Batch Processing with Freelance 2000

Batch Basics
Three Levels doing Batch System Structure Phase Logic Interface Pricing

ABB Automation Inc.
Flbatche.ppt Page 1

ISA S 88.01/NAMUR
I need flexibility!

Good for Whom?

I dont like changes !

Process Engineer

Control Engineer

Responsible for recipes No equipment details necessary Protection of a companys intellectual property

Responsible for the equipment as a basis for the batch process Little recipe knowledge required Less changes

Clear Responsibilities, better Results!

ABB Automation Inc.
Flbatche.ppt Page 2

ISA S88.01 Batch Standard

Equipment Hierarchy
Area

Procedure Hierarchy
Procedure

Process Cell

Unit Procedure

Unit

Operation

Equipment Module

Phase

ABB Automation Inc.

Flbatche.ppt Page 3

Recipe Structures
Procedure Unit Procedure Operation with Phases

Start

Start

Start
Preparation Production Dosing Reaction DOS C Dump
ABB Automation Inc.
Flbatche.ppt Page 4

DOS A

DOS B

Analysis

Recipe Structures
DigiBatch Freelance Process Station

TRUE

TRUE

TRUE

START

PREMIX:1

DOSING:1 MIX:1 SUGAR:1

PREPARE

PREMIX:1.STATE = READY

DOSE:1.STATE = READY SUGAR:1.STATE = READY

READY

MAKE:1

DUMP:1 COFFEIN:1 MAKE:1.STATE = READY DUMP:1.STATE = READY KOFFEIN:1.STATUS = FERTIG SET < = ACTUAL INGRED:1 OFF OPEN VALVE START PUMP

INGRED:1.STATE = READY

OFF

Procedure PRODUCT

Unit Procedure Premix

Operation DOSING

Phase SUGAR

ABB Automation Inc.

Flbatche.ppt Page 5

Integration DigiBatch in Freelance

DOS A

Basis Function

DigiBatch Freelance PLIFunction Block

Running

DOS A R30

DOS A R31

Control Function

DOS A R30

Technical Function (phase)

Stopping Aborting Restarting

Holding

START OPEN VALVE PUMP ON SET <= ACTUAL OFF/ CLOSED ? OFF7 CLOSED

START OFF/ CLOSED ? OFF7 CLOSED

START OFF/ CLOSED ? OFF7 CLOSED

START OFF/ CLOSED ? OFF7 CLOSED

START OFF/ CLOSED ? OFF7 CLOSED

ABB Automation Inc.

Flbatche.ppt Page 6

Three Levels of Batch Control?

3. DigiBatch 2. SFC & DDE 3 Levels of Batch 1. Seq. Func. Chart Control
What is the solution for

my process?
Dont shoot a cannon to

kill a bird!
ABB Automation Inc.
Flbatche.ppt Page 7

Three Levels of Batch Control: SFC

3. DigiBatch 2. SFC & DDE 1. Sequ. Funct. Chart

If you have ...

Single Product /

Single Stream Process Cell

Fixed Procedures

then use ...

Sequential Function Chart

of Freelance 2000
ABB Automation Inc.
Flbatche.ppt Page 8

Three Levels of Batch Control: DDE

3. DigiBatch 2. SFC & DDE 1. SFC

If you have ...

Multi Product / Single

Stream Process Cell

Many Parameter sets
Fixed Procedures

then use ...

SFC with DDE

ABB Automation Inc.
Flbatche.ppt Page 9

& e.g. Excel

High Level Batch Control: DigiBatch

3. DigiBatch 2. SFC & DDE 1. SFC

If you have / need ...

Multi Product/ Multi-Stream

Process Cell, Multiple Parameter Sets and changing Procedures

Implementation of new recipes

by the Process Engineer

Batch Reports FDA-Qualification (Validation)

then use ...

ABB Automation Inc.
Flbatche.ppt Page 10

DigiBatch

Multi Product / Multi Stream Process Cell

Unit 1 Ingred ients

Unit 3

Product

Unit 2

Unit 4

ABB Automation Inc.

Flbatche.ppt Page 11

DigiBatch Software Structure

OFF-LINE ON-LINE
Batch View
Equipment Editor Area Model Batch Server Recipe Editor Recipes Reports Journals Data base Archiver

FREELANCE Process Stations

ABB Automation Inc.

Flbatche.ppt Page 12

Reports
Freelance DigiBatch

DigiBatch SQL Report Selection

ABB Automation Inc.

Flbatche.ppt Page 13

DigiBatch System Structure

Operation DigiVis Engineering DigiTool DigiBatch BatchView Batch Server Recipe Editor Equipment Editor DigiDDE

Process Stations

ABB Automation Inc.

Flbatche.ppt Page 14

Recommended Structure
Engineering DigiTool Recipe Editor Equipment Editor Operation DigiVis BatchView

BatchServer DigiDDE

Batch Journals

Process Stations

ABB Automation Inc.

Flbatche.ppt Page 15

One DigiBatch for several Systems

Operation 1 DigiVis BatchView DigiDDE 1 Operation 2 DigiVis BatchView DigiDDE 2
BatchServer

Engineering 1 & 2 DigiTool Recipe Editor Equipment Editor

Bridge (optional)

System 1

System 2

ABB Automation Inc.

Flbatche.ppt Page 16

PLI: Phase Logic Interface

DigiBatch

Coordination of

PLI

Information flow between PS and DigiBatch

Output: e.g. Set points for controllers in Freelance PS

Input: e.g. Process values for reports in DigiBatch

Start and Stop of

SFCs in the Process Station

ABB Automation Inc.

Flbatche.ppt Page 17

The Price of DigiBatch

Scalable Price Depends on the

amount of Signal Variables SV

16.100 DM for 250 SV 23.000 DM for 500 SV

(as for demo)

32.200 DM for 1000 SV

...
ABB Automation Inc.
Flbatche.ppt Page 18

for Details refer to the Price List

How many Signal-Variables do I need?

per Phase (control function)

10 SV

e.g. e.g.

Mix Reactor 1

per Parameter in one Control Function

1 SV

Parameter Value

per Process Variable in DigiBatch

e.g.

1 SV Report Variable, Transition Criteria

If there is not enough detailed project Information available you should offer 1000 SV
ABB Automation Inc.
Flbatche.ppt Page 19

DigiBatch Performance
1 Server, 10 BatchView, x

Systems
Open for higher level

Systems e.g.
Unlimited Number of ...

Recipes, Procedures, Phases, Parameters, Report Values

ABB Automation Inc.
Flbatche.ppt Page 20

Summary

DigiBatch
Most powerful solution for Batch Automation
A perfect fit to Freelance 2000 Clear Responsibilities, better Results

Freelance 2000, your Solution for Batch Automation!

ABB Automation Inc.
Flbatche.ppt Page 21