Practical batch process management

Mike Barker B.Sc (Elec.Eng), Jawahar Rawtani M.Sc(Tech) MBA0750662778, 9780750662772

Historically batch control systems were designed individually to match a specific arrangement of plant equipment. They lacked the ability to convert to new products without having to modify the control systems, and did not lend themselves to integration with manufacturing management systems. Practical Batch Management Systems explains how to utilize the building blocks and arrange the structures of modern batch management systems to produce flexible schemes suitable for automated batch management, with the capability to be reconfigured to use the same plant equipment in different combinations. It introduces current best practice in the automation of batch processes, including the drive for integration with MES (Manufacturing Execution System) and ERP (Enterprise Resource Planning) products from major IT vendors. References and examples are drawn from DCS / PLC batch control products currently on the market. – Implement modern batch management systems that are flexible and easily reconfigured – Integrate batch management with other manufacturing systems including MES and ERP – Increase productivity through industry best practice

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Table of contents :
Front cover……Page 1
Contents……Page 6
1.1 Introduction……Page 11
1.2 Identification of batch processes……Page 12
1.3 Background of the need for integrated batch systems……Page 18
1.4 Overview of batch systems engineering……Page 20
1.5 Introduction to standards……Page 24
2.1 Introduction……Page 27
2.2 Define the physical model……Page 31
2.3 Define tags……Page 34
3.1 Introduction……Page 36
3.2 Process model……Page 37
3.3 Relationship between process model and physical model……Page 38
4.2 Procedural model……Page 41
4.3 Concept of equipment entities……Page 44
5.1 Introduction……Page 47
5.2 S88 recipe model……Page 49
5.3 Types of recipes……Page 50
5.4 Building recipe procedures……Page 55
6.2 Batch numbering, tracking and reporting……Page 58
6.3 Batch planning and scheduling……Page 60
7.2 Techniques for batch control elements……Page 72
7.3 Implementation……Page 73
7.4 Interaction with continuous process sections……Page 78
8.2 Programming PLCs/DCS……Page 80
8.3 Practical methods of functional specification……Page 83
8.4 Defining equipment procedures……Page 84
8.5 Phase logic programming……Page 85
8.6 Phase logic interface……Page 88
9.2 Display screens for batch management……Page 96
9.3 Guidelines for building user interfaces……Page 97
9.4 Consideration of human and ergonomic factors……Page 99
10.2 Control activity model……Page 103
10.3 Practical problems in batch management……Page 106
10.4 Implementation of safety issues in batch management……Page 108
11.2 Overview of DCS/PLC architecture……Page 112
11.3 Integration of batch control systems to production management and ERP systems……Page 115
11.4 Standards for enterprise/control systems integration……Page 120
11.5 Sending process quality and production reports back to ERP……Page 124
12.2 What to look for in batch software packages……Page 126
12.3 Batch control software products……Page 132
Exercises……Page 142
A. 2 Concepts of modular manufacturing……Page 161
A. 3 Modular approach in batch process manufacturing……Page 162
A. 4 Modularity using ISA S88 standard……Page 163
B.2 Introduction of manufacturing facility……Page 166
B.3 The manufacturing process……Page 167
B.5 The batch system requirements……Page 169
B.6 The system architecture……Page 173
B.7 The plant startup and validation……Page 174
B.8 Conclusion……Page 175
Solutions……Page 176
Index……Page 185