Topic 4.2.1: Process Model Configuration

  • The Batch Process
  • Prior to configuring the batch control system, the engineer must have a good understanding of the following process aspects:
    • Process equipment capabilities.
    • Production requirements.
    • The plant's standard operating procedures.
  • Steps to a Batch Control System Configuration
    • There are several recommended steps that should be followed that use this knowledge to effectively configure and utilize the batch control system.
    • Steps 1 through 8 develop a "high level" model and to create and run test recipes.
    • Steps 9 through 11 complete the design and development of a flexible batch process control system.
      • Step - 1 - Define the "High Level" Process Model.
      • Step - 2 - Define Materials.
      • Step - 3 - Create Test Recipes.
      • Step - 4 - Modify the "High Level" Process Model.
      • Step - 5 - Repeat Steps 3 and 4 as necessary.
      • Step - 6 - Define Phase Parameters in Process Model.
      • Step - 7 - Develop Production Recipes.
      • Step - 8 - Run the Recipe(s) under Simulation.
      • Step - 9 - Define and assign tags in the Process Model.
      • Step - 10 - Develop Phase Logic.
      • Step - 11 - Assign Control Links to each tag in Process Model.
  • Why Define a Process Model?
  • Modeling allows you to have Flexible Batches. By creating a model, you are defining all possible processing and transfer capabilities of the batch system. All process units, processing capabilities of the units, connections, and connection transfer capabilities are defined.
  • The "High Level" Process Model
    • The "High Level" process model components include:
      • Units
      • Connections
      • Segments
      • Equipment Statuses
      • Process Classes
      • Transfer Classes
      • Process Phases and Parameters
      • Transfer Phases and Parameters
    • The "High Level" Model exclusions:
      • Tags
      • Tag Assignments
      • Control System Addresses
    • Why define a "High Level" Process Model?
      • Simulate the execution of recipes.
      • Prove your batch management concepts.
      • Experiment with different process and control system designs, identify and solve problems before the system is implemented.
      • Construct recipes and execute them against the process model, verifying process functionality and identifying limitations. The process model can be changed to incorporate the processing functions needed.
      • Provide a vehicle for establishing communications between engineering and production early in the design cycle.
      • Reduce control system design changes during start-up.
      • Provide a vendor compliance document for your automation suppliers.
Last modified: Friday, 22 May 2020, 2:09 PM