SIMATIC Batch.pdf
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Flexible automation of batch processes
SIMATIC BATCH
simatic
In the process industry, batch processes are assuming
increasing significance. Shorter product life cycles and the
productivity demanded by consumers are two reasons for
this change in importance. Other demands include the need
for consistent quality product, faster responses to market
conditions, production reproducibility (FDA compliance),
and compliance with legal standards and controls.
To satisfy these needs, new batch plants are more and more being
designed as multi-purpose facilities. This enables multiple products
to be produced using the same equipment set thus reducing
equipment idle time. In some cases, this flexibility also enables a
single product to be produced using different paths through the
equipment set that can result in increased product production and
reduced batch cycles.
The PCS 7 process control system offers an excellent solution for
the economical and effective implementation of batch processes
in a batch automation environment: SIMATIC BATCH.
SIMATIC BATCH can be used to implement a practical and highly
flexible batch solution. This product can be applied to all batch
processes. It can be used with batch processes that have single
path structures as well as to those processes that have network
structures. It can be used with facilities that produce one product
as well as facilities that product multiple products. It is a scalable
modular software package that can be used in both small pilot
facilities as well as in large production plants.
Integration of SIMATIC BATCH
SIMATIC BATCH is fully integrated in SIMATIC PCS 7
and shares the same visualization and engineering
tools as the other standard SIMATIC PCS 7 compo-
nents. The total integration of SIMATIC BATCH in the
plant’s visualization system provides the operator
with the tools to easily monitor and control batches,
and to quickly response to process exceptions.
Integration makes it easy to consolidate batch data
and batch-related continuous data, such as a unit’s
temperature profile during the time the unit is
allocated to the batch, into a single comprehensive
XML based batch report that can be viewed using
a web browser, and/or printed.
SIMATIC BATCH can be linked to the higher-order IT
level (MES/ERP) software packages. One way to do
this is through the use of the standard SIMATIC IT
interface. A second method is through an available
open API interface that enables you to develop your
own custom interfaces to third-party software
packages.
Optimum adaptation to plant requirements
SIMATIC PCS 7/SIMATIC BATCH enables you to im-
plement a solution architecture that best reflects
the needs of your solution. For small batch processes,
an all-in-one node solution can be implemented.
For larger batch processes, a client-server architec-
ture can be used. To ensure high process availability
and complete batch data collection, redundant batch
servers can be implemented in the architecture.
Integration of SIMATIC BATCH in the SIMATIC PCS 7
engineering system means that engineering data
need to be entered only once. Once entered, the
engineering data is available for use by all SIMATIC
PCS 7 components. This reduces the time it takes
to engineer an application and minimizes data entry
errors.
Process-oriented recipe creation
SIMATIC BATCH enables you to develop a batch
solution that follows the equipment and recipe
hierarchies defined in ISA S88.01. In this model:
–
Recipe procedures execute in a Process Cell
–
Unit procedures, operations, and phases execute
in a Unit.
Integration of SIMATIC BATCH in the engineering system
Equipment-independent recipes and recipe
building blocks
With SIMATIC BATCH, a master recipe is a sequence
of process actions that describe how a batch product
is produced. These master recipes can be imple-
mented as equipment-independent sequences. At
run time, the batch manager dynamically assigns
a unit to the recipe. Using this capability, a single
master recipe can be used with different equipment
units thus reducing the time needed to engineer a
master recipe. The basic master recipe building block
is a recipe phase. The normal and exception handling
logic for a recipe phase is stored in an equipment
phase. PCS 7 enables you to create equipment phase
templates that are instantiated and assigned to as
many units as needed. Equipment phase templates
make it easy to clone and validate equipment phases.
Any change to an equipment phase template auto-
matically updates each instance that was created in
the project.
Dynamic Unit Allocation
SIMATIC BATCH supports true dynamic unit alloca-
tion. This enables the assignments of units to a
batch to be deferred until the units are actually
required by the batch. A number of unit allocation
strategies are provided with the product. The unit
allocation strategy can be selected based on the
situation in the plant. This ensures flexible and
optimum utilization of plant capacity.
Recipe Operation Procedures Library (ROP)
A Library ROP is a structure of recipe phases built
based on the unit classes defined in an application.
A Library ROP can be used in multiple recipe unit-
procedures. Changes made to a Library ROP auto-
matically updates each instance of this Library ROP
used in the application. Additionally, the link
between a library ROP and an instance of the library
ROP can be detached to allow for instance-specific
modifications independent of the library ROP. ROPs
can help reduce engineering and validation over-
head.
Validation
Increasingly, today’s plants require validation for
compliance with quality standards as well as for
adherence to marketing and statutory requirements.
Traceable and reproducible production is particularly
important in a multi-product or multi-stream envi-
ronment. SIMATIC BATCH provides features that help
you follow GMP and FDA 21CFR Part 11 standards.
At runtime, an Audit Trail feature automatically logs
each step in a batch execution. All run time control
recipe activities and operator actions are captured
and stored to batch history. This information can
be printed out and/or displayed when required.
SIMATIC BATCH provides user access protection with
Windows 2000-based centralized user management
features. In the system, each user has a unique user
ID and password that is assigned by the system
administrator. The user can be forced to change his
password the first time he logs in. A user’s user ID
defines the application and applicationfunctions
that the user is permitted to access. Electronic
signatures are available to support paperless
production. An operator action can be defined to
require one or more sign-offs before the action is
performed. You can also define sign-off requirements
control recipe phase status changes. The action
along with the signatures are captured to batch
history and can be viewed as part of the standard
batch report for the batch.
Allocation of subsystems at runtime
SIMATIC BATCH enables easy, flexible, user-friendly auto-
mation of all batch processes and provides the tools that
support you in complying with all applicable standards.
Complete batch data management
The production sequences are automatically documented
in the batch log (on paper or electronically). Production
sequences are easily reproducible.
For you, SIMATIC BATCH means
More production flexibility – a shorter time to
market
Production sequences are described in master recipes,
which can be generated or modified whenever necessary
by operating personnel that have the proper access
permission.
Reduced validation cost
Runtime recipe modifications are automatically document-
ed. SIMATIC BATCH provides features like recipe version-
ing, user access control, runtime production audit trails
and electronic signature (21 CFR Part 11).
Reduction in operating costs and life cycle costs
All standard products from Siemens receive worldwide
Siemens service and support. You can purchase and install
Siemens products anywhere in the world and expect the
same top quality service and support.
Improved plant capacity utilization
SIMATIC BATCH supports dynamic unit allocation. The
allocation of units (equipment) can be planned in advance
and can be changed on the fly to reflect the latest
production requirements until the unit allocation actually
takes place.
SIMATIC BATCH – Highlights
Modular architecture with flexible hardware and
software scalability
–
Optimum adaptation to plant size and individual requirements
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Grows with the plant, no expensive reserve capacities
necessary
Hierarchical recipes to ISA S88.01
–
Process-oriented recipe generation
–
Simple, fast, fault-minimized recipe generation
Storing, archiving and comprehensive logging of batch
data based on state-of-the-art XML format
–
Production becomes transparent and traceable
Redundant batch servers
–
High process availability
–
No loss of batch data
–
Automatic synchronization of batch data
Reduced engineering and validation effort
–
SFC type/instance concept
–
Separation of procedure and formula
Tight integration of SIMATIC BATCH in the HMI strategy
and the PCS 7 engineering system
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No customer-specific interfaces required
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One time entry of process model and engineering data
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Integrated alarm and message concept
–
Reliable operator guidance and safe, reliable response to
process faults
Unit-class-based ROP library development
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Reusable
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Centralized configuration
Validation support
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Audit trail (modification log)
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Versioning for recipes, recipe operations and formulas
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Centralized user access management and electronic signature
Equipment-independent recipes
–
Considerable simplification of recipe management and
validation
–
Flexible recipe usage and optimum plant capacity
utilization
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