Flexible automation of batch processes SIMATIC BATCH

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In the process industry, batch processes are assuming increasing significance. Shorter product life cycles and the productivity demanded by consumers are two reasons for this change in importance. Other demands include the need for consistent quality product, faster responses to market conditions, production reproducibility (FDA compliance), and compliance with legal standards and controls.

To satisfy these needs, new batch plants are more and more being designed as multi-purpose facilities. This enables multiple products to be produced using the same equipment set thus reducing equipment idle time. In some cases, this flexibility also enables a single product to be produced using different paths through the equipment set that can result in increased product production and reduced batch cycles. The PCS 7 process control system offers an excellent solution for the economical and effective implementation of batch processes in a batch automation environment: SIMATIC BATCH. SIMATIC BATCH can be used to implement a practical and highly flexible batch solution. This product can be applied to all batch processes. It can be used with batch processes that have single path structures as well as to those processes that have network structures. It can be used with facilities that produce one product as well as facilities that product multiple products. It is a scalable modular software package that can be used in both small pilot facilities as well as in large production plants.

Integration of SIMATIC BATCH SIMATIC BATCH is fully integrated in SIMATIC PCS 7 and shares the same visualization and engineering tools as the other standard SIMATIC PCS 7 components. The total integration of SIMATIC BATCH in the plants visualization system provides the operator with the tools to easily monitor and control batches, and to quickly response to process exceptions. Integration makes it easy to consolidate batch data and batch-related continuous data, such as a units temperature profile during the time the unit is allocated to the batch, into a single comprehensive XML based batch report that can be viewed using a web browser, and/or printed. Integration of SIMATIC BATCH in the SIMATIC PCS 7 engineering system means that engineering data need to be entered only once. Once entered, the engineering data is available for use by all SIMATIC PCS 7 components. This reduces the time it takes to engineer an application and minimizes data entry errors.

SIMATIC BATCH can be linked to the higher-order IT level (MES/ERP) software packages. One way to do this is through the use of the standard SIMATIC IT interface. A second method is through an available open API interface that enables you to develop your own custom interfaces to third-party software packages. Optimum adaptation to plant requirements SIMATIC PCS 7/SIMATIC BATCH enables you to implement a solution architecture that best reflects the needs of your solution. For small batch processes, an all-in-one node solution can be implemented. For larger batch processes, a client-server architecture can be used. To ensure high process availability and complete batch data collection, redundant batch servers can be implemented in the architecture. Process-oriented recipe creation SIMATIC BATCH enables you to develop a batch solution that follows the equipment and recipe hierarchies defined in ISA S88.01. In this model: Recipe procedures execute in a Process Cell Unit procedures, operations, and phases execute in a Unit.

Integration of SIMATIC BATCH in the engineering system

Equipment-independent recipes and recipe building blocks With SIMATIC BATCH, a master recipe is a sequence of process actions that describe how a batch product is produced. These master recipes can be implemented as equipment-independent sequences. At run time, the batch manager dynamically assigns a unit to the recipe. Using this capability, a single master recipe can be used with different equipment units thus reducing the time needed to engineer a master recipe. The basic master recipe building block is a recipe phase. The normal and exception handling logic for a recipe phase is stored in an equipment phase. PCS 7 enables you to create equipment phase templates that are instantiated and assigned to as many units as needed. Equipment phase templates make it easy to clone and validate equipment phases. Any change to an equipment phase template automatically updates each instance that was created in the project. Dynamic Unit Allocation SIMATIC BATCH supports true dynamic unit allocation. This enables the assignments of units to a batch to be deferred until the units are actually required by the batch. A number of unit allocation strategies are provided with the product. The unit allocation strategy can be selected based on the situation in the plant. This ensures flexible and optimum utilization of plant capacity. Recipe Operation Procedures Library (ROP) A Library ROP is a structure of recipe phases built based on the unit classes defined in an application. A Library ROP can be used in multiple recipe unitprocedures. Changes made to a Library ROP automatically updates each instance of this Library ROP

used in the application. Additionally, the link between a library ROP and an instance of the library ROP can be detached to allow for instance-specific modifications independent of the library ROP. ROPs can help reduce engineering and validation overhead. Validation Increasingly, todays plants require validation for compliance with quality standards as well as for adherence to marketing and statutory requirements. Traceable and reproducible production is particularly important in a multi-product or multi-stream environment. SIMATIC BATCH provides features that help you follow GMP and FDA 21CFR Part 11 standards. At runtime, an Audit Trail feature automatically logs each step in a batch execution. All run time control recipe activities and operator actions are captured and stored to batch history. This information can be printed out and/or displayed when required. SIMATIC BATCH provides user access protection with Windows 2000-based centralized user management features. In the system, each user has a unique user ID and password that is assigned by the system administrator. The user can be forced to change his password the first time he logs in. A users user ID defines the application and applicationfunctions that the user is permitted to access. Electronic signatures are available to support paperless production. An operator action can be defined to require one or more sign-offs before the action is performed. You can also define sign-off requirements control recipe phase status changes. The action along with the signatures are captured to batch history and can be viewed as part of the standard batch report for the batch.

Allocation of subsystems at runtime

SIMATIC BATCH enables easy, flexible, user-friendly automation of all batch processes and provides the tools that support you in complying with all applicable standards. For you, SIMATIC BATCH means More production flexibility a shorter time to market Production sequences are described in master recipes, which can be generated or modified whenever necessary by operating personnel that have the proper access permission. Improved plant capacity utilization SIMATIC BATCH supports dynamic unit allocation. The allocation of units (equipment) can be planned in advance and can be changed on the fly to reflect the latest production requirements until the unit allocation actually takes place.

Complete batch data management The production sequences are automatically documented in the batch log (on paper or electronically). Production sequences are easily reproducible. Reduced validation cost Runtime recipe modifications are automatically documented. SIMATIC BATCH provides features like recipe versioning, user access control, runtime production audit trails and electronic signature (21 CFR Part 11). Reduction in operating costs and life cycle costs All standard products from Siemens receive worldwide Siemens service and support. You can purchase and install Siemens products anywhere in the world and expect the same top quality service and support.

SIMATIC BATCH Highlights

Modular architecture with flexible hardware and software scalability Optimum adaptation to plant size and individual requirements Grows with the plant, no expensive reserve capacities necessary Redundant batch servers High process availability No loss of batch data Automatic synchronization of batch data Tight integration of SIMATIC BATCH in the HMI strategy and the PCS 7 engineering system No customer-specific interfaces required One time entry of process model and engineering data Integrated alarm and message concept Reliable operator guidance and safe, reliable response to process faults Hierarchical recipes to ISA S88.01 Process-oriented recipe generation Simple, fast, fault-minimized recipe generation Storing, archiving and comprehensive logging of batch data based on state-of-the-art XML format Production becomes transparent and traceable Reduced engineering and validation effort SFC type/instance concept Separation of procedure and formula Unit-class-based ROP library development Reusable Centralized configuration Validation support Audit trail (modification log) Versioning for recipes, recipe operations and formulas Centralized user access management and electronic signature

Equipment-independent recipes Considerable simplification of recipe management and validation Flexible recipe usage and optimum plant capacity utilization

The latest information on SIMATIC PCS 7: www.siemens.com/simatic-pcs7 Web support: www.siemens.com/automation/service&support

Subject to change without prior notice 10/04 | Order No. E20001-A190-P280-V1-7600 | DISPO 46303 | 41C8763 MK.AS.PS.XXXX.52.5.01 WS 10043. | Printed in Germany | Siemens AG 2004

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The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. SIMATIC is a registered trademark of Siemens. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners.

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