Sivakumar Sundararajan BATCH FUNDAMENTALS – 2

12-Jun-2019 Americas HUG

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.

 2

Batch Session 1 Recap

• What is Experion Batch

• Architecture
• Experion Batch Components
– UCM
– RCM
– Phase Block
– Data Block
• Activity
• Instance Based Recipe
– Implementation on Experion Batch

© 2019 by Honeywell International Inc. All rights reserved.

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Experion Batch for Class Based Recipes

• Instance Based Recipes

– Tied to specific equipment
– Implemented as a RCM
– Fixed relationship between RCM’s and their child SCM’s
• Why is a class-based recipe needed?
– More recipes needed as batch complexity increases
– Maintenance becomes harder

© 2019 by Honeywell International Inc. All rights reserved.

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Experion Batch for Class Based Recipes

• So, what is a class-based recipe?

– One recipe for one or more products
▪ Keep it as generic as possible

▪ Like a template

– Dissociated from equipment

▪ Equipment selected at runtime

– Instantiated when a batch is created for a specific product on a specific unit

▪ Master recipe is not executed – a control recipe is instantiated

▪ Control Recipe is tied to specific unit or equipment

▪ Created by the operator or external application at runtime

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Experion Batch for Class Based Recipes

• Applicable to all batch systems

• More commonly applied to systems with:
– Multiple products
– Multiple Units
– Or both
– Other complex issues
• Layering supported on CBR

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Layering in Class Based Recipes

Procedure
• CBR follows ISA-88 recommendations
– Layering of recipes as Procedure, Unit Procedure, Operation
and Phase is supported
– General CBR can be used for non S88 processes Unit Procedure

Operation

Phase

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 7

Class Based Recipe/Master Recipe Components

• In addition to the Instance Based Recipe components:

– UCM, RCM, SCM, CM, Phase Blocks, Data Blocks, Phase Block Type
• CBR includes:
– Map Blocks
– Unit Classes
– Unit Instances
– Master Recipes

© 2019 by Honeywell International Inc. All rights reserved.

 8

Sample Batch System

• Main Units
– Mixers
▪ M1, M2
– Fermentor
▪ F1, F2

• Products
– Milk Yogurt
▪ Flavored Yogurt
– Using fruit blend
– Using fruit puree
– Soya Milk Yogurt
▪ Flavored Yogurt
– Using fruit blend
– Using fruit puree

© 2019 by Honeywell International Inc. All rights reserved.

 9

Sample Batch System

• Yogurt Batch Process has multiple units and multiple products

– Frequent change in
▪ Formula parameters
– Raw materials and their quantities will vary depending upon product
» For Example: Plain yogurt does not require addition of fruit puree or fruit blend
but flavored yogurt will require addition of fruit puree or fruit blend
▪ Equipment selected for recipe execution
– Any combination of Mixers and Blenders can be selected
– Therefore Class Based Recipe is a natural approach for this process

© 2019 by Honeywell International Inc. All rights reserved.

 10

Class Based Recipe/Master Recipe Components

• Map Blocks
– Define the functions which are available
for use by a recipe In a unit class
• Block and parameter references can Functions performed in the Mixer
also be defined
Starter Addition
• In the sample, Map Block for Mixers Milk Addition
will include the following functions:
– Milk addition
Temp Control MIXER
– Starter addition
– Temperature control Homogenize

– Homogenize
– Transfer out
Transfer Out

© 2019 by Honeywell International Inc. All rights reserved.

 11

Class Based Recipe/Master Recipe Components

• Identical units in the process form a Unit Class

– In the example
▪ We have two identical mixers in the sample demo process

▪ We will create a single Unit Class for both these mixers, say Mixer

▪ Mixer M1 and M2 is called the Unit Instance of the Unit Class Mixer

Unit Class - Mixer

Unit Instance – M1 Unit Instance – M2

M1 M2

© 2019 by Honeywell International Inc. All rights reserved.

 12

Class Based Recipe/Master Recipe Components

• Master Recipe
– It is a container like SCM
and RCM
– It is equipment
independent at
configuration
– It is configured to be
associated with Unit Class
instead of a unit.

© 2019 by Honeywell International Inc. All rights reserved.

 13

Class Based Procedure Implementation

Create Control Modules Creating Sequences

Discrete and Continuous device and Control configuration
Create SCMs
Executes sequential control

Build Equipment Model

Create Phase Blocks Create MAP Blocks Create Unit Class Instantiate Unit Class
Define Formula & Report Define Functions Drag in Map Block(s) to create Unit
parameters Define Add any extra blocks for Complete function links to
Execute child recipes block/parameter unit functionality SCMs
references Complete the Block and
Parameter references

Build Master Recipes

Drag in Unit Class
Drag and connect Phase blocks, Create step/transition logic

© 2019 by Honeywell International Inc. All rights reserved.

 14

User Interface

• Unit Timeline Display

• Procedure Explorer
• Notification Center

© 2019 by Honeywell International Inc. All rights reserved.

 Don’t know when
tasks are coming up
Inefficient operators

Don’t know when

something is delayed
Production compromised

Troubleshooting is difficult

Loss of quality 1
Currently in batch operations
5
© 2019 by Honeywell International Inc. All rights reserved.
 Know immediately when
there is a delay
Know what’s coming up
and respond faster

Better asset utilization and batch

throughput
More efficient operators
1
Introducing time based visualization
6
© 2019 by Honeywell International Inc. All rights reserved.
 Know what’s coming up
and respond faster

Timely response delivers higher

quality

1
Integrated notification center
7
© 2019 by Honeywell International Inc. All rights reserved.
 18

Engineering rules for Timeline – S88 linkage

• Configure Experion Batch to follow the S88 standard and Timeline will work out of the box

Process
Cell

Unit

Equipment
Module

Control • Units get lanes

Module • Active Phases / Equipment Modules show in unit’s Now Card
• Recipe elements show in units where they run Phases / Equipment

© 2019 by Honeywell International Inc. All rights reserved.

 19
Engineering rules for Timeline - Assets

Asset item name and message count

Assets may be non-

assignable if desired

Batch ID and State of unit control

module (when acquired)

important

New in R511

New in R511

© 2019 by Honeywell International Inc. All rights reserved.

 20

Engineering rules for Timeline – details

Use unit classes • The unit must be acquired to see its batch
elements in lane
• For the Unit Timeline, if you have more
• Procedure Icon on recipe or phase reveals the
than one unit of a specific type you must bar on Timeline.
use unit classes and instances of them to
enable the use of Reference Batches – Default is only Operations have icon to avoid too
much clutter in lane.
across units of the same type.
– Active phases appear in Now Card and their bar is
Instance based recipes seen when expanding it (below)
• Supported on Timeline but Reference
Batches are likely to mismatch if they
were recorded on a different unit or RCM
to current batch
• NOTE: Reference Batch matching works
• Public Name is shown throughout Batch HMI so
solely on Recipe Step Block names and make it descriptive for operator
the top-level Procedure public name
• Recipe Step Block description has 2 lines in
Now Card so make it meaningful

© 2019 by Honeywell International Inc. All rights reserved.

 21

Batch Messaging settings

• Select Notif Option ‘Message’ on all recipes and phases

• Live value references in instruction text make it easier to communicate
with operator. No CB validation but Instruction is LWA so easy to test.
• Customize PV Format :D & width :W of live value to make it more
readable, especially in narrow Notification Pane.

© 2019 by Honeywell International Inc. All rights reserved.

 22

Server/Station configuration

• Server wide settings > Summary Displays • Flex/Console/Operator

– Delay tolerance – discuss a longer min delay
time & larger tolerance to start with so operators
do not see orange flashes
– Delay indicator – enable it to see on all stations
• Alarms > Alarm Processing
– Do not confirm message on second
acknowledgement – recommend enable this for
safety (default)
– Perform auto-acknowledge when message is
confirmed – allows operator to bypass ACK
before confirming. Recommend enable after
discussing with customer.
– Unit Timeline minutes of past and future –
discuss with customer so operator sees useful
amount of time to plan activities in their shift.
Suggest 1-4 hours of future and 1-2 hour of past,
depending if using reference batch predictions.
• DSA & Reference Batches
– Nominate 1 cluster as repository of reference
batches and save all reference batches to that
primary server.
– File Replication > enable ‘All distributed
servers’ for ReferenceBatces file share, only
the one nominated server

© 2019 by Honeywell International Inc. All rights reserved.

 23

Server/Station configuration

• Navigation between Batch HMI elements • Timeline -> Unit Graphic

out of the box
– Configure Associated Display of unit instance in
– Timeline -> PE & Messages (filtered to asset) CB
– PE -> Messages (filtered to step) • Timeline -> Unit Trend
– Messages -> PE – Configure a system trend with
<unit>.NUMOWNERS as a pen and context
– Batch Summary & Activity Tables menu navigation from Timeline unit card will then
-> PE & Messages (filtered to Batch ID) work
– Alarm Summary -> PE

© 2019 by Honeywell International Inc. All rights reserved.

 24

Notification Pane & Station layouts

• Show messages in notification Pane • Single Window Station

enabled per Station from Appearance tab. All
– Narrow popup on left of screen
message icons then redirect there instead of
Message Summary. – Can be pinned by operator, but probably respond
to flashing message light and close it
– Size and position can be customized via registry
to best fit around graphics.

[HKEY_LOCAL_MACHINE\SOFTWARE\WOW6432Node\Honeywell
\Station\PopupWindow]
"NavPaneLeft"=dword:0000000a
"NavPaneTop"=dword:0000001e
"NavPaneWidth"=dword:0000012c
Decide screen res "NavPaneHeight"=dword:00000320
and Station layouts
before display
engineering
© 2019 by Honeywell International Inc. All rights reserved.
 25

Notification Pane & Station layouts

• Multi-window Station with SafeView
• Orion Touch Panel (single screen)
- Batch HMI components have categories to
direct them to an appropriate placeholder: – ‘Enable Touch’ in Station connection (free)
• Orion Console
• HW_System_Procedure_Explorer – the small Procedure
Explorer for popups and auxiliary display placeholders
• HW_System_Procedure_Explorer_Display – the standard
display sized Procedure Explorer that is invoked when users
click the ‘full screen’ icon from the small Procedure Explorer
• HW_System_UnitTimeline – the Unit Timeline
• HW_SYSTEM_NOTIFPANE_MESSAGES – The Notification
Pane. Note: does not need to be defined when an Orion
Touch Panel is used because it automatically loads in the
Navigation Pane space on the left of the panel.
• HW_System_Display – system displays such as the Batch
Summary, Message Summary and Alarm Summary

Few Suggested allocation to standard

SafeView workspaces as follows

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Dual Screen Layout

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 27

Quad Screen Layout

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 28

Demonstration

• Unit Timeline Display

• Procedure Explorer
• Notification Center

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Batch API

• Provides programmatic access to create, remove, command, monitor and update top level
activities
• Allows integration with MES/ERP system
• External Batch Scheduling

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