09 # complex batch control

8/14/2019 09 # Complex Batch Control

1/6

Flexible automation of batch processesSIMATIC BATCH

simatic


2/6

In the process industry, batch processes are assuming

increasing significance. Shorter product life cycles and the

productivity demanded by consumers are two reasons for

this change in importance. Other demands include the need

for consistent quality product, faster responses to market

conditions, production reproducibility (FDA compliance),

and compliance with legal standards and controls.

To satisfy these needs, new batch plants are more and more being

designed as multi-purpose facilities. This enables multiple products

to be produced using the same equipment set thus reducing

equipment idle time. In some cases, this flexibility also enables a

single product to be produced using different paths through the

equipment set that can result in increased product production and

reduced batch cycles.

The PCS 7 process control system offers an excellent solution for

the economical and effective implementation of batch processes

in a batch automation environment: SIMATIC BATCH.SIMATIC BATCH can be used to implement a practical and highly

flexible batch solution. This product can be applied to all batch

processes. It can be used with batch processes that have single

path structures as well as to those processes that have network

structures. It can be used with facilities that produce one product

as well as facilities that product multiple products. It is a scalable

modular software package that can be used in both small pilot

facilities as well as in large production plants.


3/6

Integration of SIMATIC BATCH

SIMATIC BATCH is fully integrated in SIMATIC PCS 7

and shares the same visualization and engineeringtools as the other standard SIMATIC PCS 7 compo-

nents. The total integration of SIMATIC BATCH in the

plants visualization system provides the operator

with the tools to easily monitor and control batches,

and to quickly response to process exceptions.

Integration makes it easy to consolidate batch data

and batch-related continuous data, such as a units

temperature profile during the time the unit is

allocated to the batch, into a single comprehensive

XML based batch report that can be viewed using

a web browser, and/or printed.

Integration of SIMATIC BATCH in the SIMATIC PCS 7

engineering system means that engineering data

need to be entered only once. Once entered, the

engineering data is available for use by all SIMATIC

PCS 7 components. This reduces the time it takes

to engineer an application and minimizes data entry

errors.

SIMATIC BATCH can be linked to the higher-order IT

level (MES/ERP) software packages. One way to do

this is through the use of the standard SIMATIC ITinterface. A second method is through an available

open API interface that enables you to develop your

own custom interfaces to third-party software

packages.

Optimum adaptation to plant requirements

SIMATIC PCS 7/SIMATIC BATCH enables you to im-

plement a solution architecture that best reflects

the needs of your solution. For small batch processes,

an all-in-one node solution can be implemented.

For larger batch processes, a client-server architec-

ture can be used. To ensure high process availability

and complete batch data collection, redundant batch

servers can be implemented in the architecture.

Process-oriented recipe creation

SIMATIC BATCH enables you to develop a batch

solution that follows the equipment and recipe

hierarchies defined in ISA S88.01. In this model:

Recipe procedures execute in a Process Cell

Unit procedures, operations, and phases execute

in a Unit.

Integration of SIMATIC BATCH in the engineering system


4/6

Equipment-independent recipes and recipe

building blocksWith SIMATIC BATCH, a master recipe is a sequenceof process actions that describe how a batch productis produced. These master recipes can be imple-mented as equipment-independent sequences. Atrun time, the batch manager dynamically assignsa unit to the recipe. Using this capability, a single

master recipe can be used with different equipmentunits thus reducing the time needed to engineer amaster recipe. The basic master recipe building blockis a recipe phase. The normal and exception handlinglogic for a recipe phase is stored in an equipmentphase. PCS 7 enables you to create equipment phasetemplates that are instantiated and assigned to asmany units as needed. Equipment phase templatesmake it easy to clone and validate equipment phases.Any change to an equipment phase template auto-matically updates each instance that was created inthe project.

Dynamic Unit Allocation

SIMATIC BATCH supports true dynamic unit alloca-tion. This enables the assignments of units to abatch to be deferred until the units are actuallyrequired by the batch. A number of unit allocationstrategies are provided with the product. The unitallocation strategy can be selected based on thesituation in the plant. This ensures flexible and

optimum utilization of plant capacity.

Recipe Operation Procedures Library (ROP)A Library ROP is a structure of recipe phases builtbased on the unit classes defined in an application.A Library ROP can be used in multiple recipe unit-procedures. Changes made to a Library ROP auto-

matically updates each instance of this Library ROP

used in the application. Additionally, the linkbetween a library ROP and an instance of the libraryROP can be detached to allow for instance-specificmodifications independent of the library ROP. ROPscan help reduce engineering and validation over-head.

ValidationIncreasingly, todays plants require validation forcompliance with quality standards as well as foradherence to marketing and statutory requirements.Traceable and reproducible production is particularlyimportant in a multi-product or multi-stream envi-ronment. SIMATIC BATCH provides features that helpyou follow GMP and FDA 21CFR Part 11 standards.At runtime, an Audit Trail feature automatically logseach step in a batch execution. All run time controlrecipe activities and operator actions are capturedand stored to batch history. This information canbe printed out and/or displayed when required.SIMATIC BATCH provides user access protection withWindows 2000-based centralized user management

features. In the system, each user has a unique userID and password that is assigned by the systemadministrator. The user can be forced to change hispassword the first time he logs in. A users user IDdefines the application and applicationfunctionsthat the user is permitted to access. Electronicsignatures are available to support paperlessproduction. An operator action can be defined torequire one or more sign-offs before the action isperformed. You can also define sign-off requirementscontrol recipe phase status changes. The actionalong with the signatures are captured to batchhistory and can be viewed as part of the standardbatch report for the batch.

Allocation of subsystems at runtime


5/6

SIMATIC BATCH enables easy, flexible, user-friendly auto-mation of all batch processes and provides the tools that

support you in complying with all applicable standards.

For you, SIMATIC BATCH means

More production flexibility a shorter time to

market

Production sequences are described in master recipes,

which can be generated or modified whenever necessary

by operating personnel that have the proper access

permission.

Improved plant capacity utilizationSIMATIC BATCH supports dynamic unit allocation. The

allocation of units (equipment) can be planned in advance

and can be changed on the fly to reflect the latest

production requirements until the unit allocation actually

takes place.

Complete batch data managementThe production sequences are automatically documented

in the batch log (on paper or electronically). Production

sequences are easily reproducible.

Reduced validation cost

Runtime recipe modifications are automatically document-

ed. SIMATIC BATCH provides features like recipe version-

ing, user access control, runtime production audit trails

and electronic signature (21 CFR Part 11).

Reduction in operating costs and life cycle costs

All standard products from Siemens receive worldwide

Siemens service and support. You can purchase and installSiemens products anywhere in the world and expect the

same top quality service and support.

SIMATIC BATCH Highlights

Modular architecture with flexible hardware and

software scalability Optimum adaptation to plant size and individual requirements

Grows with the plant, no expensive reserve capacities

necessary

Redundant batch servers

High process availability

No loss of batch data

Automatic synchronization of batch data

Tight integration of SIMATIC BATCH in the HMI strategy

and the PCS 7 engineering system

No customer-specific interfaces required

One time entry of process model and engineering data Integrated alarm and message concept

Reliable operator guidance and safe, reliable response to

process faults

Equipment-independent recipes

Considerable simplification of recipe management and

validation

Flexible recipe usage and optimum plant capacity

utilization

Hierarchical recipes to ISA S88.01

Process-oriented recipe generation Simple, fast, fault-minimized recipe generation

Storing, archiving and comprehensive logging of batch

data based on state-of-the-art XML format

Production becomes transparent and traceable

Reduced engineering and validation effort

SFC type/instance concept

Separation of procedure and formula

Unit-class-based ROP library development

Reusable

Centralized configuration

Validation support

Audit trail (modification log)

Versioning for recipes, recipe operations and formulas

Centralized user access management and electronic signature


6/6

Siemens AG

Automation and Drives

Industrial Automation Systems

P.O. Box 48 48

D-90327 Nrnberg

w w w . s i e m e n s . c o m / p r o c e s s a u t o m a t i o n

The latest information on SIMATIC PCS 7:www.siemens.com/simatic-pcs7

Web support:www.siemens.com/automation/service&support

SIMATIC is a registered trademark of Siemens. Other designationsused in this publication may be trademarks whose use by thirdparties for their own purposes could violate the rights of theowners.

The information provided in this brochure contains merely generaldescriptions or characteristics of performance which in actualcase of use do not always apply as described or which maychange as a result of further development of the products. Anobligation to provide the respective characteristics shall onlyexist if expressly agreed in the terms of contract.

09 # complex batch control

Documents