Batch and Unit Management

The Batch Manager directs and supervises the processing of each batch. The Batch Manager interprets recipes and enables the control system. Based on the recipe procedure, blocks of control software, referred as phase blocks, are signalled to run by the Batch Manager. Phase block control logic, located in the control system, controls the process. Before enabling each phase block, the Batch Manager verifies that the phase block is ready to be processed. If so, phase parameter values are downloaded to the block, and the block starts.

The Batch Manager also interacts with batch display programs. The batch display programs provide operators with information about all batches that are initialized or running in the system. Through these displays, operators can put a batch or phase on hold, as well as restart and cancel batches or phases. Operators can change phase parameter values, acknowledge the processing of phases, review phase interlock statuses, and enter comments while the batch is running.

The Batch Manager coordinates how process units are used for each batch. The Batch Manager can run a large number of batches simultaneously. Each batch is a separate entity and contends along with other batches to possess the process units it needs. The Batch Manager allocates ownership of units to batches as units become available and releases units when the batch no longer requires the unit.

In flexible batch systems that use controllers, the supervisory workstation becomes an active participant in processing a batch. Unit management is very sophisticated in a flexible batch system. Most controllers do not have the ability to program a unit manager that is capable of interpreting and processing the recipe procedures that are constructed in the batch control system.

A master recipe uses classes of process units, not specific units. Thus, phases pertain to a class of units rather than a specific unit. When the Batch Manager runs a master recipe, each phase encountered is converted into a unit-specific phase. This process is called master recipe to partial control recipe conversion. The train assigned to produce the batch specifies all the units that can be used. The Batch Manager automatically converts the master recipe to a control recipe based on the units found in the train.