vp batch - yokogawa

TechnicalInformation

VP BatchBatch ManagementPackage

TI 33M05L10-40E

TI 33M05L10-40E©Copyright Oct. 2010 (YK)1st Edition Oct. 2010 (YK)

Yokogawa Electric Corporation2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 JapanTel.: 81-422-52-5634 Fax.: 81-422-52-9802

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TI 33M05L10-40E

IntroductionThe VP Batch is the CENTUM VP Batch Management Package. VP Batch is designed for the management of batch operations with the CENTUM VP Integrated Production Control System. It has been derived from Yokogawa’s extensive experience with distributed control systems (DCSs) and wide-ranging batch applications, and complies with international standards of batch processes.

Documentation ConfigurationThis manual is composed of the following chapters:Chapter 1 introduces the concepts of batch processes.Chapter 2 covers ISA-88 compliance of the VP Batch software.Chapter 3 summarizes the VP Batch software.Chapter s 4, 5 and 6 describe its recipe management function, process management function, and unit supervision function.Chapter 7 describes the VP Batch Operation and Monitoring Windows.Chapter 8 introduces the Access Administrator function (FDA : 21 CFR Part 11)Chapter 9 is a glossary of terms.

Applicable ReadersThis manual is intended for instrumentation/electrical engineers with basic knowledge about DCSs, who want to know the outline of VP Batch or are considering their application.

All Rights Reserved Copyright © 2010, Yokogawa Electric Corporation Oct. 29, 2010-00

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VP BatchBatch Management Package

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CONTENTS

TI 33M05L10-40E 1st Edition

1. Batch Processes ...................................................................................... 1-11.1 Requirements for DCS Manufacturers ...........................................................1-3

2. ISA-88 compliant VP Batch ..................................................................... 2-13. Overview of VP Batch Software .............................................................. 3-1

3.1 Recipes ..............................................................................................................3-23.2 Recipe Structure ...............................................................................................3-33.3 Recipe Setup and Downloading ......................................................................3-53.4 Batch-Operation Monitoring ............................................................................3-63.5 Unit Supervision ...............................................................................................3-7

4. Recipe Management Function ................................................................ 4-14.1 Overview of Recipe Management ...................................................................4-24.2 Header ................................................................................................................4-44.3 Procedure ..........................................................................................................4-54.4 Formula ..............................................................................................................4-74.5 Equipment Requirements ................................................................................4-74.6 Access Control Function .................................................................................4-8

5. Process Management Function .............................................................. 5-15.1 Overview ............................................................................................................5-25.2 Control Recipe Setup .......................................................................................5-3

5.2.1 Control Recipe Setup .........................................................................5-3

5.2.2 Reuse of Control Recipe ....................................................................5-5

5.3 Batch Control ....................................................................................................5-75.4 Batch Results ..................................................................................................5-135.5 Server/Client Function Redundancy ............................................................5-165.6 Production Planning and Scheduling Interface ................................................. 5-18

6. Unit Supervision Function ...................................................................... 6-16.1 Unit .....................................................................................................................6-26.2 Unit Data .............................................................................................................6-36.3 Unit Procedure ..................................................................................................6-4

6.3.1 SFC Language ...................................................................................6-5

6.4 Operation ...........................................................................................................6-96.5 Unit Mode and Status ..................................................................................... 6-11

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6.6 Initialization and Monitoring Operation ........................................................6-136.7 Using Generic Name and Sharing Resources ................................................6-146.8 Status Transition Matrix .................................................................................6-156.9 The definition of link between Common Block & Operation .....................6-16

7. VP Batch Operation and Monitoring Windows ..................................... 7-18. FDA : 21 CFR Part 11 Compliant ............................................................. 8-19. Glossary .................................................................................................... 9-1

1. Batch Processes 1-1

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1. Batch ProcessesThis chapter defines the word “batch processes.”

Batch ProcessThe term “batch process” is commonly used in contrast with “continuous process.”The continuous-process operation is performed continuously without any shutdown, often extending for a year or longer, at oil refineries and power plants, for example. In a continuous process, raw materials are input and products are output at the same time while maintaining steady states of temperatures, pressures, and so forth. The operation of distillation columns is a typical example.The batch-process operation is performed repeatedly in a cycle of a few hours or days. A recipe is used for process actions of charging, heating, reaction, cooling, and discharging, for example, in every operation cycle, to output a predetermined quantity of product, or a batch, in a predetermined period of time. The operation of reactors is a representative example.A batch process features an increase in operation frequency to increase production quantity and process’s applicability to production of other products. A batch process applicable to only one product is called a “single product” process and one applicable to a number of products a “multi-product” process, which are further classified into single-path, multi-path, and variable path structures according to how the processes are incorporated in a plant. Thus there are the following types of batch processes:

• Single-path, single-product process (see below)

• Multi-path, single-product process (see next page)

• Single-path, multi-product process (see next page)

• Multi-path, multi-product process

• Variable-path process (see next page)

F010101.ai

Figure Single-Path, Single-Product Process

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Figure Multi-Path, Single-Product Process

F010103.ai

Figure Single-Path, Multi-Product Process

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Figure Variable-path Process

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1.1 Requirements for DCS ManufacturersThe control of a batch process is dependent on the close alliance of continuous control and sequence control as in the control of a reactor.

Now users demand the following DCS for batch processes:

AdaptabilityA DCS has a number of recipes in order to use the same group of equipment for production of different products. Each recipe contains data (charging volume, temperature setting, etc.) and process-phase control procedure. The DCS must flexibly perform operation even if recipes and procedures vary.In batch processes, new recipes are often added. The new recipes may be different from the old ones in data and procedural combination only. In this case, new recipes must be added without affecting processes.The DCS must also support all types of batch processes from a single-path, single-product process to a variable process.

Easy OperationAlthough DCS windows may be modified if batch-process recipes or procedures are varied, the standard windows should be used for uniformity in operation and monitoring and easy operation. In batch processes, an operation monitoring window is also required for every control unit because a batch process is often separate from each other.

Open EnvironmentIt must be easy to download recipes and schedules from a supervisory computer, and to upload batch production data to the computer.

Compliance with International Standard (ISA-88.01 and 21 CFR Part 11)ISA-88 of U.S. and NAMUR of Europe are working on standardization of batch process. Also, complying with 21 CFR Part 11, the regulation of electronic records and electronic signatures established by FDA (Food and Drug Administration) of U.S., is a recent key issue of the pharmaceutical companies. To increase internationalization of production, selecting the standard-compliant packages for batch process control is vital for enterprises.

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Higher Engineering EfficiencyIt is said that every batch control varies and is not uniform, and the programming of a batch process takes more time than that of a continuous process. By dividing programs in to layers, than sharing and reusing them, efficiency in the programming and maintenance can be improved.The VP Batch is designed to automate and systemize batch processes to fulfill these demands.

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2. ISA-88 compliant VP Batch 2-1

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2. ISA-88 compliant VP BatchThis chapter covers ISA-88 compliance of VP Batch software. For VP Batch software, see Chapter 3.

ISA-88The Instrument Society of America (ISA) -88 Batch Control Standards Committee has been organized to provide batch control standards.The Batch Control Part 1: Models and Terminology was released as ISA-88.01 in 1995.

PurposeTo define terminology, models and functions for batch manufacturing plants and batch control system.

The standardization of terminology, models and functions does:• Promotes optimum plant design and operation,

• Improves batch control,

• Increases applicability.

ISA-88.01 Physical ModelThe ISA-88.01 presents a number of batch-process models including Physical Model. The following figure shows the relationship between Physical Model and VP Batch software.

Enterprise

Site (factory)

Area (plant)

Process cell

Unit

Equipmentmodule

Control module

Productionmanagement

Recipe group/Train

Unit (instrument)

Operation

Function blockSEBOL blockSequence table blockLogic chart block

<VP Batch>F020201.ai

Figure ISA-88.01 Physical Model & VP Batch

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2. ISA-88 compliant VP Batch 2-2

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The Physical Model divides physical resources of an enterprise into seven hierarchical levels — the upper three levels (enterprise, site, area) have not been discussed in detail in ISA-88.01 because of their business-oriented nature. The lower four levels (process cell, unit, equipment module, control module) are provided by grouping devices or equipment through batch engineering.A process cell is composed of more than one train. A train is a group of units required to perform each batch operation. A unit executes a procedure such as reaction, recovery and drying. An equipment module executes an operation such as charging and measuring.The following figure shows the relationship between ISA-88.01 Control Activity Model and VP Batch software. The model illustrates the total image of batch control and inter-functional relationships — various functions are required to perform batch-process operation, which are described in Chapters 4-6.

Recipe management(*1)

Productionplaning and scheduling

Processmanagement

Process control(function block)

Productioninformation

management

: Covered by the VP Batch software

*1: The ISA-88.01 Recipe Management covers general, site, master, and control recipes, but the VP Batch software supports master and control recipes.*2: The Unit Supervision has standard FCS functions. It runs by itself, without VP Batch Recipe Management and Process Managenent packages.

F020202.ai

Unitsupervision (*2)

Figure ISA-88.01 Control Activity Model & VP Batch

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3. Overview of VP Batch Software 3-1

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3. Overview of VP Batch SoftwareThe VP Batch is designed to simplify installation of a batch program on the CENTUM VP system and implement full capabilities.

The VP Batch is comprised of recipe management, process management, and unit supervision, as shown in Chapter 2. The following shows the flow of a typical batch operation and the relationship among the three parts.

General Purpose PCorHIS

Recipemgt.

HIS Processmgt.

Creates a product recipe containing data and procedures.

1. Selecting a recipe for product.2. Assigning unit and batch ID (setup).3. Downloading a recipe to FCS and giving start command.4. Monitoring batch-process operation.5. Receiving operation- completion notification and collecting operation data.6. Deleting a recipe.

FCS Unitsupervision

1. Receiving batch ID, procedure, data, etc., by downloading a recipe.2. Starting specified unit upon receiving start command.3. Notifying processmanagement of operation- completion.

F030001.ai

Figure Flow of Batch-Process Operation

Some conventional batch packages permit programming variable data in recipes and downloading the data to the controller when the operator commands it. Unlike these packages, the VP Batch software control the entire function of batch-process operation. The software have the following features:

• They can modify procedures as well as formula.

• They have their own control data and algorithms.

• They have unified windows for batch-process operation. The VP Batch software show sequential function charts (SFC) as operation windows regardless of recipes with different procedures — it is not easy to provide such flexibility with graphically created windows.

• They comply with ISA-88.01. They are designed in modules and hierarchy.

The flow of a batch-process operation is divided into four sections to cover VP Batch:• Recipe structure

• Recipe setup and downloading

• Batch-operation monitoring

• Unit supervision

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3.1 RecipesA recipe is an entity that contains the minimum set of information that uniquely defines the manufacturing requirements for a specific product. The ISA-88.01 standard defines four types of recipes as shown below, according to the required actions, resources, and so on. Of these four, the VP Batch handles master recipes and control recipes. The Process Management Package mainly handles control recipes, while the Recipe Management Package primarily deals with master recipes.

General Recipe Product-specific processing information

Site Recipe Site-specific information

Master Recipe Process cell-specific information

Control Recipe Batch ID, batch size, in-process, operator-and/orsystem-generated information

F030101.ai

Figure Recipe Types

Master RecipeThe master recipe, which is derived from a general recipe or a site recipe, is the recipe level that is targeted to a specific process cell or a set of that process cell’s equipment. Generally, the amounts of raw materials are specified as relative values rather than absolute values. To derive a control recipe from a master recipe, execution parameters must be specified according to the set of process cell equipment for batch processes and the size of the batch being processed in that process cell.

Control RecipeA control recipe contains information necessary to manufacture a particular batch of product. It has detailed information for plant operation. It may have been modified to account for actual raw material qualities and actual equipment to be utilized.

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3.2 Recipe StructureThe recipe generated by VP Batch Recipe Management has the following four items:

Header: Contains the recipe version, the issue date and other administrative information

Procedure: Contains a procedure to make a product.

Formula: Contains parameters and recipe data to make a product.

Equipment Requirements: Contains requirements of equipment required to make a product.

Recipe

Equipmentrequirements

Formula(recipe data)ProcedureHeader

F030201.ai

Figure Recipe Structure

HeaderContains the recipe name, the create date, the version and other administrative information.

ProcedureContains two procedures to make a product: recipe procedure and unit recipe procedure. A recipe procedure describes the order of used units. For example, it defines how to use a mixing unit, a reactor, and a crystallization unit. A unit recipe procedure defines how processes are executed in each step described in a recipe procedure. The following figure shows the relationship between recipe procedure and unit recipe procedure.

F030202.ai

1

2

5

Initialize

Charge1

2

Mixing Unit 1

Reactor 1

3 Crystallization 1

3 Heat 4 Mix

Reaction

6

7

Cool

Discharge

<Recipe Procedure> <Unit Recipe Procedure>

Figure Recipe Procedure and Unit Recipe Procedure

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FormulaThe formula (recipe data) is a category of information that includes process parameters to manufacture a product. It is stored in system-specific common block and user-definable common block. The system-specific common block contains the recipe name, batch ID, status and other data, while the user-definable common block contains the amount of raw materials, temperature set points, and data required for the batch process in the manufacture of a product.

Equipment requirementsEquipment requirements constrain the choice of the equipment that will be used to manufacture a product. For example, they may be expressed in a manner that specifies allowable equipment in each step of a recipe procedure.

Procedures and formulas are the most important information among the four types, because they are downloaded to the FCS. A recipe does not include an execution program to turn on/off a valve. An execution program resides in the FCS. The unit recipe procedure defines the strategy of carrying out the execution program.

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3.3 Recipe Setup and DownloadingA master recipe is a group of information. It must be changed to a control recipe and sent to the FCS to use in the FCS-resided execution program. Changing a master recipe to a control recipe is called “setup,” and sending it to the FCS is called “recipe downloading.”

To set up a recipe, one has to define the equipment of the FCS that will be used for the recipe at the initiation of the batch, which is called a “unit assignment.” The following figure shows that a recipe is assigned to the equipment “1a,” “2b,” and “3a.” Next, one has to give a name to the product manufactured using the recipe in order to distinguish them from products which have been created at different time or by different equipment. The name is called “batch ID.” After unit assignment and addition of batch ID, a master recipe is changed to a control recipe. Now recipe setup is complete.

A control recipe is divided into more than one unit recipe according to the number of equipment to be utilized, and downloaded to the FCSs, as shown below.

The VP Batch is a batch package for a multi-path, multi-product process and a variable-path process. It allows recipe downloading for any combination of equipment as long as process requirements are met, when multiple equipment are required to manufacture a product.

F030301.ai

Control Recipe

Unit Recipe 1

Unit Recipe 2

Unit Recipe 3

1a

2a

3a

1b

2b

3b

1c

2c

3c

<VP Batch> <Processes>

Figure Downloading a Recipe

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3.4 Batch-Operation MonitoringAfter a control recipe is downloaded to the FCS, actual batch operation starts in the FCS. The HIS is used as a human interface to monitor the operation.

There are two approaches to monitor the operation. One is product-basis monitoring to monitor the progress of the entire operation, and the other is unit-basis monitoring to monitor the state of the currently-operated unit.

For monitoring the entire batch processes, the Product Control View is used. The window displays the following items:

• Recipe group name/train name/path name

• Recipe name/comment

• Equipment requirements

• Recipe status

• Recipe description

• Production start and end times

• Planned production start and end times

• Batch ID

• Lot number and user codes

• Unit recipe status

• Unit names

• User-defined common block data, etc.

This window shows by which unit a product is made, and how batch operation and each unit recipe are being operated. The Product Control View may be customized by graphics builder.Creating a graphic view to understand the status of a unit (device) that is executing the unit recipe enables the operation and monitoring of the device.

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3.5 Unit SupervisionThe unit supervision function controls the batch process according to the downloaded recipe. The structure of a unit and the downloading of a recipe are explained in this section.

Unit StructureUnits can reside independently in the FCS without being related to the control recipe. There are two types of units: a unit with or without a procedure. If a procedure does not reside in a unit, it is downloaded from a control recipe.

Charge

Heat

React

Discharge

Unit procedure *1 Unit dataModeStatusOperation start timeBatch IDUser-defined dataOthers

UNIT

F030401.ai

Step

Initialize

Charge start

Charge end

Operation “Charge”program FeedA

FIC100.LS=“AUT”drive[Valve_1=on]

end

~

~

PhaseOperationprocedure

*1: When a procedure does not reside in a unit, it can be downloaded from a control recipe/process management.

Figure Unit Structure (Unit with a Procedure)

As shown above, the unit contains the unit procedure, operation, and unit data.The unit procedure describes the execution order of phases in the unit using the SFC block. For example, the execution order of “charge,” “heat,” “react,” and “discharge” as one step is described.The operation, which is the sequence of each step started by the unit procedure, is realized using the SFC block and includes the operation procedure and phases. The phases are used in actual operation, for example, to turn valves on and off or change regulator settings, and described using the SEBOL, sequence table, or logic chart block.The unit data indicate the condition of the equipment under the unit supervision function and divided into unit-specific and user-defined data.

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Downloading a RecipeData and procedures are downloaded from the control recipe. The unit recipe procedure in a recipe is downloaded to the unit procedure, properly assigning operations to the units according to the steps used in the procedure.The formula (recipe data) is not downloaded to the data area of the unit and remains outside of the unit as common block data, which can be accessed from the phase.

F030402.ai

Control Recipe

Unit

Recipe procedureHeader

Equipment requirements

Common block

Data

Formula

Temperature

Charging volume

Access from Phases

Unit recipe procedure

Charge

Heat

Reaction

Discharge

Unit data

ModeStatusExecution timeBatch IDUser-defined data




Step

Download Download

Figure Unit Structure (Unit without a Procedure)

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4. Recipe Management Function 4-1

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4. Recipe Management FunctionThis chapter describes the recipe management function of the VP Batch software.

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4.1 Overview of Recipe ManagementThe Recipe Management is positioned at the same level as production planning and scheduling, production information management. It primarily serves as an interface for process management. Recipes are classified into groups, which generate and save master recipes. This function independent from the builder can be used as separate application.

Production planning andscheduling

Production informationmanagement

Production planning andscheduling interface OPC interface

Process management

Unit supervision

F040101.ai

Recipe management

ISA-88.02 Structure

Figure Positioning of Recipe Management

FeaturesRecipe Management does:

• Managing master recipes

• Editing recipes

• Equalizing recipes

• Security Management function

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VP Batch recipes are managed by a recipe group. Master recipes and control recipes are managed by a recipe group. Any recipe is not managed by a few recipe groups. Recipes may be grouped by a physical layer such as area or production cell, or by product.

Number of recipe groups: Max. 16 groups/projectRecipe to be managed: Master recipeNumber of master recipes: Max. 1,000 recipes/recipe groupNumber of unit recipes: Max. 32 recipes/master recipeNumber of path menus: Max. 64 path menus/master recipe

Project

Recipe group 1 Recipe group 2 Recipe group 16

Master recipe Control recipe Master recipe Control recipe

F040102.ai

Figure Configuration of Recipe Groups

One recipe managed by the Recipe Management consists of the following elements:

Header: Contains the recipe version, the create date and other administrative informationProcedure: Contains a procedure to make a productFormula: Contains parameters (recipe data) to make a productEquipment Requirements: Contains equipment requirements necessary to make a product

Recipe

Header Procedure Formula Equipmentrequirements

F040103.ai

Figure Recipe Configuration

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4.2 HeaderA header contains administrative information, such as recipe name, version and issue date. These data are used for Recipe Management and Production Information Management.

A header’s elements are included in a control recipe, but elements excluding a recipe name, description, download mode and start mode cannot be displayed on the Operation and Monitoring Window. Neither can these elements be downloaded to the FCS.

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4.3 ProcedureA procedure is a series of steps which stipulate the order of actions for a batch process. The Recipe Management defines recipe procedure and unit recipe procedure. A recipe procedure shows the order of more than one unit procedure used in a recipe.

Recipe procedure

Unit recipe procedure Unit recipe procedure Unit recipe procedure

Operation Operation

Phase Phase Phase Phase

Master recipe

Unit supervision

F040301.ai

Figure Configuration of Procedure

F040302.ai

Recipe procedureUnit recipe

#1

#2

#3

1A 1A

2A

3A 3A

1B

2B 2B

3B

Figure Example of Recipe Procedure

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The unit recipe procedure, which is described using the SFC (Sequencial Function Chart), defines the execution order of the operations defined in the unit recipe.

F040303.ai

1

2

3

6

Initialize

Charge

Heat 4

Branch

7

8

Discharge

Wash

Add 5 Agitate

9 End

Figure Example of Unit Recipe Procedure

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4.4 FormulaA formula (recipe data) is a set of parameters used to produce a product, such as charging volumes, temperature settings, and result data. It is divided into data values and attributes (data type, display format, item comments). A master recipe has data values only, so use a common block for defining formula data attributes.

Formula(recipe data)

Common block name

Common block name

Common block name

Data item name Data item name

Data value

Data attribute

Data value

Data attribute

Master recipe

Definition using common blockF040401.ai

Figure Formula (Recipe Data) Structure

4.5 Equipment RequirementsEquipment requirements show the conditions required to make a product.

Table Configuration of Equipment Requirements

Requirements Description Remarks

Train-path specification(*1)

64 at maximum of a combination of train-path E.g., Train 1-Path 1

Train 2-Path 3“*” (wild card) applicable

Unit menu specification Name of the units used for each unit recipe Max. 16 “-” (dynamic unit assignment) applicable

Used as defined information for process control*1: Trains: Max 16/recipe group Paths: Max. 64/train

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4.6 Access Control FunctionAccess Control Function of CENTUM VP is to protect systems and data from any break-ins and to control individual operations by authenticating an operator, a system engineer, and a recipe engineer. By using this function, the management of a system engineer (System View/Builder) and a recipe engineer (Recipe Management Function) are ensured besides the conventional management for operators by User Name and Password enabled only in HIS Operation and Monitoring Function. This section covers the recipe engineer management (Recipe Management Function).

Recipe Engineer Authentication and Authority CheckThis verifies identity and if the recipe engineer has the authority to perform the job.

Table The Authority Types

The Authority Types Description

Read (*1) Can start Recipe Builder/Procedure Builder and view recipes.Recipe View and Builder are Read Only.

WriteCan create and edit a recipe.Cannot delete and download a recipe.Cannot create; delete; edit a project and a recipe group.

DeleteCan delete a recipe.Cannot download a recipe.Cannot create; delete; edit a project and a recipe group.

Download Can download recipes from Recipe View/Builder.Cannot create; delete; edit a project and a recipe group.

Approve(future function)

Can write in the recipe-approval person field.Cannot create; delete; edit a project and a recipe group.

Engineering (*2)Can create; delete; edit a project and a recipe group.Can start Recipe Builder/Procedure Builder and view recipes.Cannot create; edit; delete; download a recipe.

*1: All recipe engineers are automatically entitled Read authority and cannot set the authority scope.*2: Engineering authority can be used with Recipe-related authority (Read, Write, Delete, Download, and Approve (future function)).

For instance, Engineering authority plus Download authority for one recipe engineer.

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5. Process Management Function 5-1

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5. Process Management FunctionThis chapter describes the process management function of the VP Batch software.

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5.1 OverviewThe process management function controls the execution of batch operation. It implements:

Control recipe createA control recipe can be created by copying a master recipe or a control recipe that has once been tuned.

Batch execution controlA batch operation is controlled according to the transition of recipe statuses.

Message generationMessages are generated to notify the start and end of batch execution and status changes.

Execution data acquisitionThe data resulted during batch execution are collected by a batch basis.

The figure below shows the flow of a batch, from the creation of control recipes to their completion.

Master recipe

Control recipe(READY)

Control recipe(ACTIVE)

Control recipe(COMPLETE)

Control recipe(COMPLETE)

FCS

Recipe setup

Downloading

Completion of execution


Control recipe(LOG)

Control recipe(LOG)

Uploading

Delation

F050101.ai

HIS

Start of execution

Control recipe(RESERVED)

Figure Flow of Batch

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5.2 Control Recipe SetupIn the process management, the control recipes for actual production are created from the master recipe generated using the recipe management function. This execution is called “Control recipe setup.”

At control recipe setup for a batch, “Control Recipe Copy” function enables to reuse the batch formula data in another batch, which have achieved good production results.

5.2.1 Control Recipe SetupA control recipe can be set up either by manual operations via the Product Overview or by a command in a program.

Setup ProcedureFollow the procedure below for the setup of a control recipe on the Product Overview.

Master recipe selectionSelect the master recipe to be used on the Product Overview.

Unit assignmentAssign the unit or units to be executed for the selected master recipe.

Batch ID specificationGive a name to the batch to be executed for its identification.

Formula (recipe data) modificationModify formula (recipe data) of the master recipe if any formulas need be adjusted to execute the batch.

Setting of Reference Batch IDSpecify a batch ID of a completed control recipe as a reference destination of reference trend display.Reference trend display is a function to display the trend of a completed batch for which a reference batch ID is specified on top of the real time trend of a batch being executed.

Control recipe setupExecute instructions to set up the control recipe.

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Batch IDEvery batch must be named for its identification. A batch ID must be unique and composed of up to 16 alphanumeric characters including hyphens. The batch ID can be entered in either one of the following manners:

Manual EntryBatch IDs can be entered manually using the recipe setup window.

Batch ID DescriptorsBatch IDs, which are unique in a group of recipes, are automatically attached using the system-defined descriptors shown below. A user-specified ID format may be used for each recipe group.

• System-defined batch-ID descriptors: %nG: Reserved recipe group number (n = 1 to 2 digits; no zero-suppression) %nY: Reserved date: YYMMDD (n = 1 to 6 digits) %nM: Reserved date: MMDD (n = 1 to 4 digits) %nD: Reserved date: DD (n = 1 to 2 digits) %nT: Reserved time (n = 1 to 4 digits) %nN[t]: Numeric value increment [reset time: 00 thru 23] (n = no. of digits; no zero suppression) Reset value: 1 %nS: Entered uppercase characters (n = no. of entered bytes) Characters: Fixed uppercase-character string (alphanumeric characters and hyphens only)

• Examples of user-specified batch-ID format: BA-%4N → BA-0001 thru BA-9999 %6Y%2N → 93103101 thru 93103199 %2G-%4N → 01-0001 thru 01-9999 %2N-%4S → 01-**** thru 99-****

Unit AssignmentAssigning a unit name to a unit recipe is called “unit assignment.” There are two ways to assign a unit to a unit recipe, “Train-Path designation” and “Direct designation.”

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5.2.2 Reuse of Control RecipeThe operator can modify the formula data of a control recipe set up based on a master recipe. After this, the operator can make a copy of that control recipe containing the modified formula data (control recipe copying function) to set it up for the next batch, or export the modified formula data and feed it back to the original master recipe.

Flow of Control Recipe Copying FunctionThis function copies one of control recipes as another new control recipe and sets it up. This control recipe set up is called “Copied recipe”, given the status “RESERVED” at first.The source of copied recipe is called “Original Recipe”.While the most of formula data in the original recipe are copied to the copied recipe, some of formula data, such as “Batch ID” and “Reserved date and time”, are not copied, but are set newly. For formula data “Origin Batch ID” of the copied recipe, the batch ID of the original control recipe is set up.

Master Recipe

Control Recipe (RESERVED)

Control Recipe(ACTIVE)

Control Recipe(COMPLETE)

Recipe Setup

Recipe Setup

End Execution

Original Recipe(Copied Recipe)

DownloadingStart Execution

Copy the initial parameters from master reicpe to control recipe

Duplicating

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Copied Recipe

Control Recipe (RESERVED)



End ExecutionDownloading

Start Execution

Control Recipecopying function

Figure Flow of Control Recipe Copying Function

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Exporting FormulasUser can choose a formula and export the formula into a CSV format file. It is possible to export the formula of the control recipe selected by the user as a CSV format file. Formulas can be exported in two ways. The formulas can either be exported manually from the Product Overview, or they can be exported automatically when a batch is completed or the command to gather result data (GATHER) is issued.

Run export(Exported manually)

For general-purpose

CSVFormat File

For general-purpose For Recipe Builder

Exported automatically

CSVFormat File

CSVFormat File

Exporting Formula Exporting Formula

Master Recipe

Control Recipe(RESERVED)

Control Recipe(LOG)

Control Recipe(READY)


Control Recipe(LOG)



HIS

FCS

Recipe Setup

Start of execution



Downloading Uploading

Delation

F050201.ai

Figure Exporting Formula

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5.3 Batch ControlThis section describes the execution and synchronization control of units used for a control recipe.

Recipe StatusesThe control recipe has Control Recipe Status indicating the state of the entire recipe and Unit Recipe Status showing the state of the unit recipe. The control recipe status changes in accordance with the status of the unit recipe contained in the control recipe.

Table Recipe Statuses

Symbol Description Control Recipe Status Unit Recipe StatusRESERVED Reserved for execution. x

ASSIGNED Units assigned. x

NOASSIGN Units not assigned. x

READY Downloaded and standing by. x x

ACTIVE Being executed. x x

LOG Data being acquired. x x

COMPLETE Execution completed. x x

ABORTED Execution aborted. x x

Unit status: ACTIVE

Unit recipe status 1: COMPLETE

Unit recipe status 2: ACTIVE

Unit recipe status 3: READY

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Figure Unit Status and Unit Recipe Statuses

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Control Recipe Status

Master Recipe

Reserve

Control Recipe

END

DELETE

DELETE

DELETE

ABORT

ABORT

ABORT

START UP_LOADLOADRESERVED READY ACTIVE LOG COMPLETE

ABORTED

DELETED

F050302.ai

Figure Transition Between Recipe Statuses

Table Control Recipe Statuses

Notation Description

RESERVED

Indicates that recipe setup ended successfully and the required recipe has been reserved. Upon reservation completion, the recipe is in the RESERVED state. The unit recipe status becomes ASSIGNED if units have already been assigned; the status becomes NO ASSIGN if units have not yet been assigned.

READY

Indicates that downloading has been completed and the downloaded recipe is waiting for execution (start). The recipe is in the READY state when the shared section of the recipe is downloaded successfully.

ACTIVE Indicates that the recipe is running.A recipe is in the ACTIVE state when it is started.

LOGIndicates that result data are being uploaded (logged). A recipe is in this state if every unit recipe status is either LOG or COMPLETE and at least one unit recipe status becomes LOG.

COMPLETE Indicates that all of the recipes have been executed successfully. A recipe is in this state if all of the unit recipe statuses become COMPLETE.

ABORTEDIndicates that the recipe has been aborted. A recipe is in this state if every unit recipe status is either ABORTED or COMPLETE and at least one unit recipe status becomes ABORTED.

(DELETED)

Indicates that a control recipe has been deleted. Since the control recipe disappears, the recipe status does not exist. This status can take place only when the recipe status is either RESERVED, ABORTED or COMPLETE.

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Unit Recipe StatusControl Recipe

END

ABORT

ABORT ABORT

STARTLOADUNIT

ASSIGN UP_LOADNO-ASSIGN ASSIGNED

CANCEL

READY ACTIVE LOG COMPLETE

ABORTED

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Figure Transition Between Unit Recipe Statuses

Table Unit Recipe Statuses

Notation Description

NO ASSIGN

Indicates that units have not yet been assigned to a unit recipe. This status takes place if units have not yet been assigned, units are under dynamic (unit) assignment, the dynamic assignment abnormally ends, or any of the assigned units are canceled.

ASSIGNED Indicates that units have been assigned to a unit recipe. This status occurs when the assignment of units ends successfully.

READY Indicates that unit recipes have been downloaded and are waiting for execution (start). This status takes place when the downloading of unit recipes ends successfully.

ACTIVE Indicates that a unit recipe is running. This status takes place when a unit recipe is started.

LOG

Indicates that the result data are being uploaded (logged). This status takes place when the execution of a unit recipe has been completed. Since no data is available for uploading at the LOG status of a unit recipe, this status takes place soon.

COMPLETE Indicates that all of the unit recipes have been executed successfully. This status takes place when uploading is completed or a unit recipe ends successfully.

ABORTED Indicates that a unit recipe has been aborted. This status takes place if a unit recipe is aborted.

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Batch ModesA control recipe has batch modes to show whether the DownLoading Modes and Starting Modes are carried out automatically or manually.

• Downloading Modes: Receives a download command for a control recipe.

• Starting Modes: Receives a start command for a recipe or a unit recipe.

Downloading Modes• Recipe (Common Part) Downloading Mode

AUT (default): Automatically downloaded when the recipe has been reserved. TIME: Automatically downloaded at the specified time. MAN: Manually downloaded.

• Unit Recipe Downloading Mode AUT (default): Automatically downloaded as soon as the common part of the control recipe has been downloaded. TIME: Automatically downloaded at the specified time. MAN: Manually downloaded.

Starting Modes• Recipe (Common Part) Starting Mode

AUT (default): Automatically starts as soon as a control recipe has been downloaded. TIME: Automatically starts at the specified time. MAN: Manually starts.

• Unit Recipe Starting Mode AUT (default): Automatically starts as soon as a unit recipe has been downloaded. TIME: Automatically starts at the specified time. MAN: Manually starts.

IMPORTANT • Change a batch mode during the recipe setup. You cannot change it after the recipe setup.

• If a unit, which has been assigned to a unit recipe, is in use by another batch process when the start mode of that unit recipe is either AUT or TIME, the START directive will result in an error. In this case, the user must issue the START directive on the Operation and Monitoring Window.

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Dynamic Unit AssignmentThe dynamic assignment of units means to assign units to be run before a given unit recipe starts running.

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Unit recipe

#1

#2

#3

#4 UNIT A4

UNIT A2

UNIT A1

UNIT A3

UNIT B4

Figure Example of Dynamic Assignment of Units

As seen in the above example, the UNIT A1 to UNIT A3 have already been assigned to unit recipes #1 to #3 at the time a given recipe is started. The dynamic assignment of units is useful when determining which unit to use for recipe #4, UNIT A4 or UNIT B4 during the running of UNIT A3.Using the Dynamic Unit Assignment to change the name of a unit already assigned, the information on the original unit name will be lost. The directive must be used for a unit recipe that is not yet started when:

• units to be assigned are not assigned (NOASSIGN);

• the name of a unit already assigned (ASSIGNED) needs to be changed;

or

• the name of a unit for a unit recipe that has already been downloaded (READY) needs to be changed.

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The ASSIGN directive is valid only for unit recipes before starting. If the directive is issued through the Operation and Monitoring Window after downloading a unit recipe, the existing units are cancelled by the system so that the directive can take effect. The ASSIGN directive can be used to assign unit recipes within the same batch by SEBOL (urassign) as well as the Operation and Monitoring Window. To implement the dynamic assignment of units through the Operation and Monitoring Window (or Product Control View), type a unit name for separate specification of the unit name. A unit name can be designated using:

• Direct specification

• Selection from unit menu

• Selection from a list of usable unit names

Select a method as specified in the Master Recipe Builder. However, there are some restrictions.• No dynamic assignment of units is allowed for the starting unit recipe (unit recipe #1).

• If an error occurs when the ASSIGN directive is issued after downloading a recipe, a unit will be cancelled, resulting in the cancellation of downloaded unit recipes.

• If the ASSIGN directive is issued on the Operation and Monitoring Window (or Product Control View) after downloading a unit recipe, the system cancels original units, carries out dynamic assignment of units, and downloads the new units when the downloading modes of a recipe and a unit recipe are “AUT.”

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5.4 Batch ResultsThis section covers how the data recorded during batch execution are collected and saved.

Data CollectionThe data recorded during batch execution is collected on a batch basis. Processes, setpoints, quality, calculation, manual input, and other data recorded during batch execution are collected and saved in the common block data area.

Collected data“Collecting” means the FCS-resided common block data is collected at a station that manages processes, such as the HIS.

Manner of data collectionData is collected at a time after recipe execution has been completed. The user copies process data to the common block data area of the FCS arbitrarily using the SEBOL block or other blocks. The copied data is to be collected on a batch (control recipe) basis.

Timing of data collectionData is collected automatically (at the time of uploading) or arbitrarily. When data has been collected arbitrarily a number of times, or when data has been uploaded after it was collected arbitrarily, the data will be renewed by the latest data.

Table Data Collection

Collection Timing DataArbitrarily When GATHER is specified on the Product Control View Common block data

Automatically When the unit or control recipe has been Uploaded Common block data

Control start and end timeThe control start time (STRTIME) and control end time (ENDTIME) which have been defined for system-specific common block recipes and unit recipes are automatically defined for batch execution.

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Batch Related Trend Data FilingBy linking the process management of the batch management package and the trend recording functions of the HIS, trend data related to each batch and acquired by the HIS can be output to files upon the end of the batch or upon invocation of the batch result gathering (GATHER) command. These output files are referred to as batch-related trend files. Two kinds of files can be created, and whether to create one, the other or both of them can be specified using the corresponding Builder depending on the purpose.

CSV format filesBatch-related trend files in CSV format are useful for application to other systems. From the binary trend data that the trend recording functions of the HIS operation and monitoring functions store in trend data files, process management selectively extracts data related to the batch ID of a given batch for the time period corresponding to the execution time (runtime) of that batch, and saves it to CSV files.

Binary format filesBatch-related trend files in binary format are used to display the trend graphs of batch-related data using a trend window after the execution of each batch.

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Trend Data File

Trend Data Acquisition

Trend View

Data Filing

Batch Related Trend Data Filing(CSV file)Batch Related

Trend Data Filing(Binary file)

Process Management Function

Standard Operation and Monitoring Function

13:3405/10/2010

●●●●●●●●

□□□□□□□□

Tag Name

13:36 13:38 13:4005/10/2010

13:42 13:44

82.3

62.3

42.3

22.3

2.3

VP.100

CIF

102.3

Tag Comment Value Unit Lower Upper

Gathering 00:12:00 100%

FIC001. PVFIC002. PVLIC100. PVTIC100. PVTIC200. PV

12345678

Inlet flowOutlet flowLevelTemp ATemp B

M3/hM3/hMDEGCDEGC

0.00.00.00.00.0

100.0100.0100.0100.0100.0

72.153.3

3.825.714.1

TG1001 Block:10 Group:011

2

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Message GatheringThe VP Batch gathers messages generated during batch execution as part of batch result data. Messages are stored in a historical file of the HIS upon receipt of the messages by Message Management Function. The gathered messages can be retrieved with a batch ID from a historical message report.

Process ReportThe Process Report Function collects data regarding the state of system operation. The VP Batch allows the user to specify a batch ID as the search conditions. To use this function, the Process Management must have been installed.

Batch JournalThe VP Batch allows the user to access recorded data according to a batch ID, print it as a report and use it on application programs. The following data is recorded during batch execution:

• Historical messages

• Common block data

• Historical trend data

These data may be printed as batch reports by arbitrary formats at the time of batch process end. To print them as batch reports, use the Report Package. Previous batch journal includes the function.With the Report Package, current tag data, tag attributes, closing data as well as the above data are collected and detailed batch reports are printed. For data reference on the Report Package, the Open Data Interface Package (Exaopc) for OPC must be installed.

Reference from Application ProgramsWith application programs, the user can access recorded data using a batch ID through OPC communications.

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5.5 Server/Client Function RedundancyThis section describes the use of a number of HISs for operation and monitoring applying the process management function.

Specifying Server and Client StationsThe Process Management Function can be used and monitored from a number of HISs. These HISs serve as server/client stations, so the user can operate and monitor the Process Management Function from any HIS. The server station can also be made redundant (master/backup), suitable for mission-critical application. To define server and client station names for each recipe group, use the Process Management Configuration Builder.

• Server station: A station that processes requests of the client station

Up to 2 server stations/recipe group

• Client station: A station that uses information of the server station

Up to 14 client stations/recipe group

Ethernet

Control bus

HIS 1 HIS 2 HIS 3

Server #1 Client Server #2

Generalpurpose PC

Recipe management

F050501.ai

FCS

(When the Server #1 is a master, the Server #2 serves as a backup and client server.)

Figure Station Configuration

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Control Recipe Copy between ServersUp to 2 HIS that can offer the server function can be specified for each recipe group. However, during execution of the process management function, one station becomes the master server and the other the backup server.When 2 candidate servers are specified, the following control recipe copy is performed between server stations.

• Control recipe is equalized for each recipe group.

• Control recipe copy is performed automatically upon completion of recipe setup and completion of execution. If the formula is modified between recipe setup completion and recipe downloading, control recipe is equalized at the timing at which each individual data was written. With a recipe status between READY and LOG (or between recipe downloading and recipe uploading upon completion of execution), the control recipe exists in the FCS and therefore its equalization is not necessary.

• Switching between the master server and backup server is performed manually for each recipe group.

F050502E.ai

Master Recipe


Control Recipe(LOG)

Control Recipe(READY)


Control Recipe(LOG)


Control Recipe(LOG)



HIS Master Server

FCS

Recipe Setup

Start End

End

Download Upload

Equalize Equalize


HIS Backup Server

End

Delete

Figure Control Recipe Transition

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5.6 Production Planning and Scheduling Interface

Production Planning and Scheduling InterfaceThe schedule management function is used to plan the schedule of the process management function. The production planning and scheduling interface is used to exchange information between the schedule management function and the process management function. On the process management side, recipes are executed according to the schedule information file(*1) through the production planning and scheduling interface. The production planning and scheduling interface is included in the package of the process management function.*1: Including the respective batch IDs, recipe names, formulas, and equipment requirements, but excluding the headers.

F050601E.ai

Schedule management Production information managementRecipe management

Production planning and scheduling interface

Process management

Unit supervision

Function block Function described in this chapter

Figure Positioning of Production Planning and Scheduling Interface

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Overview of Production Planning and Scheduling Interface FunctionThe following describes the overview of the production planning and scheduling interface function.

Schedule ExpansionThe schedule expansion function makes it possible to expand the established schedule created by schedule management to the process management function. The process management function performs recipe setup automatically according to the recipe name, batch ID, and scheduled execution start time within the established schedule file and then executes the recipe.

Batch Progress InformationThe batch journal showing the batch progress information can be collected through the OPC interface. The schedule management function also allows scheduling which reflects messages collected from the batch journal.

System Configuration Including Schedule Management FunctionThe following shows the system configuration based on the combination of the schedule management function, production planning and scheduling interface, and process management function. The process management function registers the server station and client station for each recipe group. The schedule management function can communicate with either the server station or client station. To communication with multiple server stations and client stations, specify all the target HIS on the schedule management function side.

Ethernet

HIS

F050602E.ai

Server #1

Control bus

Host computer

Schedule management


Process management

HISServer #2


Process management

HISClient


Process management

FCS

Figure System Configuration Including Schedule Management Function

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6. Unit Supervision Function 6-1

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6. Unit Supervision FunctionThis chapter describes the Unit Supervision Function of the VP Batch software.

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6.1 UnitA number of equipment used to control continuous or batch processes can be controlled as a unit. For example, a group of reactors in batch processes can be controlled as a unit.

A unit represents a group of equipment, simplifying operation. Giving a command to a unit activates a group of equipment. The user does not need to use individual tag names.

A unit has control algorithm and unit data to control equipment. The control algorithm is composed of unit procedures (SFC) showing the order of processes, operations (SFC and SEBOL) controlling respective action of each equipment, sequence table logic, and logic charts. There are two types of units: one where procedures reside and the other where they must be downloaded from control recipes. The unit data saves the tuning data for the entire equipment. Function blocks can be placed under a unit, and operator guide messages and alarms on the blocks can also be grouped as a unit.

F060101.ai

Unit Procedure

1

Operation(SFC block)

Unit dataSET_DATA=10 kg

Phase

SEBOL Sequencetable

Logic chart

Figure Configuration of Unit with Procedures

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6.2 Unit DataUnit data is a group of data indicating the condition of the unit-controlled equipment. Data items are either unit-specific or user-defined.

Unit-Specific Data ItemsThere are unit-specific data item names, data names and data types.

User-Defined Data ItemsUp to 256 data items can be user-defined. A default storage named BIDQUEUE[ ] is reserved in the user-defined data area to save the Process Management Function-defined batch ID to start recipes. Up to 16 bytes display label can be attached to each user-defined unit data item and displayed on the Operation and Monitoring Window.

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6.3 Unit ProcedureThe unit procedure executes unit processes (procedures). It is described in SFC. To control the order of carrying out operations, a generic operation name or operation tag name is described in the action box of each step (In the following figure, “charge,” “heat,” and others).

1

2

Initialize

Charge

3 Heat

6 Analyze

7 Discharge

9 Wash

10 End

4 Add 5 Agitate

8 Discharge 2

F060301.ai

Figure Example of Unit Procedure

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6.3.1 SFC LanguageThe SFC language has the following three basic elements:

• Steps: Description of actions.

• Transition: Description of transition conditions.

• Links: Linking steps and transitions.

Basic Elements

StepsSteps are expressed by putting numbers (step numbers) in squares. A step has active and inactive states. In the active state the step is being executed, and in the inactive state the step either has been executed or has not yet been executed. The first step, which is called the initial step, is shown in double squares. The initial step is expressed differently, but the action of the initial step is the same as those of successive steps.

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10

For each step, the user defines an action in rectangles. When a step is active, the operation described in the rectangular action box starts. Upon completion of the operation, the step is inactive, moving to the next step.In the action box, a generic operation name or operation tag name is entered. A display label, if it is defined, is shown in the box using the SFC function display.

TransitionTransition from one step to another is indicated using lines. A logical expression called “transition condition” can be described for transition. Satisfying a transition condition moves to next step. The transition condition becomes active at previous step, and is examined upon completion of the operation in the action box.

5

6 7

F060303.ai

LinksLinks between steps, between steps and transition are expressed using horizontal and vertical lines. They show the order (path) of carrying out steps.

10

11 13

12

3

4

5

5

6

7

<Regular linking> <Looped linking> <Selected linking>F060304.ai

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SFC ExecutionThe unit procedure is executed as follows:1. When the unit procedure starts, the initial step is activated for execution.2. The activated step executes the operation described in the action box.3. The step is inactivated when the operation is completed.4. The next step linked to the current step is activated. If there is a transition, a transition

condition will be examined.5. When the transition condition is proved true, the step following the transition will be activated

for execution.

Complex SequencesThere are two types of complex sequences — selective and parallel sequences.

Selective SequenceThe selective sequence is used when different step must be executed according to transition conditions.

5

6 7

9

10

8

<Example of Selective Sequence>F060305.ai

In the example shown above, as Step 5 becomes inactive, three transition conditions connected to the step are examined from the left. The step of which the condition has been proved true will be activated. If more than one transition condition have been proved true, priority is given to the step on the left. If none of transition conditions is proved true, their conditions will be examined repeatedly until one is proved true. Up to eight selective sequences can be described.

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Parallel SequenceThe parallel sequence is used when a number of sequences must be executed at the same time. A parallel sequence is indicated using double horizontal lines. Steps connected to the line become active and executed at the same time. Drawing double horizontal lines at the end of parallel sequences returns to its original path.

5

6 7

9

10

8

<Example of Parallel Sequence>F060306.ai

Up to eight steps can be executed at the same time in a parallel sequence. Up to 32 steps can be executed at the same time if parallel sequences are included within parallel sequences (they can be nested up to three levels in one sequence).

Table SFC Elements

Class Name Symbol

Steps

Initial step

Step

Wait step

Transition Transition

Links

Branch

Join

Parallel branch

Parallel join

Loop out

Loop in

Jump up

Jump down

Jump in

Link

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Jnn

Jnn

Jnn

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Transition ConditionAs a transition condition, one line can be described using a simple logical expression in the following format:

“Left operand” “Operator” “Right operand”

One item can be described as the left operand, such as unit data or function block data of the present station.For the operator, either one of =, <>, <, >, <=, or >= can be entered.For the right operand, one item can be described, such as unit data, function block data of the present station, or a constant.With the Process Management Function, the common block data of the recipe being executed on relevant unit can be described as the left operand.

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6.4 OperationAn operation is a series of control steps executed in the unit-controlled device. It is an independent process in a series of production processes assigned to the device. Each operation corresponds to one step of a unit procedure. When the user tries to execute a unit procedure by a unit, operations are executed according to the progress of the unit procedure processing. When the user tries to execute multiple steps at the same time in the unit procedure, multiple operations are executed at appropriate timing.

Sequence table

Unit

Initial step

Charge 1

Charge 2

Heat

Agitation

Unit procedure (SFC)Initialize

Charge

Terminate

Operation (OPSFC)

F060401.ai

or

or

YN

SEBOL

Operation (OPSBL)

SEBOL

Logic chart

Figure Positioning of Operation

The operation has functions that are equivalent to those of the SFC block. You may think that we call the unit-started SFC block an operation. The major difference between them is that the operation can use additional functions such as access to activated units and formulas (recipe data). Other differences are described below:

• Present unit data can be accessed by data item “%%.” from the operation, while it can be accessed by data item format “unit name.” from the SFC block.

• The operation can be started by a unit only. The user cannot start the operation by themselves.

• With the Process Management Function, the common block data of the recipe can be accessed from the operation, but not from the SFC block.

• The operation can control the start and termination of the unit procedure for another unit in the same recipe.

• The operation can request the downloading of the unit procedure for another unit in the same recipe.

• The operation can reserve (or dynamically assign) the unit to be executed by the unit procedure for another unit in the same recipe.

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Operation Data ItemsOnly system-specific data items are available for operations. The user cannot specify user-specific data items.

Operation SFCThe differences between operation SFC and unit procedure SFC are shown below.

Table Operation SFC vs. Unit Procedure SFC

Item Operation SFC Unit Procedure SFCParallel sequence Not available. Available.

Transition condition SEBOL expression. Unit-specific logical expression.

Action Description using SEBOL, etc. Description of name of operation to be started.

Operation Mode and StatusThe operation is a function block with a tag name, and has its block mode and block status like other function blocks. The block mode indicates the state of operation control and the block status indicates the state of operation.The operation is normally executed under the control of a unit, which cannot be started by operators.

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6.5 Unit Mode and StatusThe user can send a status change directive to a unit, such as operation from the Operation and Monitoring Function, or emergency stop due to failure. The unit also has modes to order the actions of unit procedures and operations. The mode change directive can also be sent from the Operation and Monitoring Function.

Unit ModesLike function blocks, units have modes indicating the control state of a unit. The modes can be changed by a mode change directive from the Operation and Monitoring Function.

Table Unit Modes

Symbol Name DescriptionO/S Out-of-service mode All unit functions are stopped.

MAN Manual mode The unit can be manually operated. The unit procedure cannot be activated, however.

SEMI Semi-automatic mode Inter-step transition can be manually operated but the step itself is automatically controlled.

AUT Automatic mode All unit functions are automatically controlled.

Unit StatusesThe unit status indicates the operation condition of a unit (a unit procedure). The combination of statuses and modes expresses the overall operation condition of a unit. There are operation statuses indicating the state of operation and internal statuses indicating internal detailed condition.

Operation StatusesThe operation statuses of the unit are described below.

Table Operation Statuses

Symbol Name DescriptionEND Completion The unit procedure has been executed.

ABORTED Abnormal termination The unit procedure has been abnormally aborted.

RUNNING Execution The unit procedure is being executed.

SUSPEND Procedure suspension The unit procedure is being suspended at the start of a step.

PAUSED Sequence suspension The operation sequence is being suspended at the start of a phase.

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Internal StatusesThe internal statuses show detailed internal conditions of operation statuses.

Table Internal Statuses

Symbol Status Code Description

END

CNCT NOCNCT INIT INTR

The unit procedure is standing by for execution.There is not unit procedure to execute.The initialization operation sequence is being eecuted.An interruption process is being executed.

ABORTED USER SYSTEM

The unit procedure has been aborted by the user.The unit procedure has been aborted due to a system-detected error.

RUNNING INTR An interruption process is being executed.

SUSPEND INTRCKTR An interruption process is being executed.The transition condition is being examined.

PAUSED INTR An interruption process is being executed.

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6.6 Initialization and Monitoring OperationThe unit executes initialization and monitoring operations in addition to unit procedures and operations.

Initialization OperationThe initialization operation starts one time at system startup before a unit starts. It initializes processes.

Monitoring OperationThe monitoring operation is used for monitoring a unit. It runs regardless of the unit status. It is used when equipment must be monitored all the time, though unit procedures do not run.

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6.7 Using Generic Name and Sharing ResourcesTo use FCS memory effectively and improve engineering productivity, a generic name can be used, and units, unit procedures and operations which have the same function can be shared.

Using Generic Name for UnitsA generic name is a variable name used in a program within operation, instead of a tag name. For units, the relationship between a generic name and a tag name can be defined. With a generic name, a program can be described without a tag name.

Sharing Unit DefinitionUnit definitions, such as unit data definitions, can be shared among units.

Sharing Unit ProcedureThe same unit procedure (SFC) can be shared among multiple units. Entering a generic name of operation in the SFC action box and starting as unit SFC starts corresponding operation.

Sharing OperationTo share the same operation, the function blocks and units accessed in a program can be described by their generic names. The relationship among generic name, tag name and unit name can be registered in the unit.

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6.8 Status Transition MatrixThe status transition matrix determines actions for unit mode/status change commands. A unit changes unit mode/status according to the status transition matrix.

Status TransitionA unit mode shows the control status of a unit and a unit status shows its operation status. “Status transition” means the change of the unit mode and unit status. It is executed by unit mode/status change command. When the unit instrument receives the change command, it shifts to a new unit mode and unit status according to the state transition matrix and, at the same time, transmits operation commands to control the control status and operation status of the unit instrument and operation. The state transition matrix can be customized by the user. (*1)*1: Planned to be customized in future.

Status Transition at the AUT Mode

RUNNING END

SUSPENDPAUSED

ABORTED

END

PSTART

SUSPEND

PAUSE

RESTART RESTART END

ABORTABORT

RESET

ABORT

SUSPEND

F060801.ai

Figure Status Transition at the AUT Mode

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Status Transition at the SEMI Mode

RUNNING END

SUSPENDPAUSED

ABORTED

END

PSTART

SUSPEND

PAUSE

RESTART RESTART END

ABORTABORT

RESET

ABORT

At start of step execution or SUSPEND

F060802.ai

Figure Status Transition at the SEMI Mode

6.9 The definition of link between Common Block & Operation

While the common blocks are usually used commonly among all recipes, it is also possible to use some common blocks only for some units or some operations. This link between common blocks and units/operation is configured, as users like.Thus, by closely link between each unit/phase and formula data contributes to much more efficient configuration and to improvement plant operation and monitoring.

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7. VP Batch Operation and Monitoring Windows 7-1

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7. VP Batch Operation and Monitoring Windows

This chapter describes operation and monitoring windows of the VP Batch software.

The VP Batch has various standard windows, permitting consistent operation and reducing engineering steps. The user does not need to create graphic windows for batch control.

The operation and monitoring windows are supplied as the human-machine interface of VP Batch. They are classified into a window switching from Product overview and a window switching from Product Control view.

Windows that can be opened from the Product Overview are shown below.

F070001.ai

Recipe List

Operator GuideView (*1)

Unit Recipe List Phase ListOperation List


Historical MessageReport Window (*2)




Operation-SFCView



Phase-SFC View(or SEBOL/LogicChart/Sequence

Table View)

Faceplate

Operation FormulaDialog Box

Unit RecipeProcedure View

(or Unit-SFC View)

Recipe ProcedureView

FormulaDialog Box

Unit FormulaDialog Box

Trend SelectionDialog Box

Trend SelectionDialog Box

Trend View

Trend View

Faceplate

Product Overview

Recipe HeaderDialog Box

Operator MemoDialog Box

ProductControl View

*1: The CAMS for HIS Message Monitor is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled and operator guide messages are integrated.

*2: The CAMS for HIS Historical Viewer is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled.

Figure Windows Opened from the Product Overview (Windows for Information Display)

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F070002.ai

Recipe List

Recipe ListDialog Box

Product Overview

Recipe SetupDialog Box

Train SelectionDialog Box

Control Recipe CopyDialog Box

Server SwitchDialog Box

Formula ExportDialog Box

Dynamic Unit AssignDialog Box

Unit Recipe List

Figure Windows Opened from the Product Overview (Windows for Operations)

Windows that can be opened from the Product Control View are shown below.

F070003.ai

ProductControl View


Process AlarmView (*2)


Unit RecipeProcedure View

Unit FormulaDialog Box

Operation-SFCView

Operation FormulaDialog Box

Dynamic Unit AssignDialog Box

Phase-SFC View(or SEBOL/LogicChart/Sequence

Table View)

Recipe HeaderDialog Box

Operator MemoDialog Box

EquipmentRequirementDialog Box

Product Overview

*1: The CAMS for HIS Message Monitor is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled and operator guide messages are integrated.

*2: The CAMS for HIS Message Monitor is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled.*3: The CAMS for HIS Historical Viewer is displayed if Consolidated Alarm Management Software (CAMS for HIS) is enabled.

Figure Windows Opened from the Product Control View

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Recipe-related Views and Dialog Boxes

• Product Overview Displays batch status for each recipe group/train.

• Product Control View Displays the status of each batch. The operation of all batches or individual unit recipes can be carried out. The window is customized by the graphic builder.

• Recipe Procedure View Displays the recipe procedure (SFC) and unit recipe procedure (SFC) of the specified control recipe.

• Unit Recipe Procedure View Displays the unit recipe procedures of a selected control recipe.

• Operation Formula dialog box Displays and allows the user to change the formula applied to a selected operation.

• Unit Formula dialog box Displays and allows the user to change the formula commonly applied to a selected unit.

• Formula dialog box Defines and displays the formula of the specified control recipe.

• Recipe Header dialog box Displays the recipe header of the specified control recipe.

• Recipe List dialog box Displays a list of master recipes for each recipe group/train.

• Recipe Setup dialog box The master recipe selected from the Recipe Overview Dialogue is converted into a control recipe by adding a batch ID, assigning a unit and setting actual volumes.

• Control Recipe Copy dialog box Used to make a copy of a selected control recipe to create a new control recipe.

• Server Switch dialog box Sends a command to switch server stations according to recipe group.

• Formula Export dialog box Used to export formula data for a selected control recipe to a comma-separated value (CSV) text file.

• Train Selection dialog box Used to change the trains within the recipe group.

• Operator Memo dialog box Enters memo of the specified control recipe for operators.

• Equipment Requirement dialog box Defines and displays the equipment requirement of the specified control recipe.

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Follow the procedure below to use the operation and monitoring windows:1. Select a recipe to be formulated on the Recipe Overview.2. Set up a recipe (convert from a master recipe to a control recipe) on the Recipe Setup dialog

box.• Specify a batch ID.

• Assign a unit to be utilized.

3. Send the Load and Start commands to the FCS to download and start the recipe on the same window (When the automatic starting mode is specified, the system automatically executes the downloading and starting of the recipe upon completion of the recipe setup.)

4. After the operation has started,• the batch operation is monitored on the Product Overview or Product Control View

and

• the unit operation is monitored on the Graphic View.

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8. FDA : 21 CFR Part 11 Compliant 8-1

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8. FDA : 21 CFR Part 11 CompliantSupporting FDA : 21 CFR Part 11 compliant functions.The management of recipe engineer (Recipe Management Function) includes “Access Control Function” and “Audit Trail Management Function” that meet the regulations in FDA : 21 CFR Part 11.

CENTUM VP achieves comprehensive FDA : 21 CFR Part 11 compliant by supporting the management of an operator (Operation and Monitoring Function) and a system engineer (System View/Builder) besides a recipe engineer (Recipe Management Function).

SEE ALSO For details of FDA : 21 CFR Part 11, see following TI:

Achieving 21 CFR Part 11 Compliance Using CENTUM VP Authored by Stelex (TI 33M01A62-40E)

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9. Glossary 9-1

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9. GlossaryThis chapter gives definitions of terms used in this manual.

areaAn element in a batch process plant physically, geographically, or logically divided. An area is a component of hierarchical plant information and contains process cells, process units, equipment modules, and control modules. “Area” in this sense is different from that used in “controlled area.” (See control module, equipment module, process cell, unit.)

batchA unit of finished or half-finished products of the same kind that is processed using more than one manufacturing unit. The term is used to identify resources and recipes used in processing each kind of products. (See recipe.)

batch journalBatch data recorded during batch operation. It includes operator input, mode change, operation command, data entry, status change notification and operator guide messages.

batch messageBatch process messages from the FCS and batch history messages from the Operation and Monitoring Function during batch operation. It includes messages from currently operating units and function blocks under the control of units.

batch processA process of manufacturing a limited quantity of products by using more than one manufacturing unit in order of the defined procedure. (See batch.)

common block dataData that can be shared among unit recipes. The term, common block, is used as a means of implementing recipe data.

control moduleA unit that combines a regulating device and a state-transition control device for a combined operation. An example is a single-loop controller.

control recipeA recipe that contains information for manufacturing one specific batch of a product. The information defines all the details required for the production. More than one unit recipes comprise one control recipe. (See batch, unit recipe.)

equipment moduleA unit of functions to control specific and limited minor process activities, such as measuring and material additions. An example is process equipment such as tanks and heaters.

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equipment requirementA requirement for the unit or equipment used in manufacturing products.

formulaA set of recipe data that separates procedure-defined products from other products. A formula include the product grade, quality specification, process variables, material type and quantity. (See procedure.)

ISA-88.01Instrument Society of America (ISA)’s SP (Standards&Practices)88 Committee has been working on batch process standardization and modelling. It released Batch Control Part 1: models and terminology as ISA-88.01 in 1995.

master recipeA recipe that is prepared in accordance with specific manufacturing equipment. A master recipe contains the information for manufacturing a batch of a product. (See batch, recipe.)

operation (sequence)A sequence of steps in operation of a process unit or a sequence of phases in an independent major process contained in the procedure. (See procedure, unit.)

pathA group of process units that are configured in series or parallel and used, or planned to be used, in a batch production operation. (See batch, unit.)

phaseProcessing or action that is related to the process in an operation sequence. (See operation.)

procedureA series of actions taken to accomplish a specified purpose or that defines the order manufacturing steps and the control method for a batch production operation. The term is also applied to the order of executing a unit recipe. (See unit recipe.)

processA series of chemical, physical, or biological activities for the conversion, transportation, or storage of material or energy — excluding computers, controls, and monitors. An example is the distillation process of a refinery.

process cellA concentrated group of equipment involved in the production of batches. A cell is a component of hierarchical plant information and logically controls an entire set of process equipment in an area. (See area, batch, process.)

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recipeA recipe is a set of information that defines control requirements for the production of a batch specifying steps, methods, and parameters. Each recipe is composed of a recipe header, equipment requirements, a formula, and a procedure. Recipes are created in four levels, namely, general recipe, site recipe, master recipe, and control recipe. (See batch, control recipe, equipment requirement, formula, master recipe, procedure, recipe header, unit recipe.)

recipe groupA group of master recipes classified by plant and product line. (See master recipe.)

recipe headerA set of information given to each recipe, including recipe and product identifications, version of the recipe, and originator and originated data. (See recipe.)

recipe setupThe procedure for generating a control recipe from a master recipe by setting parameters, batch identification, and so on and assigning process units that are to be executed by the recipe. (See batch, control recipe, master recipe, unit.)

SEBOL (Sequence and Batch Oriented Language)A text language used to describe sequential control and batch control. (See SFC.)

SFC (sequential function chart)A graphical language used to describe the sequential control function. (See SEBOL.)

SFC blockA function block that executes the SFC-described control function, which controls SEBOL, sequence tables and logic charts. (See SFC.)

siteAn element in a batch production enterprise physically, geographically, or logically divided. A site is a component of hierarchical plant information and contains areas, process cells, process units, equipment modules, control modules. (See area, control module, equipment module, process cell, unit.)

trainA group of process units that are planned to be used in manufacturing a batch of products finished or half-finished. (See batch, unit.)

unit (unit instrument)An instrument having a function to execute part of a specific batch and manage the data and procedure for the purpose. It actually executes a unit procedure that describes the order of manufacturing steps and the control method for reaction, crystallization, dissolution, and so on. It is also a group of control modules or equipment modules. (See batch, control module, equipment module, unit procedure.)

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unit procedureA sequence of operation steps or phases completed within one unit. A procedure in a unit recipe is called unit recipe procedure. (See operation, phase, procedure, recipe.)

unit recipeA recipe that defines a unit for operation. (See unit.)

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VP BatchBatch Management Package

INDEX

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TI 33M05L10-40E 1st Edition

AAccess Control Function .......................................4-8Adaptability ............................................................1-3area ......................................................................9-1

BBasic Elements .....................................................6-5batch .....................................................................9-1Batch-Operation Monitoring ..................................3-6Batch Control ........................................................5-7Batch execution control .........................................5-2Batch ID ................................................................5-4Batch ID Descriptors .............................................5-4Batch ID specification ...........................................5-3Batch Journal ...............................................5-15, 9-1batch message ......................................................9-1Batch Modes .......................................................5-10Batch Process .......................................................1-1Batch Processes ............................................1-1, 9-1Batch Progress Information ................................5-19Batch Related Trend Data Filing .........................5-14Batch Results ......................................................5-13Binary format files ...............................................5-14

CCollected data .....................................................5-13common block data ...............................................9-1Complex Sequences .............................................6-6Compliance with International Standard (ISA-88.01 and 21 CFR Part 11) ..................1-3control module ......................................................9-1Control Recipe ...............................................3-2, 9-1Control Recipe Copy between Servers ..............5-17Control recipe create .............................................5-2Control Recipe Setup ............................................5-3Control Recipe Status ...........................................5-8Control start and end time ...................................5-13CSV format files ..................................................5-14

DData Collection ....................................................5-13Downloading a Recipe ..........................................3-8Downloading Modes ...........................................5-10Dynamic Unit Assignment ................................... 5-11

EEasy Operation .....................................................1-3equipment module ................................................9-1Equipment Requirements .......................3-4, 4-7, 9-2Execution data acquisition ....................................5-2Exporting Formulas ...............................................5-6

FFDA : 21 CFR Part 11 Compliant ..........................8-1Flow of Control Recipe Copying Function ............5-5Formula ...................................................3-4, 4-7, 9-2Formula (recipe data) modification .......................5-3

GGlossary ................................................................9-1

HHeader ...........................................................3-3, 4-4Higher Engineering Efficiency ..............................1-4

IInitialization and Monitoring Operation ...............6-13Initialization Operation ........................................6-13Internal Statuses .................................................6-12ISA-88 ...................................................................2-1ISA-88.01 ..............................................................9-2ISA-88.01 Physical Model .....................................2-1ISA-88 compliant VP Batch ...................................2-1

LLinks ......................................................................6-5

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MManner of data collection ....................................5-13Manual Entry .........................................................5-4Master Recipe ................................................3-2, 9-2Master recipe selection .........................................5-3Message Gathering ............................................5-15Message generation .............................................5-2Monitoring Operation ..........................................6-13

OOpen Environment ................................................1-3Operation .......................................................6-9, 9-2Operation Data Items ..........................................6-10Operation Mode and Status ................................6-10Operation SFC ....................................................6-10Operation Statuses ............................................. 6-11Overview ...............................................................5-2Overview of Production Planning and Scheduling

Interface Function ........................................5-19Overview of Recipe Management ........................4-2Overview of VP Batch Software ............................3-1

PParallel Sequence .................................................6-7path ......................................................................9-2phase ....................................................................9-2Procedure ...............................................3-3, 4-5, 9-2process ..................................................................9-2process cell ...........................................................9-2Process Management Function ............................5-1Process Report ...................................................5-15Production Planning and Scheduling Interface .......................................................5-18

RRecipe ...................................................................3-2recipe ....................................................................9-3Recipe Engineer Authentication and Authority Check .............................................4-8recipe group ..........................................................9-3recipe header ........................................................9-3Recipe Management Function ..............................4-1recipe setup ...........................................................9-3Recipe Setup and Downloading ...........................3-5Recipe Statuses ....................................................5-7Recipe Structure ...................................................3-3Reference from Application Programs ................5-15Requirements for DCS Manufacturers .................1-3Reuse of Control Recipe .......................................5-5

SSchedule Expansion ...........................................5-19SEBOL ..................................................................9-3Selective Sequence ..............................................6-6Server/Client Function Redundancy ...................5-16Setting of Reference Batch ID ..............................5-3Setup Procedure ...................................................5-3SFC ......................................................................9-3SFC block ..............................................................9-3SFC Execution ......................................................6-6SFC Language ......................................................6-5Sharing Operation ...............................................6-14Sharing Unit Definition ........................................6-14Sharing Unit Procedure ......................................6-14site ......................................................................9-3Specifying Server and Client Stations ................5-16Starting Modes ....................................................5-10Status Transition .................................................6-15Status Transition at the AUT Mode .....................6-15Status Transition at the SEMI Mode ...................6-16Status Transition Matrix ......................................6-15Steps .....................................................................6-5System Configuration Including Schedule

Management Function ................................5-19

TThe definition of link between Common Block &

Operation .....................................................6-16Timing of data collection .....................................5-13train ......................................................................9-3Transition ...............................................................6-5Transition Condition ..............................................6-8

Uunit ...............................................................6-2, 9-3Unit-Specific Data Items .......................................6-3Unit Assignment .............................................5-3, 5-4Unit Data ...............................................................6-3Unit Modes .......................................................... 6-11Unit Mode and Status ......................................... 6-11Unit Procedure ...............................................6-4, 9-4unit recipe ..............................................................9-4Unit Recipe Status ................................................5-9Unit Statuses ....................................................... 6-11Unit Structure ........................................................3-7Unit Supervision ....................................................3-7Unit Supervision Function .....................................6-1User-Defined Data Items ......................................6-3

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Using Generic Name and Sharing Resources ...6-14Using Generic Name for Units ............................6-14

VVP Batch Operation and Monitoring Windows .....7-1

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Revision Information Title : VP Batch Batch Management Package Manual No. : TI 33M05L10-40E

Oct. 2010/1st EditionNewly published

Oct. 29, 2010-00

Written by Product Marketing Dept. Industrial Automation Systems Business Division Yokogawa Electric CorporationPublished by Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN

Subject to change without notice.

vp batch - yokogawa

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