Engineering and

automation of batch
processes with PCS 7
along ISA-88 models
Siemens
SIMATIC PCS 7 / SIMATIC BATCH Industry
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 Table of contents

Table of contents
Legal information ......................................................................................................... 2
1 Scope of this document .................................................................................... 4
2 ISA-88 introduction ............................................................................................ 5
3 Models of the ISA-88 ......................................................................................... 7
3.1 Physical Model ..................................................................................... 7
3.2 Procedural Control Model..................................................................... 9
3.3 Process Model .................................................................................... 11
4 From Process Flow Diagram to P&ID ............................................................ 14
5 Process Cell Classification ............................................................................. 16
6 Unit classification ............................................................................................ 17
7 Control Module and Equipment Module classification ................................ 18
8 Generic Equipment Module versus recipe-aware Equipment Module
approach ........................................................................................................... 21
9 The implementation of Equipment Modules in PCS 7 ................................. 24
9.1 PCS 7 interpretation of EMs and EPHs ............................................. 24
9.2 What are EMTs and EPHTs? ............................................................. 26
9.3 Design guidelines (comparison of both concepts) ............................. 27
© Siemens AG 2021 All rights reserved

9.4 Principal approach .............................................................................. 28

9.5 Derived EPH and EPH interface ........................................................ 29
9.6 Shared EM ......................................................................................... 29
10 The implementation of Control Modules in PCS 7 ....................................... 30
10.1 PCS 7 interpretation of Control Modules ............................................ 30
10.2 Benefit ................................................................................................ 32
10.3 Principal approach .............................................................................. 32
10.4 Shared Control Module ...................................................................... 33
11 Implementation of the Procedural Control Model with Recipes ................. 35
11.1 Batch equipment engineering ............................................................ 35
11.2 Recipe engineering ............................................................................ 36
11.3 Separation of procedure and formula ................................................. 38
11.4 Coordination of Units .......................................................................... 38
11.5 Late binding strategies ....................................................................... 39
11.6 Monitoring area .................................................................................. 41
11.7 Command step ................................................................................... 41
11.8 Batch operation .................................................................................. 42
11.9 Batch Online Structural Changes ....................................................... 43
12 Recipe transformation and transferability .................................................... 44
13 Interfaces towards other systems ................................................................. 46
14 Acronyms ......................................................................................................... 48
15 Appendix .......................................................................................................... 49
15.1 Service and support ........................................................................... 49
15.2 Industry Mall ....................................................................................... 50
15.3 References, links and literature .......................................................... 50
15.4 Change documentation ...................................................................... 51

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 1 Scope of this document

1 Scope of this document

Whether producing polymers, beverages or pharmaceuticals – batch processes are
indispensable in many industry sectors. In terms of process control and
automation, batch production must meet completely different requirements than a
continuous process. Selecting a suitable automation philosophy is crucial for the
efficiency, flexibility and profitability of the process.
The batch market comprises a wide variety of process types and plant sizes –
there is no “one-size-fits-all” solution. This document however should provide an
overview along the ISA-88 models of how a project can be modeled and
engineered with the capabilities provided by PCS 7. Customers, system integrators
or Siemens project personnel shall get an impression what kind of tools are
available and how they can be deployed in the plants process control environment.
For more detailed information and guidance on how the different PCS 7
components are utilized in the project implementation the reader should refer to the
PCS 7 manuals and compendiums.
© Siemens AG 2021 All rights reserved

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 2 ISA-88 introduction

2 ISA-88 introduction
Industrial processes can be classified as continuous, discrete or batch
manufacturing processes. Continuous processes are classified as processes which
have a continuous outflow, for example production of paper or steel. Discrete
processes have a discrete output, for example the production of a car.
A batch process is a process that leads to the production of finite quantities of
material by subjecting quantities of input materials to an ordered set of processing
activities over a finite period of time using one or more pieces of equipment.
There was a need to provide a standard for managing batch processes because of
the following reasons:
• No universal model for batch control
• Difficult for plant operators to communicate processing requirements
• Integration of solutions from different vendors is difficult
• Batch control solutions are difficult to configure
Therefore, the ISA (International Society of Automation) decided to provide a
standard which describes a method to structure batch processes. It defines
terminology and models that makes design and operation of batch plants easier
and uniform. This standard is named ISA-88, whereby only the first part of the
standard (ANSI/ISA–88.00.01–2010), called "Models and Terminology" is
considered in this document.
ISA-88 is more than a standard for software, equipment, or procedures. It is a
© Siemens AG 2021 All rights reserved

design philosophy. Understanding ISA-88 will help to better design processes and
manufacture products.
How does ISA-88 help?
• Modularity allows for easier global replication and better return on investment.
• Isolates equipment from recipes.
• Design concepts make validation easier.
• ISA-88-aware solutions help track product and process data.
• Gathering requirements from customers and conveying requirements to
vendors is easier.
• Provides guidelines on how to recover from abnormal events.

What is needed to define batch control?

Issue Answer
How to make a product? Recipes, procedures and formulars
What equipment is to be controlled? Equipment entities
What control is needed? Control activities

Therefore, three models and their relationships have been defined in the ISA-88
standard.

ISA-88 suggests that a batch management system, usually running on a computer,

and an equipment control system, usually implemented on a controller, exist
separately. In SIMATIC PCS 7 the recipe control is handled by SIMATIC BATCH,
whereas the equipment control is handled on the AS410 controller.

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 2 ISA-88 introduction

Figure 2-1 Splitting of recipe control and equipment control

Recipe

SIMATIC BATCH
Procedural
RUP

control
ROP

RPH
Equipment control

Controller
EPH

EM
© Siemens AG 2021 All rights reserved

CM

In the next chapters you will find explanation what each of these acronyms really
mean.

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 3 Models of the ISA-88

3 Models of the ISA-88

The ISA-88 defines three main models:
1. The process model, which handles the aspects of the chemical and physical
changes during production.
2. The physical model, which handles the equipment being used during
production.
3. The procedural control model, which handles the recipe structure for the
product.
The relationship between the process model, the procedural control model and the
physical model is shown in figure 3.1 below. The mapping of procedural control
with individual equipment provides processing functionality described in the
process model. The usage of equipment capabilities to accomplish desired
processing tasks is a major point of this document. The equipment entity performs
the functions defined in procedural elements. Procedural control elements are
defined to correspond to elements of the process model to accomplish the desired
processing for a batch. Procedural control elements are defined within a recipe.
Through the application of equipment control, the equipment entity will perform the
functions defined by the recipe procedural element to accomplish a product specific
task. This allows for a high degree of process flexibility that is essential in many
batch processes. It allows for significant changes in process activities to be defined
by a recipe author without reengineering equipment entities.
© Siemens AG 2021 All rights reserved

Figure 3-1 ISA-88 process/procedural control/physical models

3.1 Physical Model

The physical model is described in detail in chapters 4 to 7, in this section only an
overview is given. The physical model is shown in the following figure. The three
top levels of the physical model are defined as Enterprise, Site and Area, but they
are not relevant for this document and will not be considered.
This application example has been created with the following hardware and
software components:

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 3 Models of the ISA-88

Figure 3-2 ISA-88 physical models

Enterprise
may contain

Site
may contain

Area
may contain

Process Cell
must contain

Unit
© Siemens AG 2021 All rights reserved

may contain

Equipment Module
may contain

Control Module

A process cell is a logical grouping of equipment (units, equipment modules,

control modules) that includes the equipment required for production of one or
more batches.
The actual batch process occurs within the units, such as a reactor, buffer or pre-
mixer, of a process cell. During the production process only one batch can reside
within a unit at a time.
A unit typically aggregates equipment modules, which in turn generally is
implemented as an aggregation of control modules to fulfill certain tasks or process
actions, such as dosing, agitating or temperature control. An equipment module is
typically centered around a piece of process equipment such as vessel outlet/inlet
manifold, process heater, a WFI drop point etc. Control modules represent single
or multiple sensors or actuators or and are the actual processing equipment that
perform one or more specific state-oriented or regulatory control tasks. Control
modules are directly connected to the process through its I/O.
In this example it is shown how the physical model is mapped to the technological
hierarchy in the PCS 7 Engineering System.

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 3 Models of the ISA-88

Figure 3-3 Mapping of the physical model to the PCS 7 technological hierarchy
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3.2 Procedural Control Model

The procedural control model is a multi-level hierarchical model to accomplish the
task of a complete process or part of a process based on a specific process cell. It
is also the basis for defining recipe procedures. Each individual element in the
model is a procedure, whose directly subordinate elements (if any) comprise its
steps. The ultimate goal of the hierarchy is to efficiently organize the process-
oriented tasks that are to be executed either automatically or manually at its lowest
level.
The highest level of the procedural control model is the overall recipe procedure,
commonly known as the recipe. The recipe can involve several production units,
and the sequence of the processing steps of each of these units are captured in
the recipe unit procedure. Within the recipe unit procedure consists of one or more
recipe operations, which themselves contain subordinate recipe phases. A phase is
the lowest level procedural element in the procedural control model which is either
a representation in a recipe (Recipe Phase - RPH) or an implementation in
equipment control (EPH) that is intended to accomplish all or part of a process
action.
Phases can accomplish a process-oriented task, however, the set of steps that
define its action are usually equipment specific. The scope of a phase is usually
small enough that the specification of its actions (with appropriate variants, such as
target values) is highly reusable from one procedure or set of equipment to
another. When the full procedural control model is used, phases shall execute the
required processing task(s).

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 3 Models of the ISA-88

Equipment phases coordinate and sequence specific process functions on a

process unit. The exact detail of what each phase does, will be the subject of
detailed design but the goal is to define phases that can be re-used in multiple
recipes for different products. Hence there is a compromise between how much the
phase should do and re-usability/flexibility. Common process operations such as
charging, mixing, heating could all be incorporated into a single phase or these
could be defined as separate phases, which could in theory be rearranged or even
used standalone (by different recipe operations and recipe unit procedures that call
them).
Examples of phases:
• Add vinyl chloride monomer
• Ramp and soak

The execution of a phase may result in one or more of the following actions:
• commands to basic control, such as
– changing controller modes, initializing their outputs, and adjusting their set-
points
– setting, clearing, and changing alarm and other limits
– modifying algorithm selections and tuning constants
• the collection of
– process measurement values, such as tank level or liquid density
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– values calculated by basic control at the behest of the phase

In this example it is shown how the procedural control model is mapped to the
different levels of a master recipe in the PCS 7 Recipe Editor.

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 3 Models of the ISA-88

Figure 3-4 Mapping of the procedural control model to the PCS 7 master recipe
© Siemens AG 2021 All rights reserved

3.3 Process Model

In the ISA-88 standard the batch process is organized in the process model, which
divides the entire process into a hierarchy of smaller subdivisions as shown in the
following figure from ISA-88 (Reference \4\).

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 3 Models of the ISA-88

Figure 3-5 ISA-88 process model

© Siemens AG 2021 All rights reserved

Process Stages
Every batch process can be divided into process stages. Process stages can take
place in series (after each other), in parallel (simultaneously) or a combination.
Each process stage typically operates independently from other process stages. A
sequence of physical or chemical changes to the material is usually the result of a
process stage.
Examples: esterify, strip, neutralize, filter

Process Operations
Each process stage consists of process operations. They represent major
processing activities, where the result is often physical or chemical changes to the
material. Process operations are a bit more concrete than process stages.
Examples: initialize, charge, react

Process Actions
Every process operation can be divided into process actions. They are the lowest
level of the process model. The actions are needed to complete the operations.
Examples: add water, add other ingredients, heat the tank to 55 degrees, hold for
120 minutes

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 3 Models of the ISA-88

Figure 3-6 Example of a process model

Process Process Process
Stages Operations Actions

Esterify Initialize Initialize

Strip Charge Add Ing. A

Neutralize React Add Ing. B

Filter
© Siemens AG 2021 All rights reserved

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 4 From Process Flow Diagram to P&ID

4 From Process Flow Diagram to P&ID

In the conceptual design phase of a facility, the Process Flow Diagram (PFD) is
established. This shows the general flow of plant processes and the equipment
involved. The PFD displays the relationship between major equipment of a plant
facility and does not show minor details such as piping, instrumentation and
naming, a high-level example is shown in the figure below.

Figure 4-1 Example process flow diagram for a biopharma facility

© Siemens AG 2021 All rights reserved

In the basic design of a facility the PFD is augmented with more details and a
piping and instrumentation diagram (P&ID) is established, which contains all the
information needed for the automation of a plant, and for the structuring according
to ISA-88. For the purpose of this document, a simplified P&ID is depicted in the
next figure.

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 4 From Process Flow Diagram to P&ID

Figure 4-2 Simplified P&ID of a reactor vessel

© Siemens AG 2021 All rights reserved

The PFD and P&ID are closely linked to the ISA-88 physical model. Properly
mapping elements of the physical model onto the P&ID will help us describe the
functionality of the units and subsequently program it for automation. The next
sections take a closer look at each of these elements.

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 5 Process Cell Classification

5 Process Cell Classification

PCS 7 only reflects the equipment model of the ISA-88 physical model. As already
mentioned, enterprise, site and area are not considered in this document.
A process cell, also abbreviated as PCell, contains all the units, equipment
modules and control modules required to produce one complete batch. Normally
the process cell encompasses the entire PFD and any supportive functions. A
process cell may simultaneously run one or more batches.
A subdivision of a process cell is called an equipment train. An equipment train is
composed of all units and other equipment that may be utilized by a specific batch.
A batch does not always use all the equipment in a train and there may be more
than one equipment trains within a PCell.
In PCS 7 the PCell is defined by the multiproject, as shown below. There can only
be one PCell per multiproject.

Figure 5-1 Process cell in PCS 7 multiproject

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 6 Unit classification

6 Unit classification
The process cell is divided into a number of units. Units represent the physical
processing equipment in the plant, such as a reactor, and are made up of
equipment modules and control modules. A unit is an independent grouping of
equipment usually centered around a major piece of processing equipment, such
as a mixing tank or reactor, and it can perform one or more major processing
activities — such as fermenting, harvest or purifying.
Usually, the modules that make up the unit cannot be manipulated or controlled by
equipment outside of its own unit. Any equipment that is considered common or
manipulated by multiple units should be defined as shared equipment, which can
be temporarily acquired by a unit to carry out specific tasks, see also chapters
9.6 Shared EM and 10.4 Shared Control Module .
An important consideration when defining batch units, is that a unit can only
operate a single batch at the same time. The batch may exist in multiple units, but
a unit can hold only one batch at any given time.
Defining the boundaries for units is important to guarantee the flexibility of the
plant, reusability of the modules, and consistent reporting over multiple plants. The
PFD can be used to initially identify the units. Once the P&ID details are known, the
unit can be further refined. In case modular integration of intelligent unit operations,
the unit and its ISA-88 structuring are defined by the OEM supplier.
In PCS 7, the unit and its modules are identified in the hierarchical folder structure
of the plant view, as shown in below.
© Siemens AG 2021 All rights reserved

Figure 6-1 Unit “Mixer1”with its modules in the PCS 7 multiproject

A recipe unit procedure is linked to possible unit candidates. The unit candidates
determine which recipe phases can be used in the recipe unit procedure, and
these recipe phases correspond to the common equipment phases for all unit
candidates.

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 7 Control Module and Equipment Module classification

7 Control Module and Equipment Module

classification
Once the unit boundary is defined, the lower level modules of the equipment model
can be identified.
It’s easiest to start with the Control Modules (CM). These are the lowest level
grouping of equipment in the physical model that can carry out basic control (state-
oriented or regulatory control) and typically have a direct relationship to the type of
instrument/device that it is being monitored and/or controlled. Examples are
pumps, motors, valves, but also PID control loops. The CMs are typically directly
connected to IO signals. CM also contain exception handling related to equipment,
product and operator protection. The CMs are easily identified on the P&ID charts,
as shown in the following figure. In PCS 7 the control modules can be controlled
via the HMI by the operator in manual mode, or by the superior CM’s or EM’s in
auto mode.

Figure 7-1 Example P&ID from process unit "Reactor" with its EM’s (highlighted) and CM’s
© Siemens AG 2021 All rights reserved

An equipment module is a functional group of control modules that can carry out a
limited number of specific minor processing activities such as dosing, charging or
temperature control. An equipment module is typically centered around a piece of
process equipment such as vessel outlet/inlet manifold, process heater etc. The
separation of a unit into functional Equipment Modules (EM) should already reflect
the process actions and recipe phases from the process and procedural control
model. Introducing a new product on the same equipment should be possible
without altering the base sequences of the EM’s. The EM’s of our example reactor

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 7 Control Module and Equipment Module classification

are shown in the figure above: feeding, temperature control, pressure control,
agitator control and transfer out.
According to ISA-88, it is possible for an equipment module to contain other
subordinate equipment modules, although this is recommended to be restricted to
areas where there are no phases or batch requirements.
An EM is usually a sequence in which all the subordinate CM’s are monitored and
controlled. The EM also contains exception handling logic that will handle failure of
subordinate CM and process failure. Usually the exception logic is labelled as held
state or held logic and drives the EM to a failsafe state. The EM itself does not
have mandatory state logic defined in the ISA-88, although in PCS 7 an EM is
usually recipe-aware and it therefore has a state logic that follows the state logic of
the recipe phase, as shown in the next figure.

Figure 7-2 State logic of the procedural recipe phases

© Siemens AG 2021 All rights reserved

As the sequence of the EM reflects the process action, it is common to enable and
disable control module related alarms and process interlocks or change alarm
limits throughout the sequence. This must be considered within the design of such
command sequences.
Arbitration of control modules shared between equipment modules within the same
unit will be performed at the equipment module level, see also chapter 10.4 Shared
Control Module.
Arbitration of equipment modules shared in the same unit or between units is
performed at the phase level. Each phase will acquire the equipment modules
needed to perform a specific process action. It is also possible to acquire
equipment modules on another unit in the same way.
When partitioning the EMs within a unit, the following criteria should be applied:
• all CMs in the EM must support a similar processing purpose and be self-
contained
• the EM must be reusable, so that a type-instance concept can be used
• the module has to be designed so that it can perform all of the available
processing functions, see above

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 7 Control Module and Equipment Module classification

• EM must have the ability to operate on its own without other EM interactions
• ability to minimize the effects of process exceptions by containing them within
the equipment module; ideally an exception will initially only affect one EM
before being propagate to other EM’s or even Units.
Like the CMs, in PCS 7 the equipment modules can be controlled by the operator
in manual mode, or by the phases in automatic mode. The EMs linked to a
particular unit are visualized in the PCS 7 hierarchical folder structure as subfolder
of the unit folder, as was shown in Figure 2-1.
It’s important to note that the CMs and EMs should ideally follow the modularization
approach where functionality is contained within modules that can be programmed
and tested as standalone with a defined interface towards other modules. To
increase reusability, within PCS 7 support for type-instance is made for the control
and equipment modules. Similar EMs and CMs can be grouped in a type. This type
can be tested and then all modules will be instantiated from this type.
By creating these standard ISA-88 batch elements, tremendous benefits can be
achieved:
• savings in software designing and engineering
• faster testing and validation during the initial process of application
implementation
• increased maintenance and flexibility - By means of the pre-tested standard
types, the expansion of the installation can be realized in a faster way, with
less (re-)validation effort.
© Siemens AG 2021 All rights reserved

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 8 Generic Equipment Module versus recipe-aware Equipment Module approach

8 Generic Equipment Module versus recipe-

aware Equipment Module approach
There is a conceptual difference between the basic control functions of the physical
elements and the procedural control elements. The functions of EMs and CMs are
equipment oriented. You can for example start and stop the agitator of a reactor
without having any material in the reactor. On the contrary, a procedural control
element is product and process oriented. The logical separation of recipes and
equipment provides the ability to separate product specific definitions, instructions
and information (e.g. recipes) from processing capabilities (e.g. equipment
entities). This separation of product information from production equipment
capability enables the same equipment to be employed to make a number of
products or have similar process equipment produce the same product with the
same recipe.
There is an element known as the Equipment Phase (EPH) that links the physical
model and the procedural control model. A recipe phase (RPH) in the control
recipe references an equipment phase in the equipment control.
There are two classifications of equipment modules defined in the ISA-88:
• Recipe-aware equipment modules
• Generic equipment modules.

Recipe-aware equipment module

© Siemens AG 2021 All rights reserved

The recipe-aware equipment module is characterized by having one or more

equipment phases that can be directly initiated by the execution of a control recipe.
The EPH is limited to the EM interface (setpoints, state model, control strategies),
which practically makes the EM directly visible in the recipe, hence the naming
recipe-aware. This also means that the states, state transitions, and commands of
the EM are limited to those recognized by recipes, and the EM state logic follows
the RPH state logic as specified in the ISA-88 closely.
In SIMATIC PCS 7 the equipment phases of the recipe-aware equipment modules
are represented by the interface between the EM and RPH, and contains the
setpoints and the control strategies, as will be detailed in the next chapter.
The following figure shows the relationship between EM, EPH and RPH for the
recipe-aware EM.

Figure 8-1 Linking between RPH and recipe-aware EM

Recipe Phase Equipment

Phase

Equipment Module

Generic equipment module

The second type, the generic equipment module is very similar to the recipe-aware
EM but lacks the ability to be initiated directly by the execution of a recipe.
Equipment modules of this type have not direct relationship to recipes, but to
procedural control elements like equipment phases and control modules. As such,
their composition can be very flexible (the state logic does not need to follow the
state logic of an RPH), and they may be commanded by other equipment modules,
higher level equipment entities or an operator.

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 8 Generic Equipment Module versus recipe-aware Equipment Module approach

In SIMATIC PCS 7 the generic equipment modules are triggered by the recipe via
the equipment phases, which are sequences with a state logic that follows the RPH
state logic as shown here.

Figure 8-2 Linking between RPH and generic EM

Equipment
Recipe Phase
Phase

Equipment Module

Why the need for the distinction between generic and recipe-aware equipment
modules?
The top-level ISA-88 design pattern is the separation of product definition
information from production equipment capability. This separation allows the same
equipment to be used in different ways to make multiple products, or different
equipment to be used to produce the same product. Product definition information
is contained in recipes, and the production equipment capability is described using
a hierarchical equipment model.
The separation of equipment capabilities – defined in an equipment hierarchy –
and product manufacturing instructions – defined in recipes – provide the basis for
improved flexible manufacturing. The master and control recipes’ procedures
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contain recipe phases, and these are where the recipe is linked to equipment.
Recipes contain references to equipment functions. The actual functions are
performed by the equipment. The logic in a recipe’s procedure specifies when the
functions are to occur, in what order, and what the transition conditions are
between functions. There is a substantial difference between general/site recipes
and master/control recipes. The general and site recipes are equipment
independent and describe the processing technique. Master and control recipes
are specific to and dependent on the equipment in a defined process cell. They
define the procedure that implements the process with actual physical resources.
Take the use-case where the same product is produced at various sites with the
same general recipe. The equipment design is not necessarily the same between
plants, as you can see in the following P&IDs, but the process actions to make the
product are.

Figure 8-3 P&IDs of similar plants that can produce the same product but have different equipment

When using recipe-aware equipment modules, it could be that each plant needs a
different master recipe for the same product, depending on the equipment specifics
in the equipment modules, that have a direct link to the recipe.

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 8 Generic Equipment Module versus recipe-aware Equipment Module approach

The use of generic EMs and EPHs separate the product manufacturing instructions
from the equipment capabilities to allow improved flexible manufacturing:
• Equipment phases: product process steps that call the various EMs (product
specific)
• Equipment modules: minor process activity sequences that are equipment
specific (plant specific) – For example temperature control EM can be done by
electrical heating, adding steam or a manual operation. EM’s of a certain class
should have the same interface towards the EPH layer.
The process actions as defined in the process model, are minor activities, needed
to make a certain product, for instance: temperature adjust, transfer, agitate, inert,
blend. Process actions should be greatly standardized for re-use in multi-purpose /
multi-product / multiple reactor plants or across sites. In case of generic EMs, the
equipment phases are defined such that there is a one-to-one correspondence
between a process action, a recipe phase and an equipment phase. All equipment
dependencies are “hidden” from the recipe phase and recipe procedure.
© Siemens AG 2021 All rights reserved

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 9 The implementation of Equipment Modules in PCS 7

9 The implementation of Equipment Modules

in PCS 7
9.1 PCS 7 interpretation of EMs and EPHs
This section follows up with the more classical interpretation of EMs in SIMATIC
PCS 7, the recipe-aware equipment modules:

Figure 9-1 ISA-88 logic for a particular unit using the recipe aware EM approach

RPH RPH RPH RPH

RPH RPH RPH RPH
EPH EPH EPH EPH
EPH EPH EPH EPH

EM EM EM EM

CM CM CM CM CM CM CM CM
© Siemens AG 2021 All rights reserved

Unit

Recipe-aware equipment modules

The equipment module consists of a Continuous Function Chart (CFC) in which a
Sequential Function Chart Type (SFC type) is instantiated. Usually other logic such
as interlocking, or a numerical computation is included in the CFC as well. The
SFC type contains the state logic, which reflects the ISA-88 phase logic. Each state
corresponds to a sequencer that is programmed according to the IEC61131
standard. It also contains the interface to the procedural batch engine, SIMATIC
BATCH. This interface is known as the recipe phase on batch level, and the
equipment phase at the controller level. This interface allows to:
• Choose the phase via the control strategy – more details on this below,
• Enter set points,
• Visualize actual process values,
• Visualize text information regarding actual step and acknowledgment of errors
and graphically visualize the complete control strategy (sequence), transitions
and actions in active steps.
Each equipment module can have a number of different running modes or
functions. Each of these is referred to as a "control strategy". For example, a
reagent addition equipment module could have one control strategy for dosing a
flow quantity, and another control strategy for dosing until fill level. Both control
strategies execute the function dosing and use mostly the same control modules.
Control strategies allow capsulation of several functions of the same control
modules, without the need to add separate EMs for each function. Use of control
strategies prevents complex sharing of control modules and makes the ISA-88
structure less complex.

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 9 The implementation of Equipment Modules in PCS 7

Only one control strategy (phase) of an equipment module can run at a time.
However, a switch from one control strategy to another without actually stopping
the equipment module could be implemented if required. For example, a
temperature control equipment module could have a control strategy to heat the
jacket of the equipment to a certain set point and keep it there. It could have
another control strategy to heat the product to a certain set point and keep it there.
The first control strategy would involve a PID controller with the jacket temperature
as measurement, while the second would involve a cascaded PID controller with
the product temperature as the primary measurement and the jacket temperature
as the secondary measurement. A switch from the first to the second control
strategy when the product temperature reaches 90% of the product temperature
set point could then be implemented in the recipe.
The EM controls and monitors its CMs, which are commonly directly linked as seen
in the previous figure.
The sequence is visualized by a block icon and faceplate, which also shows the
ISA-88 interpretation:

Figure 9-2 Faceplates for EPH and EM

© Siemens AG 2021 All rights reserved

A recipe-aware equipment module can be flagged as either an equipment phase or

equipment operation (EOP), so it can be used on the recipe phase or recipe
operation (ROP) level in the recipe.

Generic equipment module

In the generic equipment module interpretation, an additional level of equipment
phases is added to the ISA-88 logic in the PLC. These EPHs are very similar to the
recipe-aware EMs and again consist of a CFC with a SFC type instance, in which
each ISA-88 procedural state is reflected by a sequencer. The same properties as
the recipe-aware EM, such as the control strategy, apply here as well.
The EPH level can either command EMs or CMs. Commonly, the generic EMs are
programmed as SFC type sequences which still follow the SFC type state model.
But since the EMs are not linked to procedural elements in this case, it does not
need to follow the state model. Another interpretation at this level is the matrix
approach, where an EM is a table of modes, and each mode controls control
modules to a specified state.
Important here is that the equipment modules can be shared between several
equipment phases, although with exclusive use – Only one EPH can control an EM

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 9 The implementation of Equipment Modules in PCS 7

at the same time. Therefore, an explicit acquire and release of the EMs is needed.
A multiplexer is built-in per default into the logic.

Figure 9-3 ISA-88 logic for a particular Unit using the generic EM approach

RPH RPH RPH RPH

EPH EPH EPH EPH

Dynamic links and/or arbitration logic

EM EM EM EM EM

CM CM CM CM CM CM CM CM CM CM

Unit
© Siemens AG 2021 All rights reserved

In both cases, the batch context, consisting of the batchname, the batchID and the
recipe step number, is automatically sent at runtime from the batch to the
equipment phase, and is from there propagated to the EMs and CMs.

9.2 What are EMTs and EPHTs?

Equipment module types (EMTs) and equipment phase types (EPHTs) are types
for the EM instances and EPH instances. These types are centrally maintained in
the master data library (MDL) of the PCS 7 multiproject. Instances can be created
either manually in the project or automatically via the Plant Automation Accelerator
(PAA). The main advantage between the type and instance is that changes can be
synchronized from the type to the instance.
The underlying CMs and EMs are known as roles in the type, and upon
instantiation need to be linked to CM instances and EM instances of the correct
type, as shown in the next figure.

Figure 9-4 Linking the CM role to the CM instance when deploying EMTs

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 9 The implementation of Equipment Modules in PCS 7

The type-instance concept promotes reusability of tested and documented types,

over multiple Units, or even multiple PCS 7 projects or sites. Testing can be done
virtual in combination with SIMIT Simulation Platform.

9.3 Design guidelines (comparison of both concepts)

Whether a plant should follow the recipe-aware or generic interpretation of an EM
depends on the use case and plant philosophy. In general, it’s safe to say the
choice is a trade-off between flexibility and portability.
The figure below shows a comparison of the two approaches. There easily can be
seen that in case of the generic EMs, the complexity of EM coordination gets
shifted from the recipe operation level (at recipe level) to the EPH level (at
controller level).

Figure 9-5 Visual comparison of the recipe-aware EM (left) and generic EM (right) approaches

Procedure Equipment Procedure Equipment

Procedure Process Cell Procedure Process Cell

Unit procedure Unit Unit procedure Unit

© Siemens AG 2021 All rights reserved

Operation Operation

Recipe Phase Equipment

Equipment Recipe Phase
Phase
Phase
Equipment Equipment
module module

Control module Control module

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 9 The implementation of Equipment Modules in PCS 7

The following table gives a summary of the benefits and deficits of both
approaches:
Recipe-aware equipment module Generic equipment module
Benefits
• Flexibility for definition and change of master • No recipe dependency on process cell specific
recipes by configuration of recipe operations equipment
– No revalidation of the EM’s is needed in • One central definition of master recipe for a
case of modification of recipe operations product for global use. Easier to transfer
• Direct link between recipe phases and recipes to different sites as recipe does not
equipment modules dependent on process cell specific equipment
– Change recipe procedures (ROP level) • Less complex master recipes as complexity is
without changing controller programs shifted to equipment phase level
• Change recipe parameters directly at EM-level – Coordination between equipment modules
– Reduced engineering effort for exception is easier at equipment phase level
handling and assignment of EM, • Standardization: Reduced effort for (partly) re-
– as by default only one RPH can be active use of equipment phases across different
for an equipment module. plants
– Current installed base with specifications • Easier standardization at global level and
and libraries of EM’s available. more possibilities for digital support in
development and life cycle
– Takes advantage of technological
engineering methods introduced with • Possibility for parallel development of recipes
control module types (by process) and automation control (by
automation)
• Takes advantage of technological engineering
© Siemens AG 2021 All rights reserved

methods introduced with equipment module

types
Deficits
• Dependency of recipe on process cell specific • More design effort needed by End user for
equipment ISA-88 conform control design (definition of
• Multiple definitions of master recipes for same EPH-level)
product in different plants (less • No current installed base with specifications
standardization) and libraries of EM’s available
– Makes it more difficult to exchange master • Less details in master recipes by configuration
recipes across different plants of RPH at EPH-Level (EM coordination at
– Coordination between equipment modules controller level)
is more difficult at recipe level • No direct link between recipe phases and
equipment modules
– Change recipe parameters indirectly at EM-
level via EPH
• More engineering effort needed for exception
handling and assignment/monitoring/release
of EM’s for equipment phases
• Revalidation of the EPH’s in case of
modifications (in the controller)

9.4 Principal approach

The Siemens Industry Online Support webpage is the gateway to find more
information on correctly implementing ISA-88 in your PCS 7 project. Technical
details on how to implement equipment modules and equipment phases are
covered in SIMATIC PCS 7 Process Control System Compendium Part C:
https://support.industry.siemens.com/cs/us/en/view/109761602
A step-by-step description on how to practically implement the ISA-88 structure is
given in:

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 9 The implementation of Equipment Modules in PCS 7

https://support.industry.siemens.com/cs/ww/en/view/109781909
And an example project can be found here:
https://support.industry.siemens.com/cs/attachments/109781909/Batch_GS.zip?do
wnload=true
An online training is also available from Siemens Learning Campus:
https://siemens-
learning.sabacloud.com/Saba/Web_spf/EU2PRD0112/app/shared;spf-
url=common%2Flearningeventdetail%2Fcurra000000000003720

9.5 Derived EPH and EPH interface

It is possible to have several EPH types that have a very similar technological
function, yet a different implementation on each unit in the same multiproject. For
those EPH types, it is possible to define an EPH interface, so that the
corresponding RPH in the recipe will be the same across multiple units. The actual
content of the sequencer can then differ between the various derived EPHTs.
First an EPH interface object is constructed, which contains the interface to
SIMATIC BATCH, but no sequence contents. Next the actual EPHT is derived from
the interface and can be extended with additional parameters and sequence logic,
as depicted in the figure below. Note that the derived EPHT can have more
parameters than its linked interface, but those additional parameters are not visible
on batch level, as they are not included in the interface. They can thus only be
© Siemens AG 2021 All rights reserved

manipulated on the HMI faceplate.

Figure 9-6 Defining the EPH interface (IF) and the derived EPHs
EPH IF

QUANTITY
TEMP DosingIF

EPH derived from derived from EPH

QUANTITY QUANTITY
TEMP Dosing 1 TEMP Dosing 2
RAMP

9.6 Shared EM
In the case of generic equipment modules, the EPH can easily acquire EMs
beyond its unit boundary, see Figure 9-3. The built-in multiplexer takes care of the
arbitration of the shared EM.

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 10 The implementation of Control Modules in PCS 7

10 The implementation of Control Modules in

PCS 7
10.1 PCS 7 interpretation of Control Modules
A control module is typically a collection of sensors, actuators, other control
modules, and associated processing equipment that, from the point of view of
control, is operated as a single entity.
Examples of control modules are
• a regulating device consisting of a transmitter, a controller, and a control valve
that is operated via the set point of the device.
• a state-oriented device that consists of an on/off automatic block valve with
position feedback switches, that is operated via the set point of the device,
• a header that contains several on/off automatic block valves and that
coordinates the valves to direct flow to one or several destinations based upon
the set point directed to the header control module.

The control module types (CMT) in PCS 7 enable a comprehensive type-instance

concept and thus highly efficient handling of types and instances over an entire
project.
CMT are always created and updated in the master data library. They contain all
© Siemens AG 2021 All rights reserved

information necessary for the function of the measurement loop (function blocks,
signals, parameters, messages …). The instances are generated from the CMTs,
either in PCS 7 engineering tools themselves or with COMOS/PAA.
CMTs essentially consist of a conventional CFC with the function blocks and the
connection logic as well as the technological IOs. These technological IOs:
• contain the commands and statuses for the use in the above-mentioned
equipment module type,
• enable the use of variants,
• are the interface to COMOS.
Due to the split into CFC and technological IOs, the CFC part can be edited as
before and the CMT as a whole can be handled from a technological point of view.
Technological objects are created in the technological IOs and connected to the
blocks, signals, parameters and messages in the CFC part. This means that the
technological connections can be designed according to technological aspects,
independent of the function modules used.
In addition to the mentioned blocks, signals, parameters and messages,
standardized commands and statuses can be created in the types which
considerably facilitate the project engineering of the sequences in the equipment
module type.
The decisive advantages of CMT compared to conventional technology are
synchronization and variant creation.
By using CMT, it is possible to synchronize subsequent changes of types, such as
connection changes or additional blocks, into the instances without having to
create the instances again or losing already done detail engineering. Instance-
specific changes are protected against unwanted changes. In addition, a detailed
list of all changes to be executed is provided before the actual synchronization.
If instance-specific differences, such as additional interlocks or different driver
blocks are required, there are two basic ways to implement them. Which one to
choose depends on the type of difference.

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The type offers a choice between instance-specific functions. For example, should
different channel drivers with the same type functionality be used, or functionally
identical valves with or without feedback be implemented? In these cases, the
“optional” functionality is used in the technological connections of the CMT. A
change from one variant to another is possible at any time.

Figure 10-1 Basic principle of variants in CMT

© Siemens AG 2021 All rights reserved

To insert a function extension into one or more instances without changing the
type, independent functions can be created in the master data library and
integrated into the instances. These functions are always handled separately from
the CMT. As with the synchronization of the CMT, it is also possible to make
subsequent changes to the functions and synchronize them in the projects.

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 10 The implementation of Control Modules in PCS 7

Figure 10-2 Basic principle of functions in a CMT

instantiate

insert
© Siemens AG 2021 All rights reserved

10.2 Benefit
The highest priority must be given to the type-instance concept. Quick changes in
an instance would be a violation of the concept and would, for example, lead to
risks in synchronization.
In contrast to this limitation, the type-instance concept offers many advantages:
• Adaptation of changes from type to instance without unnecessary modification
of the existing application is possible.
• Changes in the central/general area only need to be tested once.
• System-side proof that the functions are the same in all instances is given.
• A type can contain several variants.
• Change from one variant to another variant without losing connections already
created.

10.3 Principal approach

The basic idea of the type-instance concept is to create a type from similar
functionalities, which covers all possible features. For example, when creating a
valve type, it must be considered whether feedback signals are available. Is a
feedback necessary? How is the valve controlled? Which interlocks are required?
All these functionalities have to be considered when creating a type and finally
implemented with fixed and/or optional function blocks.

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 10 The implementation of Control Modules in PCS 7

Figure 10-3 Basic principle with CFC

Once the type design is completed, the instances can be created.

© Siemens AG 2021 All rights reserved

Figure 10-4 Basic principle with CMT

Further information can be found in the following application examples and FAQs:
• FAQ 109475748:
Control Module (CM) Technology – Efficient Engineering with SIMATIC PCS 7
• FAQ 109758382:
Synchronization of individual control module types (PCS 7 V9.0 SP1)

10.4 Shared Control Module

In case the same equipment e.g., a motor should be used by several SFC, there is
a function block that organizes individual accesses from upstream (preceding)
applications to a downstream (subsequent) block.
The block allows to coordinate the access from up to four SFC step sequencers to
a technologic block of the families "Drives" or "Dose".

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 10 The implementation of Control Modules in PCS 7

Figure 10-5 Shared control module

© Siemens AG 2021 All rights reserved

The block can be cascaded via the fourth channel so that accesses via more than
four upstream applications are possible.
More detailed information can be found in „SIMATIC Process Control System
PCS 7 Advanced Process Library (V9.0 SP3) Chapter 7.7.

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 11 Implementation of the Procedural Control Model with Recipes

11 Implementation of the Procedural Control

Model with Recipes
How to make a product is defined in recipes.
ISA-88 defines four different recipe types as follows:

Figure 11-1 Recipe types

© Siemens AG 2021 All rights reserved

General recipes and site recipes are not developed in PCS 7.

The Recipe Editor of SIMATIC BATCH provides a comprehensive set of
functionalities to create master recipes and develop structures to challenge difficult
process situations. With the procedural and structural elements, it is very easy and
intuitive to create sequences to control the batch production process. In case
automated exception handling is needed, monitoring areas and command steps
can support operators during critical situations.
The control recipes are derived from the master recipe and can be monitored and
controlled at runtime within the BATCH Control Center or through controls
embedded in the PCS 7 OS process screens.
These components and features are described in the sections below.

11.1 Batch equipment engineering

During a process analysis the plant is structured into a process cell, units,
equipment modules and control modules. This task eventually results in the
technological hierarchy of the PCS 7 engineering system.
Based on this equipment model (ES technological hierarchy) the procedural control
model (master recipes) can be created. No double engineering of batch-specific
engineering data is required, and no additional equipment editors are needed.
At runtime the control recipes will be derived from the master recipes to produce
the batches.

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 11 Implementation of the Procedural Control Model with Recipes

Figure 11-2 Engineering workflow

11.2 Recipe engineering

PCS 7 SIMATIC BATCH provides a very powerful recipe editor with which the
procedural control model can be implemented in a convenient manner.
© Siemens AG 2021 All rights reserved

Recipe editor supports

• creation and modification of master recipes and library objects, so that it is
"engineering instead of programming”,
• documentation of master recipes and library objects,
• plausibility check and
• release of master recipes and library objects for test or production.

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 11 Implementation of the Procedural Control Model with Recipes

Figure 11-3 Example for recipe engineering

© Siemens AG 2021 All rights reserved

In detail PCS 7 SIMATIC BATCH provides the following functions for engineering
of recipes:

Figure 11-4 Functions in PCS 7 SIMATIC BATCH for recipe engineering

1 2 3 4 5 6 7 8 9 10 11 12

1 ROP 6 Parallel branch 9 Transition

2 RPH 7 Sync. line 10 Alternative branch
3 ROP library 8 Monitoring area 11 Loop
4 Operator dialog 12 Jump
5 Command step

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 11 Implementation of the Procedural Control Model with Recipes

11.3 Separation of procedure and formula

With one master recipe combined with several formulas, many control recipes
(products) can be created. This makes it very easy to modify the production
process without changing many recipe procedures for similar products.

Figure 11-5 Formula concept

© Siemens AG 2021 All rights reserved

11.4 Coordination of Units

Most batch production plants contain several units which have to be synchronized
at specific points during the production process, e.g. when a transfer takes place
from one unit to another.
SIMATIC BATCH provides a convenient solution for this synchronization called
synchronization line. No additional efforts are required on the engineering level.
The graphical representation is very clearly laid out during recipe creation and at
runtime for the operator.
There is also an option to block the progress within each recipe unit procedure
(RUP).

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 11 Implementation of the Procedural Control Model with Recipes

Figure11-6 Example for synchronization lines

11.5 Late binding strategies

© Siemens AG 2021 All rights reserved

With SIMATIC BATCH unit class-based recipes can be created. The class concept
allows equipment independent recipes (separation between recipe and equipment)
for facilities with similar units (unit classes) for optimized utilization. During recipe
creation it is not necessary to select a specific unit for a recipe unit procedure,
instead a list of units that are candidates to execute the RUP is created. With the
late binding concept, unit allocation takes place at runtime, based on the allocation
strategy and unit constraints.

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 11 Implementation of the Procedural Control Model with Recipes

Figure 11-7 Class-based recipe concept

Process Cell Master Recipe

Class
Silo

Class Control Recipe

Reactor

SIMATIC BATCH provides four different unit allocation strategies, each RUP is
© Siemens AG 2021 All rights reserved

configured to use a specific allocation strategy to select a unit from the list of
candidates.
• Operator selection: When the RUP is activated the operator can select an
appropriate unit candidate.
• Preferred unit: A unit candidate will be selected during recipe creation in the
master recipe.
• The longest out of use: A unit candidate that hasn’t been used for the longest
amount of time will be allocated.
• Process parameter: A unit candidate can be specified by an external system or
can be selected by controller logic and be deferred up to a process parameter.
The selection of a candidate unit is defined by one or more conditions. Static and
dynamic attributes can be evaluated. Static attributes can be equipment properties
like e.g. “vessel size”, “max. temperature”, “unit class”. Dynamic attributes can be
process parameters like “current pressure inside a vessel”, “actual temperature of
the product”.

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 11 Implementation of the Procedural Control Model with Recipes

11.6 Monitoring area

For exception handling process events within the procedural model can be
monitored as well as a defined area of a recipe procedure (monitoring area).
A transition condition at the start monitors process values, states and events.
When the transition condition is fulfilled, the monitoring runs concurrently.
Monitoring is configured similar to all recipe structures and can utilize all the
topological elements (loops, AND, OR, synchronization lines, etc.).

Figure 11-8 Example monitoring area

© Siemens AG 2021 All rights reserved

11.7 Command step

A command step is used to pass a command (ISA-88 command) in the recipe
operation to one or more target recipe procedure elements (RPEs). This is very
helpful in case of automatic exception handling if it can be determined upfront how
the system should react to undesired process conditions.
A command step can also perform procedural actions across procedural element
boundaries.

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 11 Implementation of the Procedural Control Model with Recipes

Figure 11-9 Example command step

© Siemens AG 2021 All rights reserved

11.8 Batch operation

At runtime of a batch the operator has many possibilities to monitor and control the
batch, depending on the user rights. Several windows can be opened and
arranged within the BATCH Control Center to monitor different sections of the
control recipe. The operator can command the different recipe elements recipe
procedure (RP), RUP, ROP, RPH and transitions. Recipe parameters can also be
modified on any level and will be forwarded to the controller level.

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 11 Implementation of the Procedural Control Model with Recipes

Figure 11-10 Runtime batch operation

11.9 Batch Online Structural Changes

You can refine the master recipes in the test mode online structure change (OSC)
© Siemens AG 2021 All rights reserved

and adjust them perfectly to the production processes. In the test mode OSC it is
possible to modify recipe structures in planned, released and started batches. The
altered or changed recipe structure in the control recipe (batch) can be saved for
further use as a new master recipe at any time, serving a faster recipe
development cycle.

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 12 Recipe transformation and transferability

12 Recipe transformation and transferability

In the middle of the figure below from the ANSI/ISA-S88 part 1 (reference \4\)
“Information flow from general recipe to the equipment entity” the bi-directional
linking between the recipe phases in the control recipes and the equipment phases
in the controller is summarized. At the righthand side the equipment entity model is
shown. These topics are described in detail in the previous chapters.

Figure 12-1 Information flow from general recipe to equipment entity

© Siemens AG 2021 All rights reserved

At the left-hand side, the figure shows the transformation steps for the recipe
entities. Portability of the recipe was mentioned in section 8, where the generic
equipment model approach was identified as the approach that could make the
recipe less equipment dependent.

Figure 12-2 Relationship between four types of recipes in the ISA-88 standard

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 12 Recipe transformation and transferability

The ISA-88 standard defines four types of recipes, each having a different purpose
from the others. The most important of these recipes are the general recipe and the
master recipe.

General recipe
The general recipe, often referred to as an equipment-independent recipe, is
generated for each product variant that is produced. The general recipe defines the
material and process dependencies required to make the product in such a way
that it is independent of the site at which the product is manufactured and the scale
of manufacture, and specific equipment used. The general recipe is usually created
during pilot plant scale up of a recipe used for R&D.

Site recipe
In addition to the general recipe, a site recipe may be maintained for each
manufacturing site at which the product is made. The site recipe may specify local
materials and may correspond to a general recipe that is modified for language and
local units of measurement.

Master recipe
Then a level down, a master recipe is usually generated for each process cell and
for each product variant, and may define exactly how the product is to be made in
© Siemens AG 2021 All rights reserved

the process cell based on the units in the cell, material flows between units and the
equipment available. Usually at this stage some equipment specifics come into the
recipe.

Control recipe
Finally, a control recipe is generated for each batch and may describe custom
options and formula values for a specific batch.

The conversion of general recipes to master recipes is documented in the part 3 of

the ISA-88. Previously this was a manual operation, but this recipe transformation
will be done more and more automatically via PLM tools. The advantage of using
such tools is that recipe development and transformation must be standardized,
which increases know-how and information transfer between the R&D and
production departments.
Although it’s possible to reuse master recipes across sites or process cells, their
portability may be reduced because of equipment execution details. In such cases
it is better to exchange the equipment independent recipes and transform these to
master recipes with the unit specific equipment information. The generation of
master recipes based on general/site recipes outside the master recipe editor is
possible by defining the master recipes electronically based on the BatchML
standard
To facilitate the import and export of recipe information to and from
SIMATIC BATCH, a BatchML interface is available. BatchML provides a set of XML
type and element definitions that are well suited for the exchange of ISA-88 based
data. Siemens expanded the standardized BatchML specification to map all
aspects of recipes in SIMATIC BATCH – in accordance with the BatchML standard.
More details and some helpful examples can be found in this FAQ:
https://support.industry.siemens.com/cs/us/en/view/109747147

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 13 Interfaces towards other systems

13 Interfaces towards other systems

SIMATIC PCS 7 and SIMATIC BATCH offer various interfaces for data exchange
with batch execution related systems. It is important to use the correct interface for
the intended use case.
To support material transfers SIMATIC BATCH inherits the location model that is
defined as part of the physical model in SIMATIC Manager. Locations are used as
setpoints of recipe phases to define source, destination and via of a material
transfer. If an equipment phase leverages SIMATIC Route Control for the material
transfer then the location setpoints are automatically transferred to the route
manager for allocation, control and monitoring of the control modules involved.
For reporting of batch-contextualized data, the reporting engine on the SIMATIC
BATCH server can be used. Reports are based on Microsoft SQL Server Report
Services (SSRS) and can easily be customized. See also
https://support.industry.siemens.com/cs/us/en/view/109481496
For monitoring, customized reporting and connection towards a 3rd party historian,
it is recommended to use the SIMATIC Process Historian. The Process Historian
(PH) collect runtime data from the PCS 7 OS and SIMATIC BATCH in near-real-
time and stores this in a SQL database for long-time archiving. The process
historian thus contains all process related data, contextualized as batch-relevant
data and non-batch-contextualized data. The main dataflows of the process
historian are shown here:
© Siemens AG 2021 All rights reserved

Figure 13-1 Dataflows of the process historian

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 13 Interfaces towards other systems

Use of process historian for external access of data offers various advantages: the
load on applications is reduced, redundancy issues are avoided, and the PH can
be placed in the demilitarized zone (DMZ) for cybersecurity compliancy. The
process historian offers various interfaces, not only SQL interfaces (commonly
used for reporting and dashboarding) but also an OPC UA interface for connectivity
to 3rd party historians and cloud-based data warehousing.
Note that the process historian only contains runtime data, such as control recipes.
Master recipe data is maintained on the batch server and can be accessed using
the batch API, which will be covered next.
SIMATIC BATCH offers a COM API interfaces that allows external applications to
interact bidirectional with SIMATIC BATCH, for instance to launch a control recipe
from a 3rd party MES engine, or to read details on master recipes. The API is
described in this manual:
https://support.industry.siemens.com/cs/us/en/view/92344632
SIMATIC BATCH supports external recipe creation, by means of a BatchML
interface, which was covered in chapter 12.
© Siemens AG 2021 All rights reserved

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 14 Acronyms

14 Acronyms
Term Definition
AS Automation System = PLC
CFC Continuous Function Chart
CM Control Module
CMT Control Module Type
DCS Decentralized Control System
DMZ Demilitarized Zone
eBR Electronic Batch Recording
EPH Equipment Phase
EPHT Equipment Phase Type
EM Equipment Module
EMT Equipment Module Type
EOP Equipment Operation
IO Input Output
MES Manufacturing Execution System
OSC Online Structure Change
P&ID Piping & Instrumentation Diagram
© Siemens AG 2021 All rights reserved

PCell Process Cell

PFD Process Flow Diagram
PH Process Historian
PLC Programmable Logic Controller
RP Recipe Procedure
RPE Recipe Procedure Elements
RPH Recipe Phase
ROP Recipe Operation
RUP Recipe Unit Procedure
SCADA Supervisory Control And Data Acquisition
SFC Sequential Function Chart Type

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 15 Appendix

15 Appendix
15.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
support.industry.siemens.com

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts.
Please send queries to Technical Support via Web form:
support.industry.siemens.com/cs/my/src
© Siemens AG 2021 All rights reserved

SITRAIN – Digital Industry Academy

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
siemens.com/sitrain

Service offer
Our range of services includes the following:
• Plant data services
• Spare parts services
• Repair services
• On-site and maintenance services
• Retrofitting and modernization services
• Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for iOS and Android:
support.industry.siemens.com/cs/ww/en/sc/2067

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 15 Appendix

15.2 Industry Mall

The Siemens Industry Mall is the platform on which the entire siemens Industry
product portfolio is accessible. From the selection of products to the order and the
delivery tracking, the Industry Mall enables the complete purchasing processing –
directly and independently of time and location:
mall.industry.siemens.com

15.3 References, links and literature

No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/109784331
© Siemens AG 2021 All rights reserved

\3\ P. A. Sinclair and J. R. Savery, "Method of Generating Recipe for Process". U.S.
Patent Patent 8,160,735 B2, April 17, 2012
\4\ International Society of Automation, "ANSI/ISA-88.00.01-2010 Batch Control Part 1:
Models and Terminology," October 2020. [Online]. Available:
https://www.isa.org/products/ansi-isa-88-00-01-2010-batch-control-part-1-models
\5\ International Society of Automation, "ISA95, Enterprise-Control System Integration,"
International Society of Automation, [Online]. Available:
https://www.isa.org/standards-and-publications/isa-standards/isa-standards-
committees/isa95 [Accessed October 2020]
\6\ Siemens, "SIMATIC PCS 7 Process Control System Compendium Part C -
Equipment Phases with SFC Types (V9.0)," October 2018. [Online]. Available:
https://support.industry.siemens.com/cs/us/en/view/109761602
\7\ Siemens, "SIMATIC Process control system PCS 7 SIMATIC BATCH V9.0 Getting
Started," August 2020. [Online]. Available:
https://support.industry.siemens.com/cs/ww/en/view/109781909.
\8\ Siemens, "SIMATIC BATCH V9.0: BatchML reference & examples," April 2017.
[Online]. Available: https://support.industry.siemens.com/cs/us/en/view/109747147
\9\ Siemens, "Sample application for SIMATIC BATCH COM API," December 2016.
[Online]. Available: https://support.industry.siemens.com/cs/us/en/view/92344632
\10\ R. Peoples, "6 Steps to Designing a Flexible Control System with ISA-88," April
2014. [Online]. Available: https://www.crossco.com/blog/6-steps-designing-flexible-
control-system-isa-88/

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 15 Appendix

15.4 Change documentation

Table 15-1
Version Date Modifications
V1.0 01/2021 First version
© Siemens AG 2021 All rights reserved

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