The PlantPAx ® Batch Design Considerations
Contents
1. Add X Unit 2 gt Three Instances of Phase Code Add X Unit 3 Rockwell Automation Publication PROCES RMO08A EN P October 2014 49 Appendix B 50 Illustrated Shared Phases A shared phase reduces the controller code because one instance of code only is required Controller Add X Unit 1 L Unit2 Single Instance of Phase Code L Unit3 However there are architectural considerations If a shared phase is in a distributed system you must determine the impact if the host controller with the shared phase goes offline Controller1 Controller2 Controller3 Add X dd X 7 Add X Phase 1 Phrase Phase 3 Phase 1 bi a Phase 3 Controller1 Controller2 Controller 3 If controller 2 is offline in the first set controllers 1 and 3 still can add because they each have a phase code But if controller 2 in the second set with the shared phase is offline controllers 1 and 3 cannot add We recommend that you consider the architecture and process requirements that is process segmentation to make an informed decision for the task that is being performed Rockwell Automation Publication PROCES RMOO8A EN P October 2014 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support y2. gallons or kilograms Figure 3 Phase Request Diagram FactoryTalk Batch Server Computer Client Active X Controller PhaseManager Phase FactoryTalk Batch BatchView 46291 For more information see Tips on Using PhaseManager with FactoryTalk Batch publication FTALK WP001 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Operator Interaction Chapter 3 Summa ry Table 2 provides a comparison of the operator interactions Table 2 Operator Prompt Comparisons Item Topic eProcedure Component P_Prompt Phase Request 1 HMI Web browser FactoryTalk View Site Edition SE or FactoryTalk Batch BatchView or Machine Edition ME software batch Active X components in FactoryTalk View SE software 2 Parameter display per instance No limit to quantity or data type Limited to four REAL or four string entry One parameter of any data type and four binary selections including enumerations 3 Reporting Responses automatically entered into Responses entered into the batch Responses automatically entered into the batch journal journal as phase report parameters the batch journal 4 Electronic signature Supported within the FactoryTalk Batch Requires custom FactoryTalk View Not supported product development 5 Electronic signature Signature signoff automatically entered Signature signoff entered into the Not supported into the batch journal FactoryTalk View diagnostic log 6 Display content
3. considerations presented are intended to help prevent confusion and avoid mistakes that have negatively impacted projects Document Format Each chapter in this document addresses a design or implementation choice often encountered in batch development Each topic opens with a discussion followed by potential solutions which are summarized in a reference table Here is a brief description of the selected topics Unit Coordination and Synchronization Examines how asynchronous units coordinate activity between two units to make product Appendix A elaborates on who is my partner and communication methods with illustrations Operator Interaction Defines three solutions for operator interaction to execute a batch process Material Management Describes supplemental systems that manage material consumption and supply Process Upsets Discusses upset conditions and batch recovery methods Transitions Examines configured conditions for processing a batch Batch Timing Examines techniques for establishing timing phases Resource Arbitration and Allocation Discusses how to establish rules for sharing resources among multiple entities Shared Phases Provides architectural considerations for using shared phases to reduce controller code for the batch Appendix B shows what can happen if the host controller goes offline Two or Three layer Model Describes how to implement controller organization f
4. equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE F
5. Contents Chapter 11 Standard Phases 5 ote bee ER el pa 37 Initiate as AS A eR aR ER KAS FAS dn EUR UE ads 37 A e RR rs BARR 37 PE OM PL c aet cris dos 38 Process Control Device Ownership voe ccce dd 38 Mods ds ud uates eL los teens 38 Naming Convento ti io 39 Recipe and Report Parameters da tica 39 PASEA Pai rri tO PEN RS bap ER ARR 39 Procedure Unit Procedure Operation 2 eese 40 Reset Idle teria Rer epu EP CREE 40 Appendix A A USERS bar E des BL NRA 42 Multiple Transfers between Units ssseseerersessersersersa 43 Connections and Controlletaig re neto tie et hri 44 Misaligntie Bt ic o dus A A A da 47 Appendix B Reducing Controller COde mi 4d ud de inus irs eeu he 49 Rockwell Automation Publication PROCES RMOO8A EN P October 2014 5 Table of Contents Notes 6 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Preface This document provides guidance on selected batch implementation topics in a Rockwell Automation PlantPAx system environment The information helps one make informed decisions when implementing projects by using FactoryTalk Batch LBSM or other batch management solutions This document is not a batch tutorial product user manual or programming guide You need to be batch literate possessing an understanding of appropriate industry practices standards and Rockwell Automation products Before You Begin A sound understanding of the current parts of the ISA 88 batch
6. Could require matching of a key formula Transparent to phase managed by FactoryTalk Batch parameter 5 Adaptability Supports any process management solution such as FactoryTalk Batch must be active and managing LBSM or coded sequencers the batch 6 Mode Supports operator mode or other means of Only functions in context of a FactoryTalk Batch activating phases executed batch by using a recipe configured with link groups 7 Display Tag based Can display conditions and status on Requires FactoryTalk Batch BatchView to determine any HMI display messaging status 8 Data format Supports multiple binary integer and real data No Single binary flag for example Ready per limit on size or quantity of data exchange PXRQ instruction 9 Data direction Bi directional Phases can continuously read and Uni directional A phase can only send or receive a write to each other flag in a single transaction or PXRQ instruction 10 Architecture Transactions require peer to peer controller Transactions require a functioning FactoryTalk server communication 12 Rockwell Automation Publication PROCES RMOO8A EN P October 2014 Discussion Chapter 3 Operator Interaction Successfully engaging the batch operator is critical to system success Most batch processes require operator interaction Typical examples of operator interaction include the following e Operator or hand additions e Quality checks e Measurements
7. Interaction often requires the operator to manage equipment such as starting an agitator lining up valves or actuating loops But operator interaction is not limited to making product as operators often need direction for the following e Disassembling cleaning and reassembling a pump e Kitting or staging of materials e Setting up or changeover of a packaging line e Confirming non automated valve transfer panel and equipment lineups Several factors influence operator interaction solutions These conditions include the following e Number of interactions or prompts required to complete a task or batch e Degree of automation e HMI e Recording and reporting operator interactions Rockwell Automation Publication PROCES RMOO8A EN P October 2014 13 Chapter3 Operator Interaction Solutions This section defines three solutions for operator interaction and provides a diagram to show the physical relationship of each one eProcedure Component The optional FactoryTalk eProcedure component displays operator instructions in a web page or browser ActiveX eProcedure supports electronic signatures and signoffs captured in the batch journal Figure 1 eProcedure Diagram Computer or Server Computer Client Web Browser I FactoryTalk Batch Server For more information see the FactoryTalk Batch User s Guide publication BATCH UMO011 IMPORTANT Thethree interactions that are discuss
8. P October 2014 Discussion Solutions Chapter 9 Shared Phases A Shared Phase is a FactoryTalk Batch feature that reduces coding while providing arbitration and allocation However sometimes it is best not to share a phase This option can provide increased availability and flexibility without reducing code The FactoryTalk Batch product and PhaseManager software support a feature that is known as Shared Phase When a phase is configured as shared the same phase can support multiple batch units but requires only one controller instance In addition the FactoryTalk Batch server arbitrates and allocates this shared phase to one batch at a time Refer to Resource Arbitration and Allocation on page 31 Shared phases arise when a phase class with multiple instances requires an exclusive use shared resource An Add X phase where X is added to multiple units but dosed through a single flow meter is an example Shared phases and their counterpart Unshared Phases are contrasted below Unshared Phases Unshared phases are defined developed coded and configured the same as other unit phases such as heat or agitate There is a unique code instance of the phase in each unit Shared Phases A shared phase has one code instance therefore leverages common phase activity For example within the Add X phase one could find common logic for all units with minor changes such as an in
9. Text photos video links Text Text 7 Controller requirements No controller required Requires controller and Supports controller based phases FactoryTalk View HMI 8 Annunciation Difficult to highlight active prompt Designed for integration into graphics Can be annunciated in graphics by menus bread crumbs using phase logic and tags 9 React to live data Not readily supported Live data integrates into prompt display Not applicable and response verification 10 Prompt from entity other than phase Not supported Supports any interaction with operator Not supported for example EM or CM batch process upset response Rockwell Automation Publication PROCES RM008A EN P October 2014 17 Chapter3 Operator Interaction Notes 18 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Discussion Chapter 4 Material Management All batches consume materials therefore the system could support material inventory storage locations and genealogy All batch process requires material additions Minimally each addition requires the following e What material to add niacinamide glycerin raisins e How much to add 5 7 kg or 2 tablespoons e When to add In many systems additional information is required which includes the following e How to add by hand or with automated controls e Source or storage location for example storage tank A warehouse sector C 3 silo 12 When using materials
10. dS a to 24 Active State Processing oue det Re d E EUR EAE AMEN 24 Phase Failures 24e died cache bee ues dul iria 24 O PEU EA Dh D esI eii 25 Rockwell Automation Publication PROCES RMOO8A EN P October 2014 3 Table of Contents Transitions Batch Timing Resource Arbitration and Allocation Shared Phases Two or Three layer Model Chapter 6 DAS CUM A BIMBI Re 27 A Ra 27 Procedure Transition Expressions i255 eile li dass 27 Evaluation Phase eese III 28 Phase ReclpeDatanmieteba srl e c UR 28 Summa cec eru d eI M uM N 28 Chapter 7 DISCUSSION ree ri teres dd a Ee eee ee eds 29 Solutions osea RT odis f uc et Ake A mud UE S LE 29 Controller based Execution sees 29 Server based Execution eee 29 SIA PER 30 Chapter 8 PRO Oe A SEES eed Bee a 31 SOlUGGHS 24 A fra ep be Dae 31 Controller based Execution eese eese 31 Server based Execution eee 31 UMN LY e chosen tus a 32 Chapter 9 DISCUSS 33 SAA edo a eee A 33 Unshared Phases sssoserrerrerrerrrrrrrr e 33 Shared Phi recette vt re ER tds 33 Summary sid Me ec a Meu het E IN Me ool O 34 Chapter 10 Discuss dra 35 SOLAS A a loc 35 o A tek EDS en Dre quA tete de 35 Three layer Model 223 640 2233 I PS Tuba AES Sateen ees 35 SAM NR 36 4 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Implementation Techniques Unit Coordination Material Transfer Illustrated Shared Phases Table of
11. method is controller based then a formula parameter called key can be configured in both the XFO and XFI phases The recipe author configures the key parameter with an integer that matches both sides of the coordinated transfer Lastly controller code verifies that the key s values match before beginning a transfer If the communication method is server based then alignment is managed through Link Group configuration Rockwell Automation Publication PROCES RMO08A EN P October 2014 47 AppendixA Unit Coordination Material Transfer Notes 48 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Appendix B Illustrated Shared Phases This appendix includes additional information and illustrations for shared phases In Figure 10 there is one raw material that is being consumed by many units 1 2 3 Even though transfer from the raw material source to any destination unit is possible in our example one transfer only can occur at a time because of one flowmeter device Figure 10 Shared Phase Example Raw Material y 1 800 Cutiet Met X Dosing Mat X Supply 92 05 kg 0 00 Hz 0 00 kg sec Met X Inlet Mat X Inlet Met X Inlet Unit 1 Unit 2 Unit 3 One method for the transfer process is to create a raw material Add X addition phase in each unit This method results in three separate instances of phase code in the controller Controller Add X Unit 1
12. my partners b How do they communicate Who is doing the transfer and how the message is conveyed between the source and destination units is orchestrated by two suggested communication methods e ControlLogix tags e FactoryTalk Batch message partners Rockwell Automation Publication PROCES RMO08A EN P October 2014 Unit Coordination Material Transfer Appendix A Figure 8a and Figure 8b use a quadrant to show differences between the number of partners controllers and methods of communication Figure 8a 1 1 Source Destination Configuration Diagram Key Shape Object Notes Controller ControlLogix controller E 2 33 ku Triangle FactoryTalk Batch server 5 t5 A E E Transfer units S gt Source gt XFO 3 n D gt Destination gt XF Communication ControlLogix Controller tags ins FactoryTalk Batch Message partners 1 Inter processor Produce consume tag communication ControlLogix FactoryTalk Batch 46287 Communication Method In the left side of the quadrant ControlLogix tags are being used for the source and destination units to transfer data between one and two controllers Spanning multiple controllers see below upper left corner typically requires inter processor communication to coordinate which source units are transferring to the destination unit In the right side of the quadrant both architectures use the Factory
13. processing control standards is necessary including the following e ANSI ISA 88 01 2010 Batch Control Part 1 Models and terminology e ANSI ISA 88 00 02 2001 Batch Control Part 2 Data structures and guidelines for languages We also suggest knowledge of the following e How to use FactoryTalk Batch equipment editor recipe editor eProcedure and MaterialManager components e How to program Logix5000 controllers with RSLogix 5000 software or the Studio 5000 Logix Designer application e How to use Rockwell Automation process library objects Additional Resources from Rockwell Automation Resource PlantPAx Process Automation System Reference Manual publication PROCES RMOO1 These documents contain additional information concerning related products Description Provides characterized recommendations for implementing your PlantPAx system PlantPAx Process Automation System Selection Guide publication PROCES SG001 Provides basic definitions of system elements and sizing guidelines for procuring a PlantPAx system PlantPAx System Application Templates Quick Start publication PROCES QSO01 Describes how to configure controller and HMI templates to start development of your PlantPAx system FactoryTalk Batch User s Guide publication BATCH UMO11 Provides a complement of FactoryTalk recipe management component guidelines and software installation procedures PhaseManager User Manual pub
14. the state running holding stopping where the upset occurs Phase Failures Phase failures leverage the FactoryTalk Batch product and associated configuration Upsets detected by controller phase logic are read by the FactoryTalk Batch service The FactoryTalk Batch service then commands batch procedural entities to Holding FactoryTalk Batch propagation configuration determines whether a phase the operation containing the phase the unit procedure containing the operation or the batch is held For more information see the FactoryTalk Batch User s Guide publication BATCH UMO11 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Summary Table 4 Upset Solution Comparison Process Upsets Chapter 5 Table 4 provides a comparison of the two solutions for upsets Item Topic Active State Phase Failures 1 Architecture Controller handles all upset activity Requires FactoryTalk Batch Service to detect upset and command phase to Holding 2 Architecture Phase remains active to assist with upset handling Phase transitions to Held an inactive state or recovery 3 Architecture Supports any batch management example LBSM Only the FactoryTalk Batch server can detect upset and phases running in operator mode and command phases to Holding 4 Reporting Can be tied to FactoryTalk Alarm and Event Batch Upset is automatically entered into the batch journal journal entities can be made by
15. time Figure 6 Batch Phase Handshake Prep Unit Procedure Mixer Unit Procedure V NV N 3 Phase Rockwell Automation Publication PROCES RM008A EN P October 2014 The next consideration is coordinating the material transfer The material cannot be transferred to Unit B until B5 process is ready for the material and the transfer cannot begin until Unit A is ready This is best handled with a Transfer Out XFO Transfer In XFI pair of phases The XFO phase is part of Unit A5 phase set while XFI is part of Bs The two phases handshake between themselves to coordinate the transfer as indicated by the dotted line in Figure 6 Unit Coordination Material Transfer Appendix A Multiple Transfers between Units The XFO XFI pair phase combination is versatile and able to handle nearly all transfer requirements Often there are multiple transfers between units within a given batch For example if Unit A is a prep vessel and Unit B is a mix tank there are two different prep transfer activities between the units as shown in Figure 7 If Unit B is not ready Unit A holds until its partner is ready before the transfer occurs and the next phase is completed Figure 7 Multiple Unit Transfers Prep Unit Procedure Mixer Unit Procedure See Connections and Controllers on page 44 to determine partnership in a unit transfe
16. Reference Manual Pla EPAX Process Automation System PlantPAx Batch Design Considerations Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits
17. Talk Batch server regardless of the number of controllers The server based approach is useful when a greater number of controllers are added because FactoryTalk Batch uses out of box functionality for associating and arbitrating partners However if the server becomes unavailable none of the units can communicate Figure 8b 2 1 Source Destination Configuration PM E Same Diagram Key applies as APO n Cs C55 shown in Figure 8a 2 A wi R RD Sp gt Same Server 1 anning Controllers Controllers ControlLogix FactoryTalk Batch Communication Method 108 Rockwell Automation Publication PROCES RMO08A EN P October 2014 45 Appendix A 46 Unit Coordination Material Transfer Up to this point we have discussed how infrastructure is used to facilitate communication Mode handshake and dialog are factors for pairing the units to complete a task Mode determines who is the owner that is responsible for making the transfer operator or program and the degree to which those partners synchronize their efforts Handshaking and dialog are types of communication to facilitate some type of action for a transaction The handshake is necessary so the recipient of the transfer can verify its readiness It also can be extended to the number of partners that need to perform a single transaction for example two sources supplying simultaneously to the same destination The source and destin
18. ation units also need to maintain a dialog during the whole transfer process in the event of an unintended consequence ofa transfer For example imagine several telephones on a network connection One telephone rings to indicate an incoming call from another telephone If the n gee is not ready for the transmission a busy single is exchanged C Y We S f No Answer Completed Transfer Eg D Destination CD mD S Source The call is then placed to another receiver and an interaction occurs when both parties communicate A batch transaction can be initiated either manually operator or by a program batch server Typically controller tags require unique batch IDs to make sure the right partners are aligned at the right time The batch server approach automatically coordinates the partnership process Rockwell Automation Publication PROCES RM008A EN P October 2014 Unit Coordination Material Transfer Appendix A Misalignment In Figure 9 the dotted lines show XFO 1 is paired with XFI 1 and XFO 2 is paired with XFI 2 Who and what safeguards against XFO2 transferring material to XFI 1 indicated by the null sign Figure 9 Key Symbolizes Partnership In Operator mode the operator is responsible for determining the unit alignment In Program mode the alignment is dependent on the selected communication method See Unit Coordination and Synchronization on page 11 If the communication
19. distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication PROCES RM008A EN P October 2014 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in the U S A
20. ed in this section do not have to be mutually inclusive To solve different functional requirements we recommend a mix of technologies as no one technology fits all 14 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Operator Interaction Chapter 3 Operator Prompt The P Prompt Add On Instruction is included in the Rockwell Automation Library of Process Objects Similar to other Process objects the P Prompt instruction consists of a Logix Add On Instruction and a FactoryTalk View global object that adds interaction to any HMI graphic TheP Prompt instruction works with multiple platforms including a controller or server based batch solution Figure 2 Operator Prompt Diagrams Computer or Server FactoryTalk Batch Server Computer Client FactoryTalk View SE or ME A Controller PhaseManager Phase Computer Client FactoryTalk View SE or ME Controller PhaseManager Phase Activity 46290 For more information see the Rockwell Automation Library of Process Objects Operator Prompt P Prompt Reference Manual publication SYSLIB RM046 Rockwell Automation Publication PROCES RMO08A EN P October 2014 15 Chapter 3 16 Operator Interaction Phase Request Phase Requests are a FactoryTalk Batch product feature Phase Requests triggered by phase logic wait for an operator entered formula value Responses can be enumerated such as yes no or values such as water quantity
21. edient Feeds Prep E Vessel NS Hand Additions Eun Mix Tank Rockwell Automation Publication PROCES RMO08A EN P October 2014 41 Appendix A Unit Coordination Material Transfer Unit Transfers 42 Procedural control of automated and manual processes involves coordinated material transfers between units Referring to Figure 4 assume the process requires material weighs in Unit A the Prep Vessel and primary batching add material heat cool agitate in Unit B the Mix Tank Furthermore the weighed material in Unit A is transferred to Unit B at some point in Unit B5 process Lastly as soon as the prepped material in Unit A is transferred to Unit B then this Prep unit is available for weighs to begin for a subsequent batch sometimes referred to as pre weigh or pre batching This arrangement requires two units since two different batches are being processed simultaneously Batch 1 still is in Unit B while Batch 2 has begun on Unit A The procedure for this batch corresponds with Figure 5 The Procedure must consist of two Unit Procedures and the Unit Procedures must be in parallel This Figure 5 Batch Procedure Prep Procedure Unit Procedure Ji Mixer Unit N structure is the only way to describe the need for two units to make the product and handle the requirement of multiple batches in the Process Cell at one
22. following phases e Initiate e Timing e Prompt Initiate Typically the Initiate phase is the first phase in any unit procedure Functions for this phase include checking equipment states example clean or dirty or device mode verification example operator or program Improper conditions can be flagged and corrected or the batch aborted before any process activity takes place on the unit Initiate being the first phase in the Unit Procedure is a good location for the PXRQ instructions that are necessary to download the Unique and User Batch ID s to the controller Timing We recommend that all units have at least one instance ofa timing phase that provides the recipe author a mechanism of adding a wait for time into the procedure For more information see Batch Timing on page 29 Rockwell Automation Publication PROCES RMO08A EN P October 2014 37 Chapter 11 Implementation Techniques Process Control Device Ownership Mode 38 Prompt We recommend that all units have at least one instance ofa general prompt phase that gives the recipe author the means of interacting with the operator anywhere in the procedure A general prompt phase is configurable and includes the following capabilities e Display text to the operator only and wait for an acknowledgement For example Confirm that the tank is clean and ready for the next batch e Display a question that can be answered with a button selec
23. hat provides integrated material management capability Material Manager provides storage location and material configuration from which FactoryTalk Batch managed batches retrieve or submit data IMPORTANT Material Manager is designed to support material usage in the batch process This tool normally complements but does not replace a site wide inventory management system Rockwell Automation Publication PROCES RMO08A EN P October 2014 Summary Table 3 Material Management Type Comparison Material Management Chapter 4 Table 3 provides a comparison of the two material management type solutions Item Topic Controller Design FactoryTalk Batch Material Manager 1 Data repository Controller MS SQL database 2 Interface HMI graphic MS SQL queries and display 3 Maintenance Controller HMI knowledge RDB tools and procedures 4 Material management Supports any batch management in any mode Supports FactoryTalk Batch managed batches or operator or program initiated from any HMI phases only 5 Find current location given recipe specified material Coded Product feature 6 Theoretical inventory updates Coded Product feature 7 Real time inventory Readily supported from available instrumentation Coded by using SOL and batch API 8 Plug flow inventory Coded Product feature 9 Pallet inventory Coded Product feature 10 Deferred material specification Supported Not supported 11 New material or location int
24. he process capability and automation control in relation to the physical model to perform a task The procedural model is a representation of how to use the equipment described by the model to make product Proper design of your batch process by using these two models provides many benefits including providing modularity to make the system easier to design implement and maintain ISA 88 provides definition of these two models and there are many experts and resources available in the field to provide practical guidance of designing and implementing these models this is not within the scope of this document Once the model is developed there are specific implementation choices that can also impact the success of the project Unlike the modeling effort these implementation choices are often specific to the platform being deployed The purpose of this document is to provide technical guidance on these topics to help you make well informed decisions when implementing projects by using FactoryTalk Batch software This document does not dictate the choice for you Detailed specific recommendations cannot be made without an understanding of requirements as they relate to the equipment capability procedural requirements and workflow related to respective projects Chapter 1 10 Overview The topics discussed in this document have been selected based on observations of hundreds of batch application projects over two decades The design
25. ler Tag based handshakes are developed to request receive and release shared resources Server based Execution The FactoryTalk Batch product provides resource arbitration and allocation Shared resources can be defined at the unit or phase level Rockwell Automation Publication PROCES RMOO8A EN P October 2014 31 Chapter 8 Resource Arbitration and Allocation Summa ry Table 7 provides a comparison of resource and arbitration methods Table 7 Resource Arbitration and Allocation Method Comparison Item Topic Controller Based Server Based 1 Development Coded Configured 2 Acquisition arbitration Coded therefore can accommodate priority batches First come first serve allocation scheme queue wait time or any algorithm in addition to first come first serve 3 Capacity arbitration Supported through code development Supported through configuration for example resource can supply up to three users 4 Coverage Arbitration and allocation active and managed at all Supports phase activity that is only initiated and times within or outside of a batch directed by active batch service 5 Communication Requires handshake protocol and possibly Transparent to phase inter processor communication 6 Hold state or similar response Coded therefore can release and reacquire resources Phase retains resource unless resource management coded by using PXRQ instruction 32 Rockwell Automation Publication PROCES RMOO8A EN
26. let valve to accommodate different owners Rockwell Automation Publication PROCES RMO08A EN P October 2014 33 Chapter9 Shared Phases For example common logic in the Add X phase could be e opening the source outlet valve e zeroing the flow meter e checking tolerances e logging actual quantities while only V101 V201 or V301 needs to be opened depending on unit See Appendix B on page 49 for illustrations of shared phases Summa ry Table 8 provides a comparison of shared and unshared phases Table 8 Shared and Unshared Phases Comparison Item Topic Controller Based Server Based 1 Development and maintenance Each unit requires a code instance that needs to be One code instance to develop and maintain for created and maintained all units 2 Architecture Phase placement with unit s other phases Single phase placement requires consideration particularly in distributed controller systems 3 Phase owner Single unit inherent to phase Defined by allocation FactoryTalk Batch in program mode user in operator mode 4 Shared resource capacity Multi use resource capability Exclusive use resource only 5 Shared resource arbitration Requires other arbitration means Inherent to phase 6 Arbitration scheme Coded can support priority batches and other First in First out FIFO maintained by FactoryTalk rule sets Batch server 7 Shared resource allocation Requires other allocation means Inherent to phase 8 Al
27. lication LOGIX UM001 Explains how to define a state model for your equipment and develop equipment phases Logix5000 Controllers Design Considerations Reference Manual publication 1756 RM094 You can view or download publications at Details howto design and optimize Logix5000 controller applications http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Rockwell Automation Publication PROCES RMO08A EN P October 2014 7 Preface Notes 8 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Design Options Rockwell Automation Publication PROCES RMOO8A EN P October 2014 Chapter 1 Overview FactoryTalk Batch software enables you to develop batch control systems that support your flexible production needs FactoryTalk Batch development tools let you define equipment configurations and then build product recipes against that defined equipment Key to successful batch implementation is careful design and separation of the batch process into two models e Equipment e Procedural The Equipment model is a hierarchical organization of the equipment and basic control capabilities of the plant The Equipment model is a representation of the plant s equipment capabilities to make product The Procedural model describes a multi tiered hierarchical model that defines t
28. ll batch procedural entities phase operation unit procedure procedure in a running state but with logic designed to respond notify correct and potentially recover from the upset Command only an impacted phase to the Holding state where holding logic is then executed Command higher level batch procedural entities such as an operation unit procedure or procedure to Hold that drives all subordinate entities for that batch to Holding then Held Rockwell Automation Publication PROCES RMOO8A EN P October 2014 23 Chapter5 Process Upsets Solutions 24 Lastly after a batch procedural entity has enacted its response one needs to consider recovery Some of the possibilities include the following e Abort batch drastic and unfortunate but could be the only option e Command batch procedural entities to the Running state e Automatically resume processing once upset is corrected Recovery methods vary and are influenced by these factors e Workstation capability e Number of operator key clicks e Security or authentication for example only a supervisor can resume batch Logging and reporting requirements Solutions are numerous and vary based on the conditions and scenarios presented above This document describes two approaches e Active State Processing e Phase Failures Active State Processing Active state processing detects responds annunciates and recovers all within
29. location relinquishment Phase can release allocation for example in phase Allocation maintained until phase returns to idle hold state 9 Unit idiosyncrasies Needed when encountering many variations for Minimal differences between units for example one example alarm handling or two valves 34 Rockwell Automation Publication PROCES RMOO8A EN P October 2014 Discussion Solutions Chapter 10 Two or Three layer Model Too little modularization is bad Too much modularization is also bad So how much modularization is good This section pertains only to controller implementation and organization This section is independent of batch management servers or services The following two architectures are prevalent in today s batch design e Two layer Model e Three layer Model The three layer design was popular and needed prior to the release of PhaseManager software PhaseManager software eliminated the PLI and associated phase interfaces which then opened the door for a practical two layer implementation A mixed approach can be used in the same project leveraging either two or three layer advantages as needed These two solutions have the following contrasts Two layer Model In a two layer application PhaseManager software hosts the Equipment Phase EP and Equipment Module EM This is one layer the other layer being subordinate control modules CM and perhaps other EM s that are needed to support the phase
30. ming phase does not preclude one from including timing recipe parameters as part of another phase when this concept simplifies recipe construction or matches a user methodology For example if one always agitates for time then providing timing setpoints in the agitation phase might be better than a timing and an agitating phase configured in parallel The following are two procedural timing phase solutions e Controller based execution e Server based execution In both cases the recipe author configures the wait time as formula parameters and the phase completes when the specified time has elapsed Controller based Execution The timing phase is a controller based phase that is implemented similar to all other controller phases such as add water or heat Server based Execution The FactoryTalk Batch product supplies timing phases for each unit Rockwell Automation Publication PROCES RM008A EN P October 2014 29 Chapter7 Batch Timing Summa ry Table 6 provides a comparison of two timing phases Table 6 Material Management Type Comparison Item Topic Controller Based Server Based 1 Time base for example wait 2 hr 23 min Configure multiple formula parameters such as Supports only one time base that can either be day 15 s and so forth minute and second 2 hr 23 min 15 s hour minute or second for example 8495 s 2 Display Tag based integrates into any HMI graphic Requires Ac
31. nerally viewed in context so unit descriptions are not needed in the phase name Maintaining a consistent verb noun arrangement improves usability Some examples include the following e Transfer e Add water e Prompt e Agitate Rockwell Automation Publication PROCES RMO08A EN P October 2014 39 Chapter 11 Implementation Techniques Class phase names are to be short and descriptive Short so that the phase name is clearly displayed on batch displays and descriptive enough that one can easily follow the procedure Recommended Not Recommended Comment Transfer Transfer Mixer to Product Storage Name is too long Information not needed or redundant when in context Name displays incorrectly Add Water Water Add Inconsistent verb noun arrangement inconsistent verbs Add Sucrose Add Fructose Sucrose Add Fructose Addition Add Alchohol ADAL Not intuitive Procedure Unit Procedure Operation Recipe entity naming conventions improve development maintenance and display of recipes Entity Convention Example Comment Operation Product Unit OP LightRanch MX OP Use a short two or three letter representation LightRanch PM OP for unit Unit procedure Product Unit UP LightRanch MX UP LightRanch PM UP Procedure Product LightRanch Top level does not carry an appendix 1 The top level entity does not have a Reset Idle State 40 level identifier Therefore if an operation or unit procedure is relea
32. ollow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley BatchView ControlLogix eProcedure FactoryTalk Logix5000 PhaseManager PlantPAx Rockwell Automation Rockwell Software RSLogix and Studio 5000 Logix Designer are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Preface Overview Unit Coordination and Synchronization Operator Interaction Material Management Process Upsets Table of Contents Before You Begin ics whist weet erp Res 7 Additional Resources lese ee 7 Chapter 1 Desin Options eso sucede des 9 Document Format ereua IY dees ai 10 Chapter 2 Discussion pr A eee ad eaa a a RER 11 OIS ao IA E A EE T EA a v e Estes 12 Controller based Execution eese 12 Server based Execution seen 12 SUMMARY ede tet paru se ceti ecd eb ale dels a doen Meta 12 Chapter 3 DISCUSION Rs ene oe eiu nU E OM P er 13 Solita be tat cu Sate ceva die IRE Le EE d EE RT eA elt 14 eProcedure Component ads become as 14 Op rator Pron Plata 15 Phase Requests rinitis 16 E E A ATEA 17 Chapter 4 DC E E E EEE OO EET 19 S LG IOFS 264 57 ye A T A Ee ee 20 Gontroller ci RSE E DEEE E E E TE 20 Factory Talk Batch Material Manager ssssesrsrrrrrererea 20 SUMMARY A c a saca one lett 21 Chapter 5 DISCUSSIONES 23 Solutions Dice oes EET de
33. one encounters requirements such as the following e Monitoring inventory e Maintaining material lot and sub lot numbers e Storing material attributes by lot such as fat content or percent moisture A recipe defines the materials their quantities and procedurally when they are added However a recipe typically doesn t include site physical data for example storage locations nor individual lot attributes Therefore supplemental systems beyond recipe management are needed when encountering material management requirements Rockwell Automation Publication PROCES RMOO8A EN P October 2014 19 Chapter4 Material Management Solutions 20 The following are two material management solutions e Controller e FactoryTalk Batch Material Manager Controller A controller array that is augmented with a HMI graphic can meet many material management requirements In general a UDT contains needed elements for lot number inventory or expiration date A material centric UDT references material while a physical centric UDT references a location The array is sized for number of either materials or storage locations depending on centricity A user developed HMI graphic displays and inputs desired data A controller based solution requires design development and support by the integrator and or end user FactoryTalk Batch Material Manager Material Manager is an optional component of the FactoryTalk Batch product suite t
34. or batches The document closes with an Implementation Techniques chapter that contains tips and often over looked items Rockwell Automation Publication PROCES RMO08A EN P October 2014 Discussion Chapter 2 Unit Coordination and Synchronization When a batch requires interaction between units a mechanism must exist to determine which units can participate of those who want to participate and of those who are ready to participate Typical scenarios of unit coordination in multi unit batch processes include the following e Bulk weigh transfer from a scale unit to a mixer unit e Content transfer from a reactor unit to a centrifuge unit e Start mashing in the mash tun unit only after a downstream lauter tun unit has finished raking A transfer in transfer out pair of phases works well when coordinating material transfer between units while synchronize phases accomplish alignment For details on unit coordination see Appendix A on page 41 These phases when configured in respective unit procedures provide the recipe author a convenient means for specifying when actions can take place in the procedure or transfers Now to complete the transaction a handshake is required between phases This handshake managed by controller phase logic communicates status such as the following e I m ready to send e Ihave a problem stop the transfer e We are both at procedural point x plea
35. ou can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your
36. r Rockwell Automation Publication PROCES RMO08A EN P October 2014 43 Appendix A Unit Coordination Material Transfer Connections and Controllers The dotted line in Figure 7 shows two unit transfers that occur at different stages of the batch This section elaborates on the dotted line by explaining how the partners communicate with each other and specifically what is being communicated to complete the transfer One degree of complexity comes from the number of partners and the distribution of those partners within controllers across the architecture For example a 1 1 one to one transfer represents one source going to only one destination while a 3 1 many to one transfer represents three sources going to one destination The latter is more complex because the more possible participants in a transfer requires aligned connections so the correct partners are interacting Another degree of complexity includes the number of controllers that are involved with the transfer Table 10 shows how the combined number of connections and controllers can change the dynamic of the transfer process within your architecture Table 10 Connections and Controllers Model Connection Controllers Total 1 1 1 1 2 1 1 1 2 3 3 1 3 1 4 31 3 2 5 31 3 3 6 1 Total is a simplified measurement of complexity Regardless of the number of participants or controllers any unit transfer uses a basic concept a Who are
37. rameter IMPORTANT Thesesolutions are not mutually exclusive and you can use more than one technique in the same project Procedure Transition Expressions FactoryTalk Batch provides an expression editor for configuring transition conditions Conditions can reference controller live data to tie transitions to specific process events or states such as reactor temperature at setpoint Rockwell Automation Publication PROCES RMO08A EN P October 2014 27 Chapter 6 Transitions Summary Table 5 Process Condition Comparisons Evaluation Phase An Evaluation procedural phase is added to the system and executed by the controller as done with most other phases Recipe parameters such as Wait until Temperature gt or Wait until Level lt describe the condition The condition is then modified with parameter values such as 60 C or 35 respectively to complete the expression Phase Recipe Parameter Ifa process condition is always or nearly always evaluated for a given phase then the evaluation can be done within the phase s execution logic by using a recipe configured value Table 5 provides a comparison of process conditions Item Topic Transition Expression Evaluation Phase Phase Recipe Parameter 1 Convenience Requires knowledge of expression Configured in same fashion as other Requires only parameter entry along editor and unit tags phases for example Add or Heat wi
38. roduction No constraint Requires restart of batch service 12 Material reference Text strings Pull down list 13 Reporting lot numbers Coded by using phase report parameters Product feature 14 Material quantities Material centric lt 20 No constraint Physical centric no limit 15 Location quantities Physical centric lt 20 No constraint Rockwell Automation Publication PROCES RMO08A EN P October 2014 Material centric no limit 21 Chapter4 Material Management Notes 22 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Discussion Chapter 5 Process Upsets All systems batch or otherwise experience upsets A successful system solution provides the means to detect inform and respond to abnormal situations A list of example upsets includes the following Equipment valve failed to open Mode operator owns and has locked a needed device Process solution fails to gel or batch fails to reach temperature Materials insufficient inventory to satisfy batch requirements Quality pH too high Unknown activity time out Safety reactor high pressure To avoid most upsets be sure to use good process control which protects life property and product with safety systems and interlocks Now after an upset has occurred and process control has done its job bringing the process to a safe state what happens to the batch Some batch responses include the following Keep a
39. rom a number of parties including operations quality safety maintenance and engineering Proceeding beyond the requirements stage without rules in place can result in chaos rework and unsatisfied system users Rockwell Automation Publication PROCES RMO08A EN P October 2014 Naming Conventions Implementation Techniques Chapter 11 Batch process management and unit supervision are additional users that can be considered in the rule set We recommend these design considerations e What unit resources can be acquired by an operator when a batch has begun on the unit e What phase or equipment module resources can be acquired by the operator when the phase is in the Running state Or in the Held state We recommend the following naming conventions Recipe and Report Parameters It s essential that if you are using the PlantPAx web based reporting package certain report and parameter names must follow the naming convention outlined in the Event Archives User Guide as part of the FactoryTalk Batch User s Guide publication BATCH UMOII Recipe parameters are sorted alphabetically when displayed in the recipe editor regardless of order entry in the equipment editor Preface parameters with a letter for example a setpoint b flowrate or PO1_xxx P02_yyy if ordering is desired Phase Because a phase is a process action it is recommended that the name be a verb Remember phases are configured and ge
40. s activity Three layer Model PhaseManager software hosts the Equipment Phase layer 1 which directs Equipment Module s layer 2 that commands subordinate CM s layer 3 Rockwell Automation Publication PROCES RMOO8A EN P October 2014 35 Chapter 10 Two or Three layer Model Summa ry Table 9 provides a comparison of architectural methods Table 9 Controller Organization Comparison Item Topic Two layer Model Three layer Model 1 Maintenance Two code layers to understand and troubleshoot Three code layers to understand and troubleshoot 2 General interface Same phase interface for batch operator or Two interfaces one for the EP and another for the EM other users 3 Batch interface Batch interfaces need to be skipped when running in Batch interfaces found only in EP leaving EM free of non batch modes any batch constructs 4 Structure EM activity must conform to phase state model EM s can be developed in any style or by using a state model that best suits the application 5 Integration Skid OEM needs to understand and provide batch Skid OEM provides equipment centric EM s that are centric solution with phase focus referenced by SI developed batch phases 36 Rockwell Automation Publication PROCES RMOO8A EN P October 2014 Standard Phases Chapter 1 1 Implementation Techniques This chapter provides some hints and tips for implementing FactoryTalk Batch Every unit typically includes an instance of the
41. se continue e I m ready for delivery 2 of 3 Rockwell Automation Publication PROCES RMO08A EN P October 2014 11 Chapter 2 Unit Coordination and Synchronization Solutions Summary Table 1 Phase Communication Comparison Two methods for handshaking or communicating between phases are discussed in this section e Controller based execution e Server based execution Controller based Execution Handshaking takes place by using controller tags Depending on the architecture these tags are read locally or moved between controllers by using peer to peer communication mechanisms such as produce consume or message read write Server based Execution FactoryTalk Batch facilitates handshaking by routing the messages between message partners Participating phases are configured as link groups in the recipe Controller based PXRQ instructions initiate message send and receive requests Table 1 provides a comparison of the two communication methods for unit coordination Item Topic Controller Based Server Based 1 Communication method Reading writing to user defined controller tags PXRQ instructions 2 Inter processor communication Produce consume tags or messaging Transparent to phase managed by FactoryTalk Batch 3 Unit to unit alignment Coded Could require matching of unique batch ID Transparent to phase managed by FactoryTalk Batch 4 Phase to phase alignment Coded
42. sed as the top level entity then drop the OP or UP appendix PhaseManager phases require an Initial state configuration the default is Idle During controller powerup or transition from Program to Run the Logix firmware sets all phases to the Initial configured state skipping all intermediate states in the state model Therefore a phase configured for Initial state Idle is set to Idle without executing Resetting logic if in the Running state when a Program gt Run transition occurs The clean up or resetting logic expected to occur following the Running Stopping or Aborting states is not executed and can cause the next instance of Running state logic to not behave as designed Rockwell Automation Publication PROCES RMO08A EN P October 2014 Appendix A Unit Coordination Material Transfer This section examines the coordination between asynchronous units in a batch process Unit coordination can consist of material transfers and synchronization among units Figure 4 illustrates a common batch process scenario that includes a Prep Vessel and a Mix Tank In general two or more major pieces of equipment known as units are required to manufacture a product Typically part of the batch is started in one unit and completed in another unit to require a material transfer between the two units Figure 4 Prep Vessel and Mix Tank Ingredient of Ingr
43. th other phase parameters 2 Display Expression and status viewed only in Condition and status are tags that Condition and status are tags that FactoryTalk Batch procedure display display on any HMI graphic display on any HMI graphic BatchView or ActiveX 3 Versatility New expressions or conditions canbe Requires knowledge of process to Works for a specific phase created as needed define a flexible phase requirement only 4 Parallelism Many transition expressions in parallel Requires additional phase instances if Not applicable legs can be evaluated simultaneously simultaneous expression evaluation is required 5 Architecture Evaluated within batch service Requires a controller for evaluation Handled within existing phase logic 6 Deferring transition parameter values Not supported Supported Supported 28 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Discussion Solutions Chapter 7 Batch Timing Choose a timing solution that saves you time while at the same time provides the correct time for your application Most batch process has some need for timing which generally appears as the following e Mix vessel contents for 20 minutes e Wait 40 seconds then add e Take sample every hour while reaction takes place Generally batch systems need a timing procedural phase that can be inserted as many times as needed into the procedure which is the focus of this section IMPORTANT Ati
44. tion For example Has the lab approved the batch e Prompt for data and accept either a numeric or string response For example Sample the batch and enter the pH For more prompt details see Operator Interaction on page 13 Architect the system so that a single equipment module EM directly controls all devices for example valves pumps to complete its assigned task Doing so minimizes handshaking that can be complex and problematic Consider for example a transfer between two units A and B which utilizes the outlet valve of A and inlet valve of B Rather than assign ownership of the outlet valve to A and ownership of the inlet valve to B and then handshake between A and B and the EM assign ownership and control of both valves to the EM or phase and eliminate handshaking Mode indicates ownership There can be one owner only and the owner only can issue commands For example ifa valve is in operator mode then the operator owns and has the exclusive right to send commands such as open and close to the valve A device often has multiple users but one owner only at a time Because there are multiple users for example operator maintenance or P pie op program but one owner only rules must be established regarding ownership acquisition retention release and override Rule definition can be difficult because these rules establish the system s operating methodology and require agreement f
45. tiveX 3 Time remaining display Can show multiple units 1 hr 8 min 12s remaining Displays single unit 4092 s remaining 4 Quantity Generally one instance only per unit therefore one Multiple simultaneous waits can be configured at a wait at a point in time point in time 5 Architecture Requires controller Managed at server level no controller required 6 Coordination for example time while at Facilitates timing coordination with other process No integration with process control or other phases temperature only conditions or activity 30 Rockwell Automation Publication PROCES RMOO8A EN P October 2014 Discussion Solutions Chapter 8 Resource Arbitration and Allocation If there are shared resources then arbitration and allocation for those resources are required Resources often have limited capacity and are used by multiple entities thus shared Examples include the following e Devices tank outlet valve e Segments common inlet header e Materials alcohol supply e Equipment dust collector e People operator When sharing arbitration is needed to evaluate contention rules as well as an allocation function for establishing ownership Arbitration and allocation solutions are typically implemented as either of the following e Controller based execution e S erver based execution Controller based Execution Arbitration and allocation code is written and managed in the control
46. using a report parameter and PXRQ instruction 5 Propagation Requires additional controller programming Batch service propagates Hold to other configured batch entities phases unit procedures batch 6 Recovery Recovers from any HMI user graphic Recovery requires BatchView Client or Batch ActiveX 7 Recovery Automatic or single graphic button press Can require many key clicks depending on recipe Rockwell Automation Publication PROCES RMO08A EN P October 2014 and propagation configuration 25 Chapter5 Process Upsets Notes 26 Rockwell Automation Publication PROCES RMO08A EN P October 2014 Chapter 6 Transitions Batch procedure execution is dependent on configured conditions Examining and going on based on a condition is only part of the story Successful solutions also consider the recipe author s effort and operator discernment during the batch Discussion Process conditions are often factored into the batch process for example Add Material y only after the temperature is above x degrees IMPORTANT Recipe configurations are for conditions that change between products not for equipment Requirements such as Never run the agitator until the lower blades are covered do not belong in the recipe Solutions Three solutions for configuring product related process conditions into a recipe are the following e Procedure transition expressions e An Evaluation phase e A phases recipe pa
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