Topic 8.2.3: Batch Execution

  • Automatic Batch Mode
  • Start a Batch: When the Batch Start command button is selected, a full batch initialization is executed. If there have been any changes to the recipe or the train, the batch may be invalid and an error box will be displayed.
  • Hold a Batch: When the Batch Hold command button is selected, the Batch Manager will put the batch in Hold.
    • The actions taken in response to a Batch Hold depend on the way in which Batch Manager was started.
    • If started by default (that is without the Phase/Batch Status application parameter in the Environment Editor), when the Hold is initiated, the Unit Hold tag for each unit allocated by the batch will be set.
    • It is the responsibility of the control system logic to alter the status of the phases associated with the unit(s). Typically, the phases are put in Held status. However, the results of a batch hold can be unique for each phase.
  • Restart a Batch: When the Batch Restart command button is selected, the Batch Manager will restart the batch. The actions taken in response to a Batch Restart depend on the way in which Batch Manager was started.
    • If started by default (that is without the Phase/Batch Status application parameter in the Environment Editor), when the Restart is initiated, the Unit Restart tag for each unit allocated by the batch will be set. It is the responsibility of the control system logic to alter the status of the phases associated with the unit(s).
    • Typically, the phases are returned to the Run status. However, the results of a batch hold can be unique for each phase.
  • Abort a Batch: When the Batch Abort command button is selected, the Batch Manager will abort the batch. The actions taken in response to a Batch Abort depend on the way in which Batch Manager was started.
    • If started by default (that is without the Phase/Batch Status application parameter in the Environment Editor), the Unit Abort tag for each unit allocated by the batch will be set.
    • It is the responsibility of the control system logic to alter the status of the phases associated with the unit(s).
  • Semi-Automatic Batch Mode
  • Manual Batch Mode: When the Batch Manager is executing in manual mode, any phase in the recipe for any unit allocated to the batch can be executed.
    • When a batch is started in Manual Mode, no units will be allocated to the batch. The operator must manually allocate the desired units using the Equipment Allocation dialog box.
    • Any manually allocated units must be released manually or they will remain allocated to the batch until the batch is complete.
  • Unit Selection Mode and Allocation: There are three approaches to allocating units for a batch. They are referred to as Automatic Allocation, Recipe Allocation, and Manual Allocation.
    • There are two Unit Selection modes. They are Automatic and Manual. Each allocation and selection mode combination is described below.
  • Automatic Unit Selection: The Unit Selection mode defines how a unit is selected when there is more than one unit from which to select.
    • When Automatic Unit Selection is employed, the Batch Manager will select the first unit encountered in the assigned train that satisfies the recipe equipment requirements and that has a Ready Status.
    • If all the possible units are not Ready, the Batch Manager will re-evaluate potential units as they become available and wait until the status of one of the units becomes Ready.
  • Manual Unit Selection: The Unit Selection mode defines how a unit is selected when there is more than one unit from which to select.
    • When Manual Unit Selection is employed, a list of available units and their status are presented to the operator. Unit statuses correspond to those defined in the process model.
    • The operator must select one unit. If the selected unit has a status of held, the Batch Manager will wait until the unit is Ready, then the unit will be allocated. If the unit is Ready, the unit is immediately allocated.
  • Automatic Allocation: When automatic allocation is defined with manual unit selection mode, the Batch Manager presents the list of possible units to the operator for selection.
    • The chosen unit will be allocated to the batch until the unit is used as the source in the execution of a transfer phase and the phase is completed or the batch ends.
  • Recipe Allocation: When an Allocate phase is encountered in the recipe, the list of available units is presented to the operator for selection.
    • The chosen unit is allocated to the batch until a recipe Release phase is encountered or the batch ends.
  • Manual Allocation: Manual allocation operates in the same manner as automatic unit selection. The Equipment Allocation display is used to manually allocate and release units in the train to the batch.
  • Transfer Phases with Material Input Parameters
  • Automatic Transfer Phases: When an automatic transfer phase with an input parameter is encountered in a recipe, Batch Manager performs a search of the Materials database in order to find the unit containing the material to be transferred.
    • The connection phase that will be executed has a source unit corresponding to the unit found in the materials database and the allocated unit as the destination.
  • Semi-automatic Transfer Phases: When a semi-automatic transfer phase is encountered, the Batch Manager will require an Acknowledge from the operator before the "automatic" part of the phase is executed.
    • However, the Batch Manager does not search the Materials database for the location of the material. A common semi-automatic transfer phase is a Drum Addition.
  • Manual Transfer Phases: When a manual transfer phase is encountered, the Batch Manager is responsible for the execution of the phase.
    • The phase does not execute in the control system, although the Batch Manager may use information, such as the Actual Value as measured by the control system in executing the phase.
  • Manual Addition using a connected Scale: Material is weighed by a scale attached to the control system. The operator is required to enter the material lot code for the material if configured in process model.
    • When the weight is within the material deviations, the operator acknowledges the completion of the phase. The Batch Manager logs the material id, target quantity, actual quantity, and lot code to history.
  • Manual Addition using an unconnected Scale: Material is weighed on a scale that is not attached to the control system. The Operator is required to enter the material lot code if configured in the process model, the actual weight, then Acknowledge the completion of the phase.
  • Acknowledge Addition of Material: In this approach, materials are pre-weighed prior to the final production.
    • As materials are added, the operator Acknowledges the addition of the material. The Batch Manager records the material usage by using the target quantity as the actual quantity.
  • Manual Addition - with Scale and without Scale: The addition may have two parts, For example, 60 pounds of salt must be added. Salt comes in 50 pound bags. A scale is attached to the control system.
    • A 50 pound bag is added to the batch. The operator enters 50 as the actual quantity and the material lot code then Acknowledges the completion of the phase.
  • Transfer Phases with Material Output Parameters: When the Batch Manager encounters a transfer phase that has an output type parameter, the appropriate destination unit will be allocated. The actual quantity of product transferred may or may not be measured automatically.
    • In some cases it is desirable for the operator to enter in the actual quantity. Either of these situations can be handled and is determined by how the phase is configured in the process model.
  • Process Phases
  • Automatic Phases: When an automatic process phase is encountered, the Batch Manager will first check if a suitable unit is allocated. If so, the Batch Manager will evaluate the status of the phase.
    • If the phase is Ready, the formula parameter values are downloaded to the control system and the phase is started. The phase status normally will go to Run.
  • Manual Phases: Manual Type Process Phases will require the operator to Acknowledge the completion of the phase. Manual Process Phases typically include instructions that the operator must perform. When the instructions have been performed, the operator Acknowledges the phase.
  • Batch Execution Mode Changes
  • Automatic to Semi-automatic: Operation will continue normally except that any new phases encountered will require the operator to Acknowledge the start of the phase.
  • Automatic to Manual: Any active phases will continue to run to completion. The Batch Manager will monitor these phases and will Reset the phases when they are Done. No new phases will be executed. The Batch Manager will maintain its position in the recipe procedure, and the operator may manually execute any of the phases associated with allocated units.
  • Semi-automatic to Manual Mode: Any active phases will continue to run to completion. The Batch Manager will monitor these phases and will Reset the phases when they are Done. No new phases will be executed. The Batch Manager will maintain its position in the recipe procedure, and the operator may manually execute any of the phases associated with allocated units.
  • Semi-automatic to Automatic: Any phases that are running will continue to run. Any phase waiting for an operator Acknowledgment or any new phase encountered will automatically start. This assumes that the phase is not configured for Acknowledge on Entry in the recipe procedure. If this is the case, the Acknowledge will still be required.
  • Manual to Automatic: Execution of the recipe will begin from the point where Manual Mode was started. Phases will start as configured in the recipe procedure. Any phases started in Manual Mode will complete and will be Reset by the Batch Manager. Any units that were manually allocated will stay allocated until a Release phase for the unit is encountered or the batch completes.
  • Manual to Semi-automatic: Execution of the recipe will begin from the point where Manual Mode was started. Phases will require an Acknowledge before they can be started. Any phases started in Manual Mode will complete and will be Reset by the Batch Manager. Any units that were manually allocated will stay allocated until a Release phase for the unit is encountered or the batch completes.
Last modified: Wednesday, 6 May 2020, 4:05 PM