Batch Process Overview

EMERSON Process Management Educational Services Copyrighted Material / Duplication Prohibited

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-2
 Objective
Upon completion of this module you will be able to define
• Objectives and models of ISA S88 standard
• Process Cell Class and Process Cell
• Unit Class and Unit
• Equipment Module Class and Equipment Module
• Control Module Class and Control Module
• Unit Phase, Operation, Unit Procedure, and Procedure
• DeltaV Batch System Architecture
Note: For more S88 information, select . . .
DeltaV Books Online  Batch  Batch Reference 
Appendix A – DeltaV Batch and S88

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-3
 S88 Standard
The objectives of the S88 standard are to:
• Provide a common, consistent model for the design and operation of batch
manufacturing plants and batch control systems
• Improve control and efficiency in batch manufacturing processes
Defined models within the S88 standard include:
• Physical Model – defines the hierarchy of equipment used in the batch process
• Procedural Control Model – defines the control that enables equipment to perform
a process task
• Control Activity Model – defines the relationships between the various control
activities required to perform batch processing
• Process Model – defines the results of performing procedural control on the
equipment in the process
Note: The focus of this class is on Physical and Procedural Control Modules. Refer to
Books Online for information about Control Activity and Process Models.
EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-4
 Physical Model
Enterprise
Batch Definitions Defines a hierarchy consisting of
several levels that identifies
equipment within an enterprise. Site

Procedural Control Model

Procedure Area
Defines the hierarchy of actions
required to complete a batch
Process Cell

Unit Unit
Unit
Procedure Procedure

Equipment
Operation Operation Operation Module

Control
Phase Phase Phase Phase Phase Phase Module
EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-5
 Class Based Objects
The DeltaV system lets you create a standard set of reusable logic that you can
incorporate into the recipes of multiple products.
If your plant has multiple, similar units, you can save configuration effort by
implementing a Class-Based design.
• A class is a template from which objects may be created.
• Objects created from the class become an instance of the class. Each instance of a
class has the same structure and properties as all other instances of that class.
Process cells, equipment trains, units, phases, equipment modules, and control modules
are defined at both the class and instance (individual) level in the DeltaV system. The
class level defines common properties that apply to all instances of that equipment entity.

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-6
 Batch Definitions
• Process Cell Class – Common properties for a class of process cells.
• Process Cell – Logical grouping of units that includes the equipment required for
production of one or more batches. A Process Cell can be created from a Process
Cell Class.

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-7
 Batch Definitions
• Unit Class – Common properties for a class of units. Unit Classes represent a
logical groupings of similar equipment; that is, mixers, reactors, cooling, or dryer
tanks. Aliases are created as part of the Unit Class.
Unit Classes

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-8
 Batch Definitions
• Unit Module – A unit module runs the Unit Phases and contains the equipment and
control modules for the equipment associated with the unit. Unit Modules can be
created from the Unit Class and are able to run independently of other units.
Aliases are resolved within the Unit Module.

Unit Module Unit Module

UM_MIXER_1 UM_MIXER_2

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1-9
 Batch Definitions
• Equipment Module Class – Common properties for a particular type of equipment
module. Equipment Module Classes can contain control modules derived from a
class and other equipment modules derived from Equipment Module Classes.
• Equipment Module – An equipment module normally provides supervisory control
for a collection of control modules. Equipment modules contain one or more
modules and are typically controlled using states or commands. Equipment
modules are typically used to coordinate the operation of multiple modules that
must work together to control related equipment.
• Control Module Class – Common properties (for example algorithms, conditions,
alarms, and displays) for a particular type of control module.
• Control Module – A control module links algorithms, conditions, alarms, displays
and other characteristics (parameters) together. A control module is the lowest level
grouping of equipment in the physical model that can carry out basic control.

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 10
 Batch Definitions
• Equipment Train Class – An Equipment Train Class references the unit classes that
define a production path; that is, a logical grouping of all the units and related
equipment that is needed to make a batch.
• Equipment Train – An Equipment Train is all of the equipment required for
production of one or more batches and one or more products.

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 11
 Batch Definitions
• Phase Class – Defines common properties for a class of phases. Phase class
contains user-defined parameters and user-written code to accomplish a specific
process-oriented task; for example Fill, Agitate, Reaction, or Dry.
• Unit Phase – Defines the instance of a phase class associated with a particular unit
module. As many as ten unit phases may be running simultaneously on the same
unit module.
Unit Module Unit Module
UM_MIXER_1 UM_MIXER_2

Phase Class
AGITATE AGITATE
AGITATE
EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 12
EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 13
 Batch Definitions
Unit Module Unit Module
UM_MIXER_1 UM_MIXER_2

Unit Unit
Procedure Procedure

Operation Operation

Unit Unit Unit Unit

Phase Phase Phase Phase
EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 14
 Batch Definitions
• Operation – A collection of phases, transitions and parameters. An operation
executes a sequence of Unit Phases to perform a certain function on a specific unit;
for example, Charge or Finish.
• Unit Procedure – A collection of operations, transitions and parameters. A Unit
Procedure executes a sequence of operations to perform a certain function on a
specific unit.
• Procedure – A collection of unit procedures, transitions, and parameters. A
procedure executes a sequence of unit procedures using one or more units to
produce a product batch. This is the procedural hierarchy’s highest level.

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 15
 Batch Definitions

Procedure

Unit Unit
Procedure Procedure

Batch
Operation Operation Operation Operation Executive
Controller
Unit Unit Unit Unit Unit Unit Unit Unit
Phase Phase Phase Phase Phase Phase Phase Phase

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 16
 Batch Definitions
• Controller – A DeltaV node that runs the algorithms; that is, Unit Modules,
Equipment Modules, Control Modules, Unit Phases, and so forth. The controller
communicates process data to other DeltaV nodes such as workstations and other
controllers.
• Batch Executive – Application which runs as a Windows service that executes
recipes. Operators interact with the Batch Executive through the Batch Operator
Interface and DeltaV Operate. To support loading and handling of large batch
systems, DeltaV supports multiple Batch Executive subsystems. A maximum of
four Batch Executives can be enabled on a single DeltaV network.

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 17
 Batch System Architecture
DeltaV Batch typically requires dedicated nodes for the Batch Executive and
Batch Historian applications.
We will be using the Professional Plus to perform the Batch Executive,
Batch Operator Interface, Batch Historian, and Campaign Manager functions.
Control Studio, Recipe Batch Historian,
Studio, Version DeltaV Operate, Batch Analytics
Batch Executive
Control BOI Applications
(Application Station)
(Professional Plus) (Any DV Station) (Application Station)

On-line Recipe Data Historical Data

Control Data

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 18
 Batch Definitions
• Control Studio – Used to create/edit control modules and phase logic
• Recipe Studio – Used to create/edit operations, unit procedures and procedures
• DeltaV Operate and Batch Operator Interface (BOI) – Used to interface to the
Batch Executive for the purpose of loading and running a batch (recipe)
• Batch Executive – Used to execute recipes
• Batch Historian – Collects both Batch Event Journal files from the Batch
Executive and Event Chronicle records and stores them in an SQL database
• Batch History View – Used to view historical data from the Batch Historian
• Campaign Manager – Used to run multiple iterations of a batch. Campaign
Manager must run on the same node as the Batch Executive
• Version Control – Runs on the ProfessionalPLUS workstation and uses an SQL
database to keep a record of all configuration changes
• Batch Analytics - Faults in your batch process are detected in real time giving
operations the ability to take corrective action before a negative impact occurs.
EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 19
 Review
1. The objectives of S88 are:
A. Provide a common, consistent model for the design and operation of batch
manufacturing plants and batch control systems
B. Improve control and efficiency in batch manufacturing processes.
C. None of the above
D. All of the above
2. What model defines the hierarchy of equipment used in the batch process?
A. Physical Model
B. Control Activity Model
C. Procedural Control Model
D. Process Model

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 20
 Review
3. In DeltaV Explorer, the following items are part of the Physical Model:
A. Area (Plant Area)
B. Operation
C. Process Cell
D. Unit (Unit Module)
E. All of the above
4. Which application runs as a Windows service that executes recipes?
A. Batch Analytics
B. Recipe Studio
C. Batch Executive
D. Version Control

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 21
 Review
5. Which components are defined at both the class and instance (individual) level in
the DeltaV system?
A. Process Cell
B. Area (Plant Area)
C. Equipment Module
D. Phases

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 22
 Summary
You should now be able to define
• Objectives and models of ISA S88 standard
• Process Cell Class and Process Cell
• Unit Class and Unit
• Equipment Module Class and Equipment Module
• Control Module Class and Control Module
• Unit Phase, Operation, Unit Procedure, and Procedure
• DeltaV Batch System Architecture

EMERSON Process Management – Educational Services Course 7016 – Rev 17 – 3/18/2014 Copyrighted Material / Duplication Prohibited
1 - 23