Sivakumar Sundararajan BATCH FUNDAMENTALS – 1

12-Jun-2019 Americas HUG

Batch Fundamentals: Key Concepts and Configuration Part 1

• Topics
– Introduction to Experion Batch
– Instance vs. Class Based recipes
▪ Experion Batch for Instance Based Recipes

– Experion Batch components

– Activity functionality in Experion
– Create an Instance Based Recipe
– Operator Interface
– Common Device functionality
– Alias table usage

© 2019 by Honeywell International Inc. All rights reserved.

Batch Fundamentals: Key Concepts and Configuration Part 2

• Topics
– Experion Batch Session 1 recap
– Experion Batch for Class Based recipes
– Unit Timeline display
– Batch messaging interface – Notification Center
▪ Usage in SafeView

– Procedure Explorer
– Batch Application Service

© 2019 by Honeywell International Inc. All rights reserved.

Introduction to Experion Batch

• Experion Batch is a set of features and capabilities in Experion PKS which can be applied to
batch processes
• These features and capabilities are integrated into the Experion environment
– They run on supported controllers along with the rest of process control on the control system
– Experion Batch provides
▪ Sequential and device control

▪ Recipe and procedure control

▪ Support for ISA-S88 batch standards

• These features can also be applied to certain continuous processes and to procedural automation
• Experion Batch is supported on ACE, C300, C200E, UOC, VUOC and their respective simulation
environments
– On C200 controllers, Experion Batch supports SCM/CM execution when another controller provides
recipe control

© 2019 by Honeywell International Inc. All rights reserved.

Batch Architecture & Execution

Distributed Batch Engine

Recipe &
Configuration Recipe Database Operator Operator
Database Batch Server Station Station

UOC UOC UOC vUOC

C300

© 2019 by Honeywell International Inc. All rights reserved.

Batch Applications

Scenario #1 Scenario #2

• Single Recipe • Multiple Recipes

• Single Equipment • Single Equipment
• Fixed set of Formula • Frequent change of Formula

© 2019 by Honeywell International Inc. All rights reserved.

Batch Applications

Scenario #3 Scenario #4

• Single Recipe • Multiple Recipes

• Multiple Equipments • Multiple Equipments
• Fixed set of Formula • Frequent change of Formula

© 2019 by Honeywell International Inc. All rights reserved.

Batch Terms

What is a Recipe?
S88 Definition:
– The necessary set of information that uniquely
identifies the production requirements for a specific
product

What is a Unit?
Unit is physical equipment where the recipe is executed

© 2019 by Honeywell International Inc. All rights reserved.

Instance vs. Class Based Recipes
Recipe 1 Recipe 2
RCM1 RCM2

• Instance based recipes

– Recipe is linked to a specific unit at the time of coding
– It will be run only on the linked unit
– Multiple recipes can be linked to the same unit
– Typically used in single-unit batch applications
• Class based recipes
– Recipe is not linked to a specific unit
Recipe 1
– Corresponds to a Master Recipe in the S88 model Master Recipe

– A control recipe instance is created for each batch on a given unit

– Typically used in multi-unit and multi-product batch applications

• Experion Batch supports both type of recipes

© 2019 by Honeywell International Inc. All rights reserved.

 9

Experion Batch Components

For Instance Based Recipes
• Unit Control Module (UCM)
– UCM represents a physical unit in the plant against which a RCM can be run
• Recipe Control Module (RCM)
– RCM is a container built to run recipes
– It is similar in structure to SCM, but includes support for Phase Blocks
– Can be run at different S88 levels like Procedure, Unit Procedure, Unit Operation or a Phase
• Phase Block
– Phase block is used to interface with child SCM or an RCM and control them
– It is built from Phase Block Type defined in the library
– Phase Block Type is used to specify parameters and reports for a Phase or a Data Block

© 2019 by Honeywell International Inc. All rights reserved.

 10

Experion Batch Components

For Instance Based Recipes
• Data Block
– Created when a Phase Block Type is associated with a SCM or a RCM
– Aligns parameter definition in layered recipes
• Sequential Control Module (SCM)
– Executes sequential control using devices on the system
– Includes support for normal and abnormal handlers
• Control Module (CM)
– It is the container used to provide discrete and continuous control for PID loops, discrete valves, etc.
– It is typically controlled by a SCM

© 2019 by Honeywell International Inc. All rights reserved.

 11

Activity and Activity Entity

• What is an Activity?
– Activity is an instance of an activity entity and represents a sequential task or procedure with a beginning
and end
– Activity types include Batch for batch recipe execution and Procedure for procedural operations execution
– Activity execution can be created and managed in Batch, Procedure or Activity summary pages on the
station
– Activities participate in resource acquisition/release and allow for better arbitration during batch execution
– Activities can be only created during runtime and are not configured
– Activities have a lifecycle
• Activity Entity
– In Experion activity entities include SCM’s, RCM’s and Master Recipes
– Activity Entity is a template from which an Activity can be instantiated

© 2019 by Honeywell International Inc. All rights reserved.

 12

Activity Lifecycle
Create Remove
activity Start RESET Command activity

Read/Modify
Operator/API
Enter/Modify Read/Modify
Formula/Report
Formula/Report Formula/Report
parameter
parameter parameter

Init Pre-Executing Execution Post-Execution

EPKS

Activity is independent of SCM Activity has acquired Activity is independent

the SCM of SCM

Activity Data block Act Ent Start Act Ent RESET Activity
Created initialized removed

© 2019 by Honeywell International Inc. All rights reserved.

 13

Create an Instance Based Recipe

Equipment database
• Identify the equipment modules in the example Inert Gas

• Build the Control Modules

Add A Inerting
F1
– Discrete and Continuous device configuration PIC
Vacuum
M
– PID loops, discrete valves, pumps, motors etc. Ingredient A Agitate Waste Air

Hot
PIC

Cold

Hot

Cold
Heating

Xfer

Next Unit

© 2019 by Honeywell International Inc. All rights reserved.

 14

Create an Instance Based Recipe

Equipment Database
• Identify the equipment modules in the example Inert Gas

• Build the Control Modules

Add A Inerting
F1
– Discrete and Continuous device configuration PIC
Vacuum
M
– PID loops, discrete valves, pumps, motors etc. Ingredient A Agitate Waste Air

• Build Phase Block Types

Hot
– Identify Parameters and Reports
PIC

Cold

Hot

Cold
Heating

Xfer

Next Unit

© 2019 by Honeywell International Inc. All rights reserved.

 15

Create an Instance Based Recipe

Equipment Database
• Identify the equipment modules in the example Inert Gas

• Build the Control Modules

Add A Inerting
F1
– Discrete and Continuous device configuration PIC
Vacuum
M
– PID loops, discrete valves, pumps, motors etc. Ingredient A Agitate Waste Air

• Build Phase Block Types

Hot
– Identify Parameters and Reports
PIC

Cold

• Build SCM’s for the equipment Modules Hot

Cold
– P_ADDA, P_INERT, P_XFER, P_AGIT, P_HEAT Heating

– Phase Block Type linked as a Data Block on the SCM Xfer

• Build UCM’s Next Unit

© 2019 by Honeywell International Inc. All rights reserved.

 16

Create an Instance Based Recipe

Recipe Building
• Build an RCM in the Control Builder or
Recipe Builder
– Associate with the Unit UCM
▪ Configure to acquire unit

– Add Phase Blocks by dragging in SCM’s

▪ System adds Phase Blocks and links with
the SCM
– Add Sync, Transition and Step blocks as
needed
– Configure parameters, reports
– Configure event reporting
– Configure abnormal state propagation
and projection
– Configure Procedure Level and Icon

© 2019 by Honeywell International Inc. All rights reserved.

 17

Operator Interface

• Chart View and Table View are available

from Station Detail Display for SCM and
RCM
• These interfaces have been available since
SCM’s were available
• These displays allow for interfacing with the
RCM or the SCM

© 2019 by Honeywell International Inc. All rights reserved.

 18

Operator Interface
Procedure Panel control
• UI Toolkit is available to embed
SCM/RCM control and visualization into
custom graphics
Procedure Details Pop-up
• It is accessed as a set of objects from
the HMIWeb Display Builder

Step/Phase List control

Command Button control

© 2019 by Honeywell International Inc. All rights reserved.

 19

Operator Interface

• Summary Displays
– Batch, Procedure and Activity
summary displays are available • When Activity is in Activity
– Batch and Procedure Summary Summary Display User can:
displays show the respective type – Command the RCM
of activities
– Activity Summary shows all
Activities
– Navigate to Detail and
Associated display

– View and Modify values of

Header, Formula and Report
parameters

• From the Summary Display

new activity can be created
© 2019 by Honeywell International Inc. All rights reserved.
 20

Operator Interface

• Unit Timeline and Procedure

Explorer are new system
displays available for batch
visualization
• Notification Center to be
introduced with R511.1 will
provide a window for batch
messages as a popup screen
• These features are explored in
the second batch session

© 2019 by Honeywell International Inc. All rights reserved.

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Alias Tables

• Alias Table available in SCM and RCM

• It is used to create alias names to refer to tag parameters which can be resolved at runtime

Alias Name Model Block Model Parameter Instances

• In RCM’s aliases can be used to represent Units, Recipes or Equipment

• This allows RCM’s to execute against different Units
– Note: Only one instance of an RCM can be active at a time though multiple activities can be created and
queued up for execution.

© 2019 by Honeywell International Inc. All rights reserved.

 22

Common Device Function

• This functionality allows multiple SCM’s to control a commonly shared device

• This feature is built into Experion and can be accessed through simple configuration
• Simplifies configuration effort
• This feature
– Allows a CM to be shared by multiple SCM’s
– Supports action qualifiers to acquire and release the CM
– Only supports Boolean values
Select SCM Option as
– Lets the user have control over acquiring an releasing resources COMMON on CM

© 2019 by Honeywell International Inc. All rights reserved.