What is Batch Process

A process that manufactures a finite quantity of

material by subjecting measured quantities of raw
materials to a sequential order of processing
actions using one or more pieces of equipment.
Where as Continuous process control
involves maintaining desired process
conditions.
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Applications of Batch Package

Food Processing Industries

Paper Plants
Pharmaceuticals
Chemical Plants

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YOKOGAWA Batch Package

1970s

- ISA S88.01 (1995/6)

- IEC61512-1 (1997)
1990s

1980s

- SP88 founded (1988/10)

- SP88 draft 1 (1990)

Implemented by DCS
conventional functions

- DCS
developed

- SP88 part 2

Micro XL
Recipe Mgmnt

CENTUM-V
Recipe Mgmnt

CENTUM-XL
Recipe Mgmnt

CENTUM CS
Recipe Mgmnt

CS 1000/3000
PICOT : FCS data
setup/acquisition function

- Recipe Data

- Batch data block

- Sequence Table

CENTUM-XL
XL Batch

- Formula
- Recipe
Procedure
- Plant
Hierarchy

CENTUM CS
CS Batch

S88 01
Standard

06/02/16
3
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Features
Virtual
Virtual Test
Test
Function
Function

Scalable
Scalable
System
System

Redundant
Redundant
Platform
Platform

Open
Open &
&
Reliable
Reliable

Efficient
Efficient
Engineering
Engineering

Structured
Structured
Procedure
Procedure

Flexible
Flexible
Operation
Operation

Refined
Refined
HMI
HMI

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Scalable System
CS Batch 1000 and 3000
- Different application sizes
- Identical software functions

- CS1000 : 80 - 8,000 tags

- CS3000 : 1,000 - 100,000 tags

Large

Production
Scale

Small

PICOT
Simple,Non-critical

Complex,Critical

Complexity
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Levels of solutions to batch applications

Recipe management
Batch management
Unit management (process unit control)
are the basic functions of Batch. The application of these functions changes
based on the batch complexity.

Typical characteristics of a Simple batch processing

Single-stream used to produce a single product one
batch at a time
Small number of recipe changes in formula values
A procedure that rarely changes
System usually consists of one process unit
Operator interaction is a normal activity
Data collection is manual

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Levels of solutions to batch applications

Typical characteristics of a Medium batch processing
Single-stream is used to produce products one batch at a time
(may be parallel lines)
Large number of product recipes
Multiple procedures required to produce product variations
Moderate operator interaction is required as system is automated
Data collection
is moderate of a Complex batch processing
Typical
characteristics
Multi stream (multiple line) capability
Multiple batches running simultaneously on same or different lines
Many recipes or recipes are changed frequently
Numerous procedures, or the sequence of production changes
many process units
Operator interaction is an exception
Much data collection is required for validation, etc.

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Features
Virtual
Virtual Test
Test
Function
Function

Scalable
Scalable
System
System

Redundant
Redundant
Platform
Platform

Open
Open &
&
Reliable
Reliable

Efficient
Efficient
Engineering
Engineering

Structured
Structured
Procedure
Procedure

Flexible
Flexible
Operation

Refined
Refined
HMI
HMI

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Redundant Platform
Recipe
Management

ENG

HIS Batch Server

- Master & Backup

Ethernet

HIS
Batch Client

V-net
(Process Data Highway)

FCS
- Redundant CPU

Standard FCS
(LFCS)

Compact FCS
(SFCS)

ooo

PLC

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Refined Human Machine Interface

Standard Displays
Quick Creation of Overviews, Control and Trend Groups
Automatic Creation of Faceplates, Tag Details, Process Alarms and System Pages
Automatic Creation of Control Drawings, Logic Charts, Sequence Tables, and SEBOL for
Phase Logic
Custom Graphic Displays

Batch Displays
Recipe Overview, Product Setup, Product Overview, Product Detail and Batch Journal
Procedural Control via IEC based Sequence Flow Charts for Recipe Procedure,
Unit Recipe, Operations
Automation Creation of Operator Guides Messages (read only, confirmation & input
request types)

Operator Keyboard with Function Keys

Easy Generation of Operator Displays and

Quick Access to Desired Information

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Standard Displays

Standard Displays

And,
- Process Alarm window
- Faceplate window
- Historical report window
- Process report window
- System Alarm window
- HIS Setup window
- System Status window
- Sequence Table window
- Control Drawing window
- Help Dialog box.
etc.

Batch Displays

Execution of Recipe
Master Recipe
1 Add Raw A
2

Heating

Discharge

3 Add Raw B

Recipe
ManagementReservation

Add Raw A

Heating

Discharge

Add Raw B

HIS Server/Clients
FCS

Unit : REACTER-A

Add
Raw A

Add Raw A

Heating

Operation

Add Raw B

1 Interlock Check

Add
Raw B

Discharge

Heating

Discharge

Valve Open

Level Low

Close Valve

End

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Flexible Operation
Unit: A collection of associated elements,control modules
& equipment modules,that performs the coordinated
Functions.A unit operates relatively of one another.

Unit 1

Unit 2

Unit Recipe 1

Unit Recipe 2

Unit 3

Dynamic Unit Assignment

The Operator can select which Unit to be used for Unit Recipe 2 before Discharging
The Operator can select the Unit depending on the current availability of Units and
the priority of the Batches to optimize the plant performance

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Efficient Engineering
Generic Name
Sequence Library
- Unit Procedure, SFC Sequence

Unit Supervision
- Status Transition Matrix, Main Program execution, Interrupt processing,
Monitoring Operation, User Defined data

Normal Sequence & Exceptional Processing

Standard Languages according to IEC 1131-3
- Function Block Diagram (Control Drawing), Sequential Function Chart (SFC),
Structured Text (SEBOL), and others (Logic Chart, Sequence Table, Calculation Block)

Recipe Structure

Reducing Total Cost of Ownership

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Generic Name
V201

GENERIC
NAME

TAG NUMBER
ACTUAL UNIT
FLT101

FLT201

FQC101
|
|
|

V202

M201

_ _ _ _ _ _ _ _ _ _V101
|
|
|

V102

M101

___

FQI1

FQIC101

TI1

___

T201

V1

V1O1

V201

V2

V102

V202

V3

V103

V203

M3

M101

M201

FLT201
FLT101

T201
V203

V103

Generic Names are designed for Units.

All the Sequence logic are implemented with Generic Name, not with actual Tag
Number
Each Unit has the conversion table between Generic Name and Tag Number.
If not available, Tag Number for Generic Name does not have to exist in some Units.

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Sequence Library (Shared Sequence)

SFC Sequence Library
Unit Procedure Library
SEBOL User Function

SFC Sequence
1 Interlock Check

FQC101
|
|
|

_ _ _ _ _ _ _ _ _ _V101
|
|
|

V102

M101

V3 Open

Level Low

Close V3

End

V201

FLT101

V103

Operation
Racking
(for FLT101)

V202

M201

FLT202
GENERIC
NAME

TAG NUMBER
ACTUAL UNIT
FLT101

FLT201

FQI1

FQIC101

___

TI1

___

T201

V1

V1O1

V201

V2

V102

V202

V3

V103

V203

M3

M101

M201

T201
V203

Operation
Racking
(for FLT201)

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Process Display

CLV

OPV

CS
SFTYV

PIC

SFTYV

PIC

FIC
VCMV

CO2V

CLV1

CO2V

VCMV

AIRV

AIRV

PUMP

FTT

ST

RESTV

RESTV

CLV
FTKLSM
FTKV2

FWV

FTKLSM

FTKV1

TTKV1

TTKV2
CLV
CS

CIP
TAV02

TAV01

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Structured Procedure

Transfer Procedure
from Fermentation
tank to Storage Tank

Operation

Recipe Unit
Procedure

Initialize
Pre Rinse

Initialize

Pre Rinse

Water Cut
Fnl Rinse

SEBOL, Sequence
Tables, or Logic Charts
1 * VALVE OPEN AND
CONDUCTIVITY CHECK *

Pr Control
Racking

Phase

Racking

2
3
*
*
*
27 drive [VLV01==OPEN]
Err1
28 wait until (CI.PV > CISET)
*
*

Transfer
Fnl Rinse

Step
End

Water Push

28 CI.PV = 1%
CI.PV=CI101.PV
CISET = 1

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Design of Unit
A group of equipment
Resident Unit
--- Fixed Unit Procedure
Non-Resident Unit --- Recipe Unit Procedure
Unit

Unit

Unit

Unit

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Configuration of Unit
UNIT INSTRUMENT
Sequence general
configuration
MANAGEMENT

TRANSITION MATRIX
STATUS
RUNNING

MODE
AUT
SEMI
MAN
AUT

SUSPEND

STATUS CHANGE COMMAND

PAUSE
PAUSED.A.PAUSA
PAUSED.A.PAUSA

SUSPEND

MAIN EXECUTION
UNIT RECIPE
PROCEDURE

MAIN EXECUTION
PROGRAM

ABNORMAL PROCESSING

MONITORING

ABNORMAL
PROCESSING

INITIAL

CONDITION CHECK

AFTER PAUSE
PROCESSING

PROCESS

VALVE OPERATION

AFTER STOP
PROCESSING

END

MONITORING
INDEPENDENT SEQUENCE

MEASUREMENT

ABNORMAL PROCESSING

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State Transition Matrix

Command
PSTART

PAUSE

STEP

Total 9RESET

Status
Mode
ABORTED Aut
Semi
Man
RUNNING Aut
PAUSED, A, PAUSA
Semi
PAUSED, S, PAUSA
Man
SUSPEND Aut
SUSPEND, A, STEP
Semi
SUSPEND, S, STEP
Man
PAUSED Aut
Semi
Man
END
Aut RUNNING, A, STRA
Semi RUNNING, S, STRA
Man

END, A, END
END, S, END
END, M, END

end
scomp

IDLE

pstart

RUN

repeat

END
Pause

restart
end

PAUSED
step

Users Unit Operation Method can be implemented

Actions and Status are User configurable

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Each Unit Management Details

UNIT

PROCESS
MANAGEMENT UNIT

DATA SET UNIT

MANAGEMENT DETAILS
THIS UNIT IS STARTED MANUALLY OR BY SOME OTHER UNIT
THE ACTIVITY DONE BY THIS UNIT IS GIVEN BELOW.
RECIEPT OF OTHER PROCESS WHICH HAS BEEN STARTED
RECIEPT OF OTHER PROCESS WHICH HAS BEEN COMPLETED
CONDITION CHECK BEFORE STARTING ANY PROCESS
LINEUP DATABASE DOWNLOAD
PROCEDURE DOWNLOAD
CHECK THE DATA SET FOR THE NEXT BATCH

CONDITIONAL CHECK BEFORE STARTING THE PROCESS .

TANK & LINE STATUS CHECK
CIP LEFT OUT TIME CHECK
EQUIPMENT INSPECTION CHECK
CONDITION CHECK UNIT
SAFETY/VACCUM VALVE STATUS CHECK
TANK LEVEL CHECK
PRESSURE CONTROL CHECK
OTHER CHECKS BASED ON THE PROCESS
TANK/LINE DATA
EACH TANK/LINE DATA WILL BE UPDATED
STORAGE UNIT
LINEUP INFO. UNIT

LINE UP INFO WILL BE PROVIDED BASED ON THE PROCESS SELECTED IN

THAT LINE.

CIP UNIT

AUT CIP REQUIRED/NOT CIP PATTERN SELECTION THROUGH GRAPHICS.

PROCESS UNIT

EACH PROCESS WITH RESPECT TO EACH TANK WIIL BE MADE AVAILABLE

FOR EASY OPERATION

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Exception Processing
Operations active in a Batch unit
Unit Procedure is determined by the
Recipe
1

Monitoring

Add Raw A

Heating

Reaction

Add Raw B

A Monitoring Operation is always

Active
! continuous exception check
On Interrupt signal PRESS-HIGH;
L1,3
On Interrupt State Change;L1.4
L1,3
! Reactor pressure is too high
UNIT = STOP
REACT.mode = MAN
drive [HEAT - VLV = CLOSE]

Responses to Exceptions can be programmed in dedicated Block

Exception Response can be initiated by:
Other Units (Signal)
Operator (Status Change Command e.g... Pause, Restart))

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Standard Languages
S88.01
Procedure
Unit Procedure

SEBOL
TM[PHASE].op = TMSTART
! Start
timer
SEQREACT.mode = AUT
!Enable
drive [CIP - VLV = OPEN]
drive [CIP - PUMP = ON]
PHASE = CLEANING
delay 12000
! CIP for 2 minutes
drive [CIP - PUMP = OFF]

Logic Chart (IBD)

Operation

&
S
R

Phase

OR

Sequence Decision Table

Condition Y
YY
Action

N
Y N

Y
Y

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Recipe Structure
Recipe # 1

Recipe # 2

Header
Recipe Name
: PVC-X
Comment : This is a test recipe, developed for demonstration purposes only!
Customer : Mr. Y. O.

Recipe Procedure
1

Preparation

Reaction

Filtration

Centrifugation

Unit Recipe # 1

Unit Recipe # 2

Procedure
1

Add Raw A

Heating

Reaction

Discharge

Add Raw B

Formula
Charge A : 100 L
Charge B : 75 L
Heat time : 50 min
Heat Temp :
85degC
React Time : 2 hour
Discharge : Tank
D

-Master Recipe is created by Chemical engineer, not by Process engineer (different PC also possible).
- New Master Recipe can be easily created by coping and modifying as well.

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Virtual Test Function

Design

Test

Generation

- Reducing Project Lead Time

- Engineering and Test in the office

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Hands on Experience
Projects Executed :

Suntory (Beer Process) System CS3000 FCS :20

ELCO (Lube Oil Blending/Grease) System CS3000 FCS :2 HIS : 2

Complexity of Batch
Batch report

Asahi Denka (Cake Process) System CS3000 FCS :4

Guji Film (Film Process) System CS3000 FCS :2

Takeda Pharma (Tablets Process) System CS3000 FCS :5 HIS : 4

Customized Batch report

HIS : 6
Recipe Management
Unit Supervision
Batch Design
User defined FCS

HIS : 4
V-Sign Tool

HIS : 4
Standardization of Batch

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What is a Batch Report??

Reports containing process & user supplied

information,collected manually or
automatically,
before, during, and after completing the
batch.

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Fcs User Definition

Tool used to modify the FCS Database

according to
the requirement.

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Batch Using V-Sign Tool

V-Sign means Visual Sebol desIGN Utilities.

Draw a flow Chart for Sequential functions

with custom
Visio Shapes (SEBOL parts).
Convert Flow Chart to SEBOL code.
Creation of new custom Visio shape (SEBOL parts).
Database management tool to register or modify a Visio
Shape (SEBOL parts) and SEBOL code linked with it.

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Merits of Batch Package-1

Provides a cost effective solution(Template usage)
Provides better recipe management
(Off-line recipe creation with any PC providing security for confidential files)

Improve design & simplfy your installation

Reduce integration engineering requirement(Tag assignments for status and alarm
functions/Predefined data transfer).

Provides Production enhancement

Increase Production through scheduling process control units to run the multiple
batches.
Optimize use of process control equipment:Allocation of process units
equipments for maintenance and cleaning as daily routines.
Manage recipe changes on the plant floor:recipe software enables you to manage
recipe at the operator interface-on line saving.

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Merits of Batch Package-2

Provides information about batch status
(Pre-defined Monitoring/Summary screens)

Reduce product changeover time:

Running multiple batches simultaneously(Tracking/Testing/continuing)

Use consistency basic operator interface

Software screens communicate info to operator in ordinary batch language
terminology, such as procedure/operation/formula/phase etc as per ISA standards.

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Merits of Batch Engineering Vs SQT

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

Batch
Ease of Understanding
Built in feature for Operation Start
Built in feature for Messaging
No restriction for messaging in length
wise, can be dynamic
Batch set data max of 256 with array
definition is possible
Program can be written any no of lines up
to 1024 bytes and this can also be
increased.
Availability of built in functions (get
time /get date)
Sub routine programs facility available
Generic name concept is one of major merit
Template Standardization is possible which
reduces the Engg. Activity helps in Revamp
or addition in future.
Program can be written in text file and can
be imported later.

1.
2.
3.
4.
5.
6.

Sequence Tables
Understanding is Difficult
Start Operation to be defined in some
other table
Messaging through builder
Messaging length wise is restricted in the
builder
Batch Set data blocks are restricted per
FCS.
Only 32 Conditions/Actions can be
defined per sequence table.

7.

No built in function as such

8.

Sub routine, Achieving thru ST is

difficult.
No such concept

9.
10.

Template Standardization is not possible,

Engineering activity is more.

11.

Creation to be done in builder only

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Packages With Relevant Functions

Sl.No

Description

Necessary Package

Function

1.

Supervisory computer

Information Management System

packages (Tokuchu)

Information from this PC will

be down loaded to ENGS

2.

ENG - Engg. Stn.

CSBatch 1000/3000 Builder

Package(PHS 5160/LHS 5160)

All the builder level

operation and down loading
to FCS can be done using this
PC and all master files will
be available in this.

3.

HIS Batch server

1000/3000 Recipe Management

Package(PHS 5161/LHS 5161)

All receipe files creation and

down loading to HIS will be
done using this PC.

Back-up

1000/3000 Recipe Management

Package(PHS 5161/LHS 5161)

Same function as that of

master can be achieved in
this.This acts as a backup for
the master but when the
master fails Auto change
over is not available.
"Manual change over" to be
done by operator.

Remarks

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Packages With Relevant Functions

Sl.No

Description

Necessary Package

Function
In all these PC`s operation
is possible.Irrespective of
operation from any client,
the data will get updated in
the HIS Batch Server
Master.

4.

His Batch Clients

CSBatch 1000/3000 Process Management

Package

5.

Batch report printing

PC`s

Report Package(PHS6530/LHS6530
HIS Based ExaOPC
(PHS2411/LHS2411)MS Office Suite

Remarks

Batch report can be printed

on any PC connected in the
network provided the
packages are loaded and
HIS name is defined(the
source data will be
collected only from defined
HIS).
Regarding SP88 : SP88 Is a committee which has laid the S88 standards which defines about Batch terminology
and Models defined for batch engineering which is used by all batch process package holders world wide.As
such there is no certification is available.Even in Japan they convince the customer through verbal
explanations and suitable presentations indicating Yokogawa batch package compiling to S88 standards.
Further information can be obtained from the given link below:

http:// www.controlmagazine.com/Web_First/ct.nsf/ArticleID/MFEY-4M5NK5/

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ELCO

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TPI

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