experion batch manager sample demo -...

7/22/2010 EXP21R310 Experion Batch Manager 1

Honeywell, Inc.

Topic: Experion Batch Manager Sample Demo

Contents

Describe Alias Table Functionality ........................................................................................................3

Demonstrate Experion Batch Manager Sample Configuration..............................................................9

2 EXP21R310 Experion Batch Manager 7/22/2010

Honeywell, Inc.

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Experion Batch Manager Sample Demo

Describe Alias Table Functionality


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Practice

In practical scenarios, a batch process may require to change the process equipment for loaded recipe. ‘Alias Table Load Option’ allows user to change the instance details (an instance represents a process Equipment) without disturbing the loaded control strategy.

When any change is made to a loaded RCM/SCM, including alias table parameter reference, the delta flag appears on the project tab and remain until the object is loaded, or is updated from project.

Step Action

1 Open Control Builder from Configuration Studio if not already open.

2 Click File Import

3 Browse for C:\Documents and Settings\All Users\Application Data\Honeywell\Experion PKS\IXPORT\Student \AliasTable.

Click Select All

Verify that checkbox Import CEE Assignments is checked

Click Import

4 The imported CMs, SCMs, UCM and RCMs with prefix ‘DCB_’ will be assigned to ACE_13 controller

5 Load and activate all parameters

6 Right-click on RCM DCB_CIP_OP in Project mode




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Step Action

7 Right click on DCB_CIP_OP RCM and select Module properties….

ATTENTION

Alias Table load option works only in the following scenarios:

Modifications are done without opening the RCM in chart view.

Only ‘Existing Instances’ are modified.

Alias Table load option will not work for any major change e.g. Adding a new instance in the alias table




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Step Action

8 Build Instance 2 for CIP_BLENDER

Type DCB_B2_CIP.NAME under Instance 2 tab of CIP_BLENDER

Type DCB_BLE2_UCM.NAME under Instance 2 tab of BLENDER_UCM

Type DCB_B2_CIP.DATA.PURGE_TIME.VALUE under Instance 2 tab of PURGE_TIME

Click Ok

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A Yellow delta flag will appear against RCM DCB_CIP_OP in the Project tab.




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Step Action

10 Right click on DCB_CIP_OP and select Load Alias Table… option

TIP

The option Load Alias Table option can also be selected from Controller Menu




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Step Action

11 Click Continue button

12 Click Continue

13 The Instance 2 of Alias table is successfully loaded




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Demonstrate Experion Batch Manager Sample Configuration



Objectives:

Perform Recipe Execution

Observe Updated Report Parameters

Perform Arbitration

Pre-requisite:

All control Strategy for Alias Table is loaded and activated.

Alias Table Configuration lab is completed.

Process Introduction:

Demonstration describes batch process with the help of an example. The example process consists of a mixer and two blenders. It works in semi-continuous and batch Polymer industries where mixing of ingredients prior to blending is common.

In this process, two materials Material1 and Material2 are mixed in Mixer and the resultant intermediate is transferred to one of 2 Blenders. The blender can be selected by the user. The Material3 and Material4 are then blended with the intermediate transferred from the Mixer. After completion of Agitation process in the selected Blender, Final Product is transferred to Storage Tank.

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As same set of equipment is used for different recipes, Clean In Place (CIP) process is used in Blender for purging operation. Blender 1 and Blender 2 will be acquired by different Recipes. So Clean In Place is required.

Each batch of material has an association formulation that varies from batch to batch. The formulations may vary the amount of the two ingredients (Material1 and Material2) and Blending Time. The formulation also indicates which Blender, the Mixer will transfer the batch to.

Demo Batch Control Application:

This pre-built strategies and Custom Displays will help the user to understand how EBM Components can be configured.

This example uses names for Phase block library that reflects S88 standards

This demonstration mainly focus on following key EBM Functionality

1. EBM Layered Recipes

a. Allows user to build and execute multiple hierarchical recipes using RCM, SCM, UCM, CM and Phase Block

2. Formulations using Data block

a. To store data and provide automatic alignment of formula and report parameters between Recipe layers

3. Alias Table

a. Acts as switch to connect the client block to different destination blocks as defined through user selected instances parameters at run time. This gives SCM/RCM the ability to control different equipment each time it runs.

4. Common Device

a. The Common Device Functionality in Control Module enables an Exclusive use resource to completely acquired by a Sequence (SCM/RCM) and own it unless and until the sequence intends to release it.




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Step Action

Recipe Execution and Report parameters

1 Open Control Builder from Configuration Studio if not already open.

2 Verify all CMs, SCMs, RCMs and UCM with prefix ‘DCB_’ imported in the prior lab are loaded and activated

3 Open the Station window if not already opened.




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Step Action

4 To start Demo, call SampleConfig_demo

1. Create Batch :- Enables the operator to select a Recipe and create Batch

2. DCB_DEMO1, DCB_DEMO2 and DCB_DEMO3:- Procedural level RCM for the recipe Sample Configuration

3. Batch Detail:- This button invokes a customized popup for operator to command batch

4. Units:- This button invokes a customized Pop up for Blender selection

5. Arbitration:- This button invokes a customized Pop up for UCM arbitration

6. Messages:- This button invokes message Summary pane to acknowledge/confirm messages

7. Process:- This button invokes the Process Graphic Display Page for the Common Batch Demo

8. CIP:- This button invokes a Customized Popup that enables the operator to start a CIP operation for the desired blender

9. Reset Masses:- Resets all simulation variables

10. Initialize Demo:- Used to initialize the complete Demo

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Step Action

5 Select the checkbox against DCB_DEMO 1

Enter the Batch ID : Batch01

Press <Enter>

Click Confirm

1. Selected Instance: Shows the name of selected instance

2. Enter Batch ID: Enter a Batch ID for selected instance.

3. Enter Batch Size: Enter Batch Size. By default kept as 100%. (this is scaling factor)

4. Edit Parameters: Parameters are edited for selected batch

5. Confirm: Click to confirm edited parameters

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Step Action

6 Click the Batch Details button located at the right hand side corner of the SampleConfig_demo display.

The Batch Details popup will appear




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Step Action

7 Select the Batch ID

ATTENTION

The Batch ID is ‘Batch01’




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Step Action

8 Click the Start button to start the batch process. The active step field indicates currently executing step in the batch process

Close the Batch Details popup window

9 Click the Process button on the SampleConfig_demo. The detail display of the demo process will open




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Step Action

10 Click ‘Show All Status’ and ‘Show Tags’ buttons located at the right-hand side of the Process display

Observe raw material valves (DCB_RM_ZXV011, DCB_RM_ZXV021), agitator (DCB_M1_AGIT001) and level in mixer.

ATTENTION

When RM1 (raw material 1) addition completes, the valve DCB_RM_ZXV011 is closed and the DCB_M1_ADDMAT1 state will show Idle. The raw material RM2 will be added to the mixer, hence DCB_M1_ADDMAT2 will show state as Running. The agitator will be started as indicated by DCB_M1_AGIT001




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Step Action

11 When the state of DCB_M1_ADDMAT1, DCB_M1_ADDMAT2, and DCB_M1_AGIT001 is Idle, click the ‘Batch Summary’ button

12 The SampleConfig_demo display will open. The Units button on the display will be activated and flashing.

Click the Units button




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Step Action

13 The Unit Selection popup will open.

Select the Batch ID, i.e. Batch01.

14 Select Blender 1checkbox

Click Confirm

15 Click the Process button to open the demo process detail display.

Click ‘Show All Status’ and ‘Show Tags’ buttons located at the right-hand side of the Process display




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Step Action

16 Observe the material being transferred from Mixer to Blender1.

17 Click on valve DCB_B1M1_ZXV011 to open its faceplate when the state of DCB_BX_RECVX is Running




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Step Action

18 Change the state of the valve DCB_B1M1_ZXV011 to ON. The quantity of RM4 (raw material 4) will begin to increase. When the quantity of the RM4 crosses 3, change the state of the valve DCB_B1M1_ZXV011 to OFF.

ATTENTION

DCB_B1M1_ZXV011 and DCB_B2M1_ZXV011 are manual valves. Hence, the quantity of RM4 will be manual input

The quantity of RM4 must be set before addition of RM3 to blender completes i.e. before the state of DCB_BX_ADDMAT3 changes to Idle from Running




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Step Action

19 The batch process will continue as follows:

RM3 (raw material 3) added to blender DCB_BX_ADDMAT3 Running

RM4 (raw material 4) set by user added to blender DCB_B1_ADDMAT4 Running

Agitator starts running DCB_B1_AGIT001 Running

Material transferred from blender DCB_B1_XFEROUT Running

ATTENTION

Note that, when RM4 (raw material 4) is added to the blender, the quantity set by the user will drop till it reaches zero.

20 The pump DCB_ST_P001 is turned On, and the material will be transferred from the

blender to the storage tank.




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Step Action

21 At the end of material transfer, the pump DCB_ST_P001 is turned Off and the valve DCB_ST_ZXV001 is closed

22 Click the Batch Summary button to return to the SampleConfig_demo display

23 The status of DCB_DEMO1 will indicate Complete

24 Click the Batch Details button located at the right-hand side corner of the SampleConfig_demo display




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Step Action

25 The Batch Details popup will appear

Select the Batch ID i.e. Batch01 and view the Report Parameters table

ATTENTION

The Report Parameters table is updated after batch completion. It indicates the raw material and final product quantities used during a particular batch process


Demo ate Experion Batch Manager Sample Configuration nstr


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Step Action

Arbitration

26 Start batch process DCB_DEMO2 with Batch ID as Batch02

Repeat steps from 1 to 11.

ATTENTION

Before selecting the blender for batch process, the CIP process will be executed for the blender. CIP stands for “Clean In Place”. Clean In Place procedure is done for cleaning the equipment, before the same equipment is used by another recipe.

27 The Units Button will be activated and flashing for blender selection. Do not select the blender.

ATTENTION

At this point, we will proceed to CIP Unit-Selection without selecting the blender for DCB_DEMO




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Step Action

28 Click the CIP button on SampleConfig_demo display. The CIP – Unit Selection popup window opens.

Click Start




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Step Action

29 The CIP Status changes to Running and the blender selection appears.

Select Blender 1 and click Confirm

ATTENTION

In CIP process, blender selection is done dynamically. When we select Blender 1, Alias Table Instance 1 will get selected.

Alias Table Instance configuration was done in earlier lab based on which specific Blender is selected for CIP process




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Step Action

30 Click the Units button to open the Unit Selection popup window.

Select the Batch ID i.e. Batch02

Select the Blender 1 checkbox and click Confirm

31 Click the Arbitration button on SampleConfig_demo display. From the drop-down menu select DCB_BLE1_UCM




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Step Action

32 The Unit Arbitration Status window indicates that, the current owner of DCB_BLE1_UCM is DCB_CIP_OP. Also, DCB_BLENDER1 is in a queue to use DCB_BLE1_UCM

Close the Unit Arbitration Status window

ATTENTION

Blender 1 is currently acquired by DCB_CIP_OP for the Clean In Place process, and hence it appears under Owner ID

DCB_BLENDER1 is another requesting RCM and is commanded by DCB_DEMO 2 process, hence it is in queue to acquire DCB_BLE1_UCM

The CIP process lasts for 10 seconds. Hence the UCM, DCB_BLE1_UCM will be acquired for 10 seconds.




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Step Action

33 Click the CIP button to open the CIP – Unit Select window and wait for the CIP Status to indicate Complete (when the CIP process on blender is completed)




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Step Action

34 Click the Arbitration button on SampleConfig_demo display. From the drop-down menu select DCB_BLE1_UCM

The Unit Arbitration Status window indicates that, the current owner of DCB_BLE1_UCM is DCB_BLENDER1. Close the Unit Arbitration Status window

ATTENTION

DCB_CIP_OP completed, and hence it released DCB_BLE1_UCM for the next requesting RCM i.e. DCB_BLENDER1

35 Click on Initialize Demo button to reset DCB_DEMO RCM. Reset Masses button will

reset the report values of batch




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