Posts Tagged ‘ISA 88’

Batch Control – Communicate and Control

Wednesday, June 26th, 2013

Moving on from the last Batch Control blog entry, we now put this powerful control into commission. Previously we stated that Batch Control separates out the equipment control and the process control. This is a powerful structure, continuously evolving, and the ultimate in flexibility.

But this power is only released through communication.

Hardware integration through native drivers

Competitor products achieve this level of control only using their own hardware and software; Batch Control in zenon connects different systems, basically any PLC or control device can be lifted into a batch control environment through our connectivity. Once you have this effective communication, in such a flexible and powerful structure, evolution can really take hold. Remove manual processes, integrate isolated equipment, remove paper-based operating procedures and paper-based reporting. All can be commanded, controlled, monitored, and reported through this integrated automation environment. From start to finish, production orders are managed, produced and reported on in one automation environment, which has been achieved on your existing processes and current control equipment.

Vertical integration

Effective communication doesn’t stop at the process equipment – connectivity into business and manufacturing execution systems is of extreme importance. Removing manual steps from a production process removes the risk of error. Batch Control recipes can be created and controlled by functions which can be called up by other higher level systems. This integrates the physical batch production into the supply chain commanded by the business ERP or MES systems.


As multiple batch recipes can be executed concurrently, this connectivity to different machines, and different generations of machines, can bring any facility to the latest level of production control architecture and control.

All processes are different; we understand this difference in both the communication and its control.


zenon Batch Control – let’s go!

Monday, May 6th, 2013

Batch_Control_ScreenWelcome to the first blog entry on zenon’s ‘Batch Control’ module. Let us get the feeling of the next generation of automation, and see how batch control fits in zenon, and where zenon fits in batch control.

Flexible process control

One principal entity of the ISA 88 compliant batch control is that the process engineering and the equipment automation is kept separate. Having equipment control blocks (called phases) which can be flexibly placed, moved and modified in the process flow; opens up the equipment to a multitude of process combinations and thereby enables a wide selection of product possibilities.

The equipment control links the hardware together and controls this collection of hardware to obtain a certain state. For example, in a reactor there are temperature, pressure, and agitation control loops. The PLC knows which hardware is used and how to control the equipment to obtain a certain temperature, pressure or agitation speed.

The Batch Control module then uses ‘Recipes’ to describe the production control, and choose where in relation with other equipment in the process, these control loops are used. Each phase includes parameters which defines how the equipment will control this loop, and when the phase has completed with the ‘Phase done condition’

The Batch Control module is fully integrated into the zenon Supervisor SCADA software; here the full complement of functionality, flexibility and possibilities are available. More importantly it makes use of the extensive communication possibilities, where any equipment hardware can be connected and tightly controlled – whether standalone or distributed solutions are needed, from ERP to sensor.

Conclusion –
Continuous improvement in compliance with ISA 88

The Batch Control module and zenon’s mature functionality bring process automation to life, adding the dimension of flexibility and continuous improvement to distributed or standalone solutions.

My next entry will be about communication and connectivity in zenon’s Batch Control module.