58 CMD quit 91 03 26 15 54 35 CMD comstatus 91 03 26 15 54 35 CMD time x634 91 03 26 bkbon 2 9 Chapter 2 Becoming Familiar with Batch Process Control Product Figure 2 7 Data Log 91 01 21 LOOP101 CV 91 01 21 LOOP101 PVSCALED 91 01 21 LOOP101 SP 91 01 21 1 LOOP101 CV 91 01 21 LOOP101 PVSCALED 91 01 21 LOOP101 SP 91 01 21 LOOP101 CV 91 01 21 LOOP101 PVSCALED 91 01 21 LOOP101 SP 91 01 21 LOOP101 CV 91 01 21 LOOP101 PVSCALED 91 01 21 LOOP101 SP 91 01 21 LOOP101 CV 91 01 21 LOOP101 PVSCALED 91 01 21 LOOP101 SP 91 01 21 LOOP101 CV 91 01 21 LOOP101 PVSCALED 91 01 21 LOOP101 SP 91 01 21 LOOP101 CV 91 01 21 LOOP101 PVSCALED HM HP H H H H H H P BH H HP P H H H H RPP
44. ntario NIR Tel 1 414 382 2000 28 Watson Road 5X1 Telex 43 11 016 Hong Kong Canada FAX 1 414 382 2400 Tel 852 887 4788 Tel 1 519 623 1810 Telex 780 64347 FAX 1 519 623 8930 FAX 852 510 9436 Copyright 1992 Allen Bradley Company Inc Printed in USA Oe Rockwell Automation Allen Bradley a Rockwell Automation Business has been helping its customers improve pro m ductivity and quality for more than 90 years We design manufacture and support a broad range Allen Bradley of automation products worldwide They include logic processors power and motion control devices operator interfaces sensors and a variety of software Rockwell is one of the worlds leading technology companies Worldwide representation M Argentina Australia e Austria e Bahrain e Belgium Brazil e Bulgaria e Canada e Chile e China PRC Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Ecuador e Egypt e El Salvador e Finland e France e Germany e Greece e Guatemala e Honduras e Hong Kong e Hungary e Iceland e India e Indonesia e Ireland e Israel Italy e Jamaica 9 Japan e Jordan e Korea e Kuwait e Lebanon e Malaysia e Mexico e Netherlands e New Zealand e Norway e Pakistan e Peru e Philippines e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden Switzerland Taiwan e Thailand e Tu
45. ocal Interface i Control Program i developed using i Process Control Unit Operations 1 software anda PLC 5 Unit Operations Process I O Interface Process Units A Complex Batch Application Solution Chapter 4 Building Your Own Batch Process Control System The Allen Bradley batch process control solution reduces both the PLC and the batch management development engineering effort and provides the following functions Function Application Method Recipe Management Recipe generation off line or in ControlView DOS window Recipe control at plant level within ControlView Batch Management Interactive operator interface for Batch Process control Resource management if multiple units are used Data collection for batch reporting Recipe driven procedures sequences Recipe driven data collection ControlView PLC control methodology based on SP88 ControlView tag structures PLC data table unit table process control Communication drivers batch data device status and control system level diagnostics Process Unit Control Programmable sequential control Configurable loop control Configurable device control PID with faceplate and tuning display Configurable Analog I O Device drivers with faceplates Batch Process keyboard By using the same PLC based software and programming approach Control View and its options are layered onto the PLC system extending its capability
46. ol systems They are also an excellent choice for entry level or pilot plant systems since they can expand with the growth of the application And being PLC based means that as your process control needs grow you can increase the functionality of your system by simply adding the necessary hardware or software products Your initial installation can become the foundation for expansion This approach not only reduces project cost initially but minimizes system integration cost over the long term as well The advantages offered by this approach are m costeffective method of doing process and batch control m aflexible system that uses standard hardware m solid methodology for implementing batch and process control in PLC processor m fully supported tools for doing batch and process control 1 1 Chapter 1 The Allen Bradley Batch Process Control Advantage A Flexible System Allen Bradley products let you build custom designed control systems using proven off the shelf hardware and software Each product is available separately so you can achieve any level of control by simply choosing the right combination of products With the addition of application based software that uses a consistent approach for batch process control you can now have system flexibility yet maintain manageable control code The key to this approach is that each product has the necessary hooks to allow out of the box integration with other
47. on files are text files you create and edit You can develop your own user friendly screens to create product recipes These screens can be based on any standard word processor database or spreadsheet package The only requirement is that the output ASCII files be in the simple format defined by Allen Bradley Screens can then be tailored to your specific needs refer to Figure 1 3 Chapter 1 The Allen Bradley Batch Process Control Advantage Figure 1 3 Recipe Builder Software Creates Allen Bradley Batch Recipes Recipe Builder Procedure EE Formu Procedure Add ingredients Mix ingredients Transfer ingredients Allen Bradley Batch Recipe Binary File Compiler Procedure Formula and Operation files are checked and compiled into a binary file Secure Recipe for production Word Processor or Spreadsheet Program About the Files The procedure file contains the specific sequence of operations necessary to produce a particular product This file specifies the way a product will be manufactured Operations are major processing activities subsets of the total procedure executed during the batch Every operation is a group of one or more control activities referred to as phases or steps The formula file contains the specific values for all variables required by each operation for the product These variables can be amounts of ingredients times temperatures pressures and so on Of
48. oring Batches Monitoring Units Controlling Batches _ Controlling Lots _ gt leo l lo le Building Your Own Batch Process Control System INMOGUCHON ao aient eto sasan op aL P SpE Eq Sea erect etes A Simple Batch Application Solution A Medium Scale Batch Application Solution A Complex Batch Application Solution _ len leo Configuring Your Batch Process Control System Introduction 2 00 cee cece eee RBS Understanding Batch Process Control Component Relationships Your Design Responsibilities _ Ino Glossary 52 22s es aa 1 Chapter 1 The Allen Bradley Batch Process Control Advantage What Is an Allen Bradley Allen Bradley has combined the inherent control flexibility of Batch Process Control programmable logic controllers PLC with the data management capability of industrial workstations and applied a methodology based on tem Sys standards to implement and control batch processes The Allen Bradley batch process control offering is a collection of standard PLC hardware and software integrated with application specific software Our solutions are cost effective for small and medium scale batch process contr
49. rging standards from the ISA Batch Control Committee SP 88 Regulatory and sequential control are totally integrated with each other and with batch management functions 1 5 Chapter 1 The Allen Bradley Batch Process Control Advantage How Does a Batch Process Control System Work Reduce Your Maintenance Use traditional programmable control The batch process controller uses the powerful PLC 5 family of programmable controllers As a standard product it provides all the advantages associated with a PLC based system configurability expandability familiarity flexibility and maintainability Rely on Allen Bradley support and service Allen Bradley supports batch process control products with written warranties telephone support and other continuation programs To understand how the batch process system works you need to become familiar with m the components in the system and how they relate to one another m the functions of the components a concept called functional partitioning how the system manages recipes how the system controls a batch or process System Components The batch process control system consists of several software and hardware components we describe these in detail in chapter 2 Figure 1 2 shows the the relationships between the batch process products and the process equipment in your plant Chapter 1 The Allen Bradle
50. rkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela e Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 6724 2 1 January 1996 Supersedes Publication 6724 2 1 September 1992 Copyright 1985 Allen Bradley Company Inc Printed in USA
51. s etc It also includes an integrated section that can be connected to your PLC processor to provide special functions The Batch Process Control Keyboard can be used on a desktop or permanently mounted to an operator s console or batch controller BatchView Operator Console The Batch View Operator Console is a desk enclosure complete with industrial computer and Batch Process Control keyboard It is available in left and right hand versions to provide a double CRT with a large work space when connected together BatchView 60 Operator Workstation The Batch View 60 Operator Workstation combines the T60 Industrial Workstation and the Batch Process Control Keyboard The workstation includes pre configured software and is factory tested Software includes a Process Control software for the PLC processor a ControlView software Batch Management software Other Allen Bradley Products Use these other Allen Bradley products to build upon your custom batch process control system a PanelView Operator Terminal The PanelView terminal is a CRT based operator s terminal designed for plant floor applications The PanelView terminal uses utilities provided with the process control software It provides a fast easy flexible low cost plant floor operator interface a Dataliner Message Displays The Dataliner message display is an operator display designed for plant floor applications It displays status or fault messages on an alphanum
52. s been developed to reduce the engineering effort normally required in the development of a cabinet and console This is a cost effective way to provide an integrated interactive control room All hardware modules have been fully tested and are backed by the standard Allen Bradley warranty The products are a BatchMaster Batch Process Controller FlexFactory product Batch Process Control Keyboard cat no 6721 BKBD a BatchView Console FlexFactory product Operator s BatchView 60 Operator Workstation FlexFactory product BatchMaster Batch Process Controller The BatchMaster Batch Process Controller consists of a NEMA 12 enclosure suitable for use in industrial environments and includes the following components a PLC 5 programmable controller O chassis power supply m field terminal blocks m standard enclosure items such as lights and locks etc 2 11 Chapter 2 Becoming Familiar with Batch Process Control Product T imum Batch Process Control Keyboard The Batch Process Control Keyboard is an industrially hardened operator s keyboard designed to simplify your operator s efforts It features sealed membrane switches with process oriented labels The keyboard is divided into nine functional sections to allow rapid access to process equipment displays alarm report
53. ss Control Advantage Related Publications Use these sources to learn more about batch process control systems Publication Publication Number Batch Management User Manual 6190 6 5 18 Process Configuration and Operation User Manual 6190 6 5 23 ControlView Core User Manual 6190 6 5 1 ControlView Derived Tags User Manual 6190 6 5 11 ControlView Trending User Manual 6190 6 5 6 ControlView Data Logger User Manual 6190 6 5 7 ControlView Event Detector User Manual 6190 6 5 10 ControlView Alarming User Manual 6190 6 5 4 ControlView Allen Bradley Drivers User Manual 6190 6 5 5 Mouse GRAFIX Editor User Manual 6190 6 5 3 ControlView Reporting User Manual 6190 6 5 8 PLC 5 Programming Software Installation and Configuration 6200 6 4 6 PLC 5 Programming Software Programming 6200 6 4 7 PLC 5 Programming Software Testing and Maintenance 6200 6 4 10 PLC 5 Programming Software Instruction Set Reference 6200 6 4 11 PLC 5 Programming Software I O Configuration 6200 6 4 12 PLC 5 Family of Programmable Controllers Installation Manual 1785 6 6 1 Introduction Software Products Chapter 2 Becoming Familiar with Batch Process Control Products When building a batch process control system with Allen Bradley equipment you can choose from a full line of software and hardware control products Although each product is available separately we ve integrated some products to further reduce engineering and integration time This chapter describes the sof
54. ten a family of products uses the same procedure but with different formulas to produce various grades or types of product Since the procedure and formula files are independent you can create store and execute numerous recipes by editing and recombining the procedure and formula files It should be noted that what is being created is a master recipe This will be used by the batch system but can be modified during batch execution within limits prescribed by data within the recipe Added Security The Recipe Builder lets you create and maintain your confidential recipes at a level that best meets your operational requirements After the recipe is created the file product recipe can be loaded onto the batch operator interface terminals The recipe is created as a binary file which adds another level of security to your recipes since it can not be modified on the plant floor without proper security software 1 9 Chapter 1 The Allen Bradley Batch Process Control Advantage 1 10 Batch Process Control The batch controller which consists of a PLC 5 processor and I O programmed for the specific application controls process devices with sequential logic and regulatory PID loops based on information from the product recipe You can simplify a batch application and achieve a high degree of batch flexibility by segmenting the batch process into identifiable independent
55. ting C Tool Kit Networking a l a ub v T oY vn p YY Combine all options for a full scale batch process control system Chapter 2 Becoming Familiar with Batch Process Control Products Process Configuration and Operation Software 6190 PC0 The Process Configuration and Operation software is PLC based code that is the foundation on which you build a batch process control system It includes an extensive set of controller logic extended regulatory loops device drivers and communications services to the operator interface and or other intelligent I O devices With Process Control software you get Configurable two and three state device drivers Device drivers provide a consistent means of communicating with external devices such as solenoid valves and motors The drivers handle the handshake logic between the process logic and the devices In addition they provide alarm and mode control functions to the operator interface Faceplates in the software let you monitor device driver status Analog I O configuration Reading and transferring analog data from the I O module to and from the PLC processor is accomplished with this function By completing a configuration screen the analog I O logic is invoked and the data automatically transferred into the PLC processor data table to be used by PID instructions or any other programmed instruction As with the device drivers faceplates for analog I O let you
56. ting additional tags or modifying existing ones Communication between the PLC based controller and the operator interface is defined and included in the system software Reduce equipment setup time Control oriented functions are preprogrammed and supplied with the process control software These enable you to configure batch process control devices by entering information about their characteristics into configuration screens Provide flexible batch process control The industrial workstation provides a control system that takes advantage of the power of an industrial workstation without sacrificing the inherent reliability of the programmable logic controller You have a controller that is designed specifically for control provides predictable startup and shutdown sequences and offers operator security Chapter 1 The Allen Bradley Batch Process Control Advantage Enhance Your Production Increase production Batch Management software has the capability of scheduling process control units to run multiple batches simultaneously This maximizes equipment usage and throughput while reducing direct labor required to manage a given batch run Optimize use of process control equipment Allocation of process units to batches lets you integrate maintenance and cleaning schedules into daily production routines to automatically start batch operations when process equipment units are available Manage recipe changes on the plant floor R
57. ting a specific recipe and establishing a schedule The system then displays the Batch Name State Recipe Schedule and assigns a unique ID number To set up a batch you select the Batch Setup window Figure 3 3 from the System Summary screen by using the cursor and respond to prompts which appear on the screen Figure 3 3 Batch Setup Window System Summary setup start Detail Modify Suspend Continue abort Appr pei Name ID state Recipe Schedule Start Time Stop Time ACTIVE START AT 8AM 10 12 07 59 PENDING lt START AT COMPLETE 10 12 06 45 10 12 07 23 PENDIN E Batch Setup Batch Recipe Schedule Modifying Batches Once a batch is set up you may need to modify the batch mode the schedule or one of the formula values contained in the recipe To modify a batch mode or schedule you access the Batch Modify screen Figure 3 4 from the System Summary screen You can then modify the batch approval mode and the batch sequencing mode You can also access other screens that let you alter details of the batch For example if you want to modify the ingredients or mixing times in a formula of a particular batch you access the Formula Detail screen Figure 3 5 You can change the working value of the formula between the specified minimum and maximum values 3 4 Chapter 3 Understanding Batch Process Control Operations Figure 3 4 Batch Modify Screen Batch Modify
58. to recipes at your plant computer and distributes them to the designated plant floor system When you assign a recipe to a batch Batch Management downloads the recipe data and directs the operations to execute in the batch controller The batch controller then executes operations on the process equipment as directed by the recipe The batch controller receives production values from the process and returns them to the operator interface for monitoring purposes and for batch logs Operation and phase status is reported back to the operator interface Figure 5 1 You are responsible for establishing your system to solve your application problems and perform control and management functions However we have identified key steps or tasks that lead you through this process Figure 5 2 summarizes these tasks In the following pages we describe some of these tasks and tell how the system can help you perform them This approach is provided as a guide and will enable you to develop your system using a bottom up methodology This will structure your system and programming development so that the batch system can be flexible Chapter 5 Configuring Your Batch Process Control System Figure 5 2 Summary of Tasks Recommended to Develop Your Batch Process Control System e Establish the physical process units to be controlled in the batch process and the operations which those Define Your Process units will perform Control Units Assi
59. tware and hardware products from which you can choose Batch process control software consists of the following modular products Process Configuration and Operation software cat no 6190 PCO Batch Management software cat no 6190 BAT ControlView software Figure 2 1 shows the software its functionality and its relation to the computer PLC system hardware Chapter 2 Becoming Familiar with Batch Process Control Product Figure 2 1 Batch Process Control Software Process Configuration and Operation option Batch Management option 5 Configurable Process Control Recipe Generation E s 5 5 x 3 PID w Faceplate and Batch Management 5 2 2 312 gS EISE Tuning Display Recipe Execution HEHE S s 518 ControlView Analog Resource Management 5 8 4 g 2 r Device Drivers w Batch Data Collection 8 2 2 Options ai eis Faceplate l u 2 Sl s Z 2 t amp amp TagDatabase ControlView PL C 2 Batch Process m Control Methodology 5 ane Structured Data Control Functions a D un n i d Unit Table j Process Control a Con Communication LN unit operations Device Status and ontro Process I O 2 2 System level Diagnostics ControlView Core and options ControlView Core including A B Drivers Mouse GRAFIX Event Detection Derived Tags Trending Data Log Alarm Management Repor
60. us of activities occurring within them Each box shown on the screen represents one of the 16 possible process units Figure 3 8 Unit Summary Screen Unit Summary Operation Detail Group Display ES 32 0 2 PREWGH 2AUTO 3MASTER_BLE AUTO 4 18 MASTER BUSY 130 NOT CONFIG NOT CONFIG NOT CONFIG NOT CONFIG NOT CONFIG 10 NOT CONFIG NOT CONFIG NOT CONFIG NOT CONFIG 14 NOT CONFIG NOT CONFIG NOT CONFIG NOT CONFIG HWi1 1 OCT 12 08 16 20 Accessing Detailed Information From the Unit Summary screen a mechanism has been included so you can easily access detailed information about each process unit For example if you want a graphic representation of a unit in your plant you select the process unit and access the Group Display screen Figure 3 9 The custom graphic screen will be displayed You develop these unit custom graphic screens by using ControlView Mouse GRAFIX software The pixel based graphics editor gives you the capability to display live process data as graphic screens 3 8 Controlling Batches Chapter 3 Understanding Batch Process Control Operations Figure 3 9 Group Display Screen of Graphic Unit Configuration UNIT 3 MASTER BLEND T NK IHOR THRE ince IMGs m ACTUA d DIL ACTUAL IME quar 1 I il B IHGA Ps JI YS zi RASTER THRE HEIGHT a LES Fl HEAT UMIT 1 MASTER TEMP s OO B B MG F uHIT 3 F
61. y Batch Process Control Advantage Figure 1 2 Relationship of Batch Process Control Components To Recipe Creation Business Plant Production Scheduling Manufacturin System Computer Batch Tracking Execution 4 Inventory Control System Computer Network Industrial 0 a perator Interface Batch Workstation Batch Management Management Based Console Data Collection Operator ControlView Interface Processor Network ig sss ss Raw Material PLC amp 1 0 Batch Process Packaging Integrated Controller Area Sequential Regulatory PLC amp 1 0 PLC amp 1 0 Control Storage Area Process Controi d Equipment Equipment NN DN Field Wiring coal rs Recipes cy Formulas Procedures Units Devices Cc Loo ps Functional Partitioning The building block approach to batch processing described on page 1 2 is possible because of our unique approach to functional partitioning This concept has been applied in conjunction with emerging ISA Instrument Society of America batch standards As a result every batch specific product is compatible with and builds upon the capabilities of other Allen Bradley products You can use the plant computer at the top level refer to Figure 1 2 for creating recipes scheduling production tracking batches and controlling inventory On a network the plant computer can communicate with multiple

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