Batch and Unit Management

The Batch Manager directs and supervises the processing of each batch. The Batch Manager interprets a recipe and enables the control system. Based on the recipe procedure, the Batch Manager signals blocks of control software, referred to as phases, to run. Automatic and Semi-Automatic phases are programmed logic blocks that exist in the control system. They are responsible for controlling functions associated with a unit or a connection. Before enabling each phase, the Batch Manager verifies that the phase is ready to be processed. If so, phase parameter values are downloaded to the phase, and the phase is started.

The Batch Manager also interacts with the batch application. AVEVA Batch Management provides operators with information about all batches running in the system. Operators can put a batch or phase on Hold, restart and abort batches or phases, and change the batch processing mode. The Batch Manager also has a Jump mode that allows you to change the processing point of an active batch that is on hold. Operators can use this feature to either jump ahead during recipe processing or repeat phases that have already run. In addition, operators can change phase parameter values, acknowledge the processing of phases, review phase interlock status, and enter comments. All of these can be done while a batch is running.

The Batch Manager coordinates the usage of process units for each batch. Each batch is a separate entity and contends along with other batches to own the process units that it needs. The Batch Manager assigns (allocates) ownership of units to batches as units become available and releases units when they are no longer required by the batch.

Note: The unit and equipment will not be considered available for allocation if its unit status has bad quality.

You must design flexible batch control systems with the supervisory workstation as an active participant in the processing of a batch. Unit management is very sophisticated in a flexible batch system. Most control systems do not have the ability to program a unit manager capable of interpreting and running complex recipe procedures.

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

After a batch is done, the operator has the option of saving the as-built recipe to the recipe database. All final formula targets, and optionally all the specific equipment used for the recipe, can be saved. These capabilities allow the recipe, which may have produced a high quality batch, to be re-run at a later date.