2. PBWW 311 Wonderware InBatch Software
Session ID #: PBWW 311
Dirk Kozian – Invensys
Ryan Plester - MatrikonOPC
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© Invensys 00/00/00
Invensys proprietary & confidential

3. Batch Processes Spectrum
31-Mar-17
Batch Processes Spectrum
(c) 2002 Invensys Systems, Inc.

4. Invensys Enterprise Control Offerings
Corporate Systems
Platform IT
Corporate
Industry Solutions
Services:
Consulting, Project
Execution,
Learning,
Operational Improvement, Maintenance & Support
Partner Ecosystem
Software Applications
Invensys and Third Party
Collaboration Platform
Integration and
Manufacturing / Production Operations
Automation
Invensys and Third Party
As you heard in the opening sessions, addressing the need to move to Enterprise Control is critical for all organizations today as they look to optimize their business performance.
By way of a quick reminder, at the simplest level, Enterprise Control is achieved by integrating the two major Manufacturing/Production Operations capabilities with your corporate systems and embracing the IT platform that is already in place.
Invensys enables the creation of your Enterprise Control system by providing:
a single integration platform that brings together the two operations components and integrates tightly with your existing IT infrastructure. This platform allows you to align Invensys and non-Invensys offerings
a wide range of leading hardware and software and solution offerings at the automation and production software levels, extended by offerings from our extensive partner ecosystem
proven expertise in designing, implementing and supporting complete Enterprise Control solutions, beginning with consulting services to help you identify the opportunities within your organization and deliver an execution plan
Enterprise Control System

5. Where The Offerings We Will Discuss Fit Within The InFusion Enterprise Control System
Integration & Collaboration
Platform
Enterprise
Integration
Workflow
Open Device
Web Portal
Application
Toolkit
Historian
Third-Party Offerings
Software Applications
Execution
Manufacturing Execution
Systems
Batch
Enterprise Asset Management
Mobile Workforce Management
Performance
Enterprise Manufacturing Intelligence
Performance Measurement
and Reporting
Visualization
Quality
Asset Performance
Optimization
Operator Training
Design
Advanced Process Control
Simulation / Optimization
Control
DCS
PAC
SCADA
HMI
Safety
Safety Instrumented Systems
General Purpose Safety
Turbomachinery Control
Measurement &
Instrumentation
Controllers
Recorders
Automation
Software Applications
In it’s fullest form, an Enterprise Control System brings together a large number of functional capabilities. For the purposes of this presentation, we’ll be focusing on the component that you see highlighted, but it is important to note that all these offerings, both Invensys and 3rd party, can be an element of an Enterprise Control System.

6. Batch Execution Management
Batch Management
Batch Management
Recipe Management
Batch Execution Management
Batch Management Systems are traditionally composed of two subparts:
One assuring the creation and configuration of the recipes, and;
The other assuring the execution of the recipes, i.e., driving the equipment to make a product according to a production order.

7. What is Wonderware InBatch software?
InBatch is Flexible Batch Management Software Designed to Model and Automate Batch Processes
Model-based - Easy recipe creation -Consistent with ISA88
Beyond ISA88 - Connection & Transfer Management
Comprehensive production history - Electronic Batch Records and Material genealogy, Web based reports
“Out-of-the-box” batch simulation
Control System independent via state interface and DA Servers
Scalable System Architecture – single node to large systems, integration to ArchestrA System Platform
Security options and FDA CFR21 Part11 compliance
Built-in Redundancy concepts

8. Wonderware InBatch, a Short History of Batch Management in Invensys
1994 FoxBatch Batch Manager (Soft Systems/Foxboro)
1996 InBatch (Soft Systems/Wonderware – WINDOWS port)
1999 I/A Batch/InBatch (Foxboro/Wonderware) Unix/Windows
2003 I/A Batch 8.1 – InBatch 8.1 (Foxboro - Wonderware)
2005 I/A Batch 8.1 SP1 – InBatch 8.1 SP1 (Foxboro - Wonderware)
2009 Code alignment + New Features + ArchestrA integration = “Wonderware InBatch Software 9.0”
2010 InBatch 9.0 SP1 & InBatch 9.5 SP2 – necessary steps towards 9.5
2011 Wonderware InBatch Software 9.5
2012 InBatch 9.5 SP1 …. InBatch 2012 R2 (v10.0)

9. Wonderware InBatch Software
… is specifically designed to address the needs of the process industry, in other words, it is made to
“manage the production wherever free fluent materials are processed”
InBatch allows managing complex, networked process equipment and is usually seen as Process MES
InBatch provides S88 conformity and allows going beyond S88 with its Transfer Classes and Material Management capabilities
InBatch is used more than 1000 times around the globe, often for more than 10 years

10. High Fidelity Batch Processes
Common Characteristics of demanding Batch Processes
Ingredients
Recipes often times complex
Conditional / dynamic rules assessed during batch execution
Equipment
Equipment can be used to make many product families
No pre-determined use of equipment – varying material path through shared equipment
Procedure
Sequence of operations can vary widely for different types of products
Can incl. complex conditional statements

11. Modeling through ISA-88 Forces a structured approach
Decouples production procedures from PLC Logic
Allows the user to model the physical equipment within an ISA-88 Process Cell
Modeling includes not only equipment but also possible flow paths through the equipment
Leaves Batch Control in controller but introduces the concept of Batch Management as a system

12. ISA-88 Model Units: BS1,BS2,R1,R2,HT1,HT2 Connections: Blk1_Rx1
Segments: Blk1_Out
Blk2_Out
Rx1_In
Rx2_In
Common
Bulk Storage 1
Bulk Storage 2
Blk1_Out
Common
Blk2_Out
Rx1_In
Rx2_In
Reactor #1
Reactor #2
In addition to defining classes and connections, InBatch Premier allows you to go one level lower and define segments. Segments are the physical pieces of pipe, pumps, valves etc. that make up a connection. In our example, with our bulk tanks going to our reactors, we have four connections: Bulk 1 to Reactor 1, Bulk 1 to Reactor 2, Bulk 2 to Reactor 1 and Bulk 2 to Reactor 2. From these 4 connections, we derive five segments as shown in the example. From Bulk 1 to Reactor 1, we have 2 segments: segment 1 and segment 2. These segments serve two major purposes. The first purpose is to provide segment status to the batch engine, which the batch engine can use in its decision making process. The second purpose is for process interlocking. When a transfer is executed from Bulk 1 to Reactor 2, segment 1, 4 and 5 are allocated to the batch. Any transfer that uses any of these segment will automatically be interlocked out. Segments eliminate large amounts of interlocking logic which is typically done in the control system.
With regard to status information, the user can configure the status of the segments. For example, if product flows from Bulk Tank 1 to Reactor 1, the status of segments 1 and 2 would be in use and after the product is run, the status could be dirty. At that point, the batch engine would allow product to run from Bulk Tank 2 to Reactor 2, as the status of segment 3 and 4 would be clean or sterile. The batch engine would not allow product to run from Bulk 2 to Reactor 1 as the status of segment 2 would be dirty. This would provide the basis for automation of Clean In Place (CIP). A CIP unit could be included in the model and a CIP recipe would be scheduled and run to clean segment 1, segment 2 and Reactor 1. Once they are cleaned, the status of those segments and the unit would revert to clean. At that point, product could be moved from Bulk Tank #2 to Reactor #1 through segments 2, 3 and 5.
Changing equipment status is the responsibility of your application. Equipment status can be changed from an InTouch display in a recipe using a phase or in phase logic.
Hold
Tank 1
Hold
Tank 2 19 19 19 19 19

13. Define Phases And Their Parameters
Process Class: Reactors
Phases: Heat
Cool
Soak
Agitate
Manual Add
Phase Parameters:
Heat: Temperature
Cool: Temperature
Soak: Temp & Time
Agitate: Speed & Time
Manual Add: Quantity
Bulk Storage 1
Bulk Storage 2
Reactor #1
Reactor #2
In our example, we define the process class called reactors, the phases in that class and the parameters for each phase. Since this is done at the class level, a level of abstraction is created that will allow for the creation of equipment and path independent recipes. The chemist building the recipe does not know about the specifics of Reactor #2 in our example manufacturing facility. He just knows that he needs a reactor that can heat, cool, soak, agitate and that material can be added manually. Each phase can then have parameters such as temperature, speed, time and quantity.
The granularity of the phases defined is up to you and your manufacturing specifications. You can have a phase that opens a valve or turns on a motor or a phase that starts the plant. The number of parameters is also unlimited. Typically, phases that define a function like heat, cool, mix, agitate, and add are commonly used.
Hold
Tank 1
Hold
Tank 2 18 18 18 18 18

14. Unified Phase Logic Phase Logic Block Phase Logic
Required for each process and connection phase.
Control Parameters
Status Parameters
Interlocks
Formula Parameters
Can reside anywhere, but most commonly found in DCS and PLCs.
Modular, easy to maintain and re-use.
Phase Logic
Start
Restart
Abort
Reset
Ready
Run
Held
Done
Aborted
Interlocked
Control Inputs
Formula Parameters
Phase Status
Phase Control
Interlocks
Control Outputs
Hold
The phases that we define in our model and our example represent objects that reside in the controller or PLC. The InBatch Premier batch engine enables these phase objects at runtime. The interface between the InBatch Premier batch engine and the phases which run in the controller, is shown on this slide. On the left are the phase control bits. These discrete bits are used to control the phase. On the right is the phase status, which is used by the Batch Manager to evaluate the status of a phase. The Batch Manager is responsible for executing recipe procedures. Upon encountering a phase, such as a Heat phase, the Batch Manager checks the status of the phase to see that it is Ready. If so, the formula parameter target values (e.g., Temperature) is downloaded to the phase. Then, the Start is enabled. The phase goes to Run and the steam valves, etc. are opened so that heating takes place. The heat may take a minute, an hour or a day. It doesn't matter to the Batch Manager. When the target temperature is achieved, the phase goes to Done. The Batch Manager upon seeing the Done, captures the data, stores it to history and then Resets the phase to return to Ready.
There will be a phase in the controller for each connection and each process phase. InBatch Premier is not concerned with where a phase executes as long as this handshake interface is followed. You could have phases in a Siemens PLC, an Allen-Bradley PLC, Honeywell controller and in InTouch scripts. They can reside anywhere as long as the interface is followed. So with this structure, InBatch Premier is truly control system independent. The phases that we showed in our example have all been phases that reside in the controller. They are automatic phases with the exception of manual type phases like the manual add or instruction phase. These are manual phases that are handled by the Batch Manager. No phase logic is required.
The implementation benefits are that phases are very modular and easy to maintain and, if properly designed, can be reused. 20 20 20 20 20

15. InBatch - System Platform Integration
Extremely flexible and powerful batch management capabilities
InBatch Server
Phase Logic
Start
Restart
Abort
Reset
Ready
Run
Held
Done
Aborted
Interlocked
Phase Status
Phase Control
Hold
Phase Logic
Start
Restart
Abort
Reset
Ready
Run
Held
Done
Aborted
Interlocked
Phase Status
Phase Control
Hold
PHASE 1
PHASE 2
PHASE 3
Phases modeled within Control System
MX communication
PHASE 4
PHASE 5
PHASE 6
Phases modeled in System Platform
Device Integration
Device
System Platform
Extremely flexible and powerful platform and plant model

16. Master Recipe Content Header Equipment Recipe Formula Procedure
Recipe ID: F Recipe Name: Vanilla Yogurt Version #: Version Date: /20/03 Author: Claire Grube
Min. Batch Size: Max. Batch Size: Def. Batch Size:
Equipment
Class Attribute
Blenders Capacity: 500 Reactors Lining: 1 Bulk Tanks Finish Tanks Hold Tanks Pack Lines
Recipe
Formula
Material Inputs: Milk Vanilla
Material Outputs: Vanilla Yogurt
Process Variables: Mix Time
Temperature
Procedure
Add
Once we have defined our process model and the materials that we require in our materials database, we are ready to build recipes. This slide defines the four components that make up a recipe. The header is simply a title block. The equipment requirements define the equipment required to make the particular recipe. The formula defines the ingredients needed to make the recipe. The procedure defines the logic or sequence for making the recipe.
Building the recipe becomes as simple as pointing and clicking on icons. Class-based equipment is pulled from our process model. If we were to build a recipe using our example plant, we would require a bulk tank, a reactor and a packaging line. Once again, the specific equipment won’t be determined until runtime. Our ingredients for this recipe are then pulled from our materials database simply by pointing and clicking on the needed ingredients from a list. Finally, our procedure is generated graphically by selecting from the equipment we defined, allowing us to select phases and parameters, all of which were predefined in the process model.
Heat
Mix
Cool 21 21 21 21 21

17. Master Recipe in InBatch’s Recipe Editor
31-Mar-17
Master Recipe in InBatch’s Recipe Editor
Recipe Procedures are developed using Graphical Sequential Function Charts. Procedures are developed by pointing and clicking on the tool bar menu items. The far left side of the editor represents Unit Procedures. The center section of the editor represents Operations. The right side of the editor represents the Phases that are associated with a selected Operation which relates to a selected Unit Procedure. Unit Procedure, Operation and phase properties are accessed by double-clicking the appropriate Unit Procedure, Operation or Phase object.
The toolbar icons in the contain the available objects: Unit Procedures, Operations, Phases, Transition logic, Branches, and Loop backs. These icons allow the user to build logic into the recipe. The Transition allows the user to build Boolean expressions into the procedure. The Branch allows the user to run multiple operations or phases in parallel. The Loopback allows the user to loop back into the procedure based on the result of a Boolean expression.
Each of these objects can be freely moved throughout the editor by dragging-and-dropping the appropriate object. In addition, there is both a unit procedure and an operation library that allows the user to store unit procedures and operations in a recipe independent repository for future use in the current or other recipes.
(c) 2002 Invensys Systems, Inc.

18. System Architecture Standalone System InBatch Server System Platform
InTouch View
InBatch Client
I/O Server FS
Control System
Let’s talk about the hardware architecture for a moment. The InBatch Premier system is very scaleable. The smallest system would include a batch server, typically InTouch, a batch client, and a SuiteLink I/O Server for communication to a PLC.
Redundant servers are also available. This standalone system should only be implemented on small pilot projects or non production development systems. This can only be implemented with Microsoft Windows 2000 Server or 2003 Server.
(As an FYI in case you are asked, the InBatch Information Server for batch history using Microsoft SQL Server is not supported on XP) 42 42 42 42 42
(c) 2002 Invensys Systems, Inc.

19. InBatch Redundant Server
31-Mar-17
System Architecture
Multi-Node Client/Server
InBatch
Historian
&
WIS
InBatch Redundant Server
InBatch
Server S FS
SCADA
Nodes
InBatch
Development Clients
Client Platforms
Most common is a server (with optional redundant server) and multiple Clients. We actually have customers with much larger systems.
Control System 44 44 44 44 44
(c) 2002 Invensys Systems, Inc.

20. InBatch Redundant Server
System Architecture
31-Mar-17
Multi-Node Client/Server
InBatch
Historian
InBatch Redundant Server
InBatch
Server
WIS S FS
SCADA
Nodes
InBatch
Development Clients
Client Platforms
Most common is a server (with optional redundant server) and multiple Clients. We actually have customers with much larger systems.
Control System 44 44 44 44 44
(c) 2002 Invensys Systems, Inc.

21. InBatch Value - Proposition & Benefits
InBatch provides unmatched capabilities:
Batch execution management for multiple batches at the same time
Equipment allocation and arbitration, including Connections
Comprehensive Electronic Batch Record (EBR) and reporting capabilities out of the box
21 CFR Part 11 compliance
InBatch provides increased production flexibility and tracking
Recipe procedure changes
Material formulation changes
Complete material genealogy - US and EU standards, IFS, Bio-terrorism
InBatch & ArchestrA System Platform – a unique solution

22. How to Expand the Use of System Platform Combined with InBatch?
Existing Batch System
Desire for a modern Batch Management System
Existing solution uses control code that cannot be touched and that does not reflect ISA 88
SOLUTION: Combine InBatch 9.5 & System Platform to create abstraction layer
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23. Creating an Abstraction Layer…
31-Mar-17
Creating an Abstraction Layer…
Use InBatch Model Editor to create the required Units…
(c) 2002 Invensys Systems, Inc.

24. Creating an Abstraction Layer…
31-Mar-17
Creating an Abstraction Layer…
Create Classes for Equipment with similar functionality and create their phases including the needed Control and Status Tags
(c) 2002 Invensys Systems, Inc.

25. Creating an abstraction layer…
31-Mar-17
Creating an abstraction layer…
Add IBMX to the list of runtime services in InBatch.
Remember that a platform needs to be deployed for the service to start
(c) 2002 Invensys Systems, Inc.

26. Creating an abstraction layer…
31-Mar-17
Creating an abstraction layer…
Use the IDE to create object templates for your Units and Phases –
This is “where the rubber hits the road” as it is your duty to know the existing PLC code and how to interact with the existing system
(c) 2002 Invensys Systems, Inc.

27. The Other Problem Legacy APACS DCS still meets current needs
Existing InBatch/InTouch versions no longer available / supported
Operating System and Hardware no longer available / supported
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28. Original Solution Original system used:
MOORE APACS DCS (today Siemens-Moore)
Siemens APACS driver
Used InBatch v.7.0 and older
Used InTouch v.7.1 and older
Windows for Workgroups 3.11 or Windows NT 4.0
Siemens APACS Driver

29. Original Solution Challenge #1
Legacy APACS DCS at the end-of-life
Siemens migration path offered
Legacy DCS still meets user requirements
Siemens APACS Driver

30. Original Solution Challenge #2
Latest InTouch runs on modern Windows OS
Proprietary APACS driver only supports obsolete Windows OS’s
Users can not upgrade to latest version of InTouch
Siemens APACS Driver

31. Solution: Use MatrikonOPC Server for APACS Direct
Continue using APACS DCS
Renew Hardware
Use latest Windows OS
Upgrade InBatch to latest version
Upgrade InTouch to latest version
No need for proprietary API driver!

32. MatrikonOPC Server for APACS Direct
Connects to a NIM, IEM or RNI
No Siemens software required
Support for Windows 2008/7
OPC and SuiteLink support
Simple tag syntax
Automatic configuration
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33. MatrikonOPC Server for APACS Direct
Throttling options at the APACS resource level
Advanced error recovery based on OPC Quality for OPC Items
Fault Prediction
Network and NIMs performance monitoring
Get timestamps direct from the device or from local PC - your choice
load-balancing and redundancy
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34. InBatch What’s New?
The ability to use a single Batch History Server as the central historian data repository for multiple InBatch Servers.
InBatch
Server “Alpha”
InBatch
Server “Charlie” S
InBatch
Historian
WIS
InBatch
Server “Piper”

35. InBatch What’s New?

36. InBatch What’s New?

37. InBatch What’s New?

38. InBatch What’s New?
The ability to use non US Date/Time Format for InBatch Reporting (!)

39. InBatch 9.5 – What’s New?
Recipe Export and Recipe Import using XML documents based upon BML (Batch Markup Language) as defined by the World Batch Forum

40. InBatch 9.5 – What’s New?

41. InBatch 9.5 – What’s New?
Recipe Export and Recipe Import are available through the Recipe COM Automation Server interface and allow creating branches – a major improvement for the ability to create recipes on demand…

42. InBatch 9.5 – What’s New?

43. InBatch 9.5 – What’s New?

44. InBatch 9.5 – What’s New?

45. InBatch 9.5 – What’s New?
Recipe Names now up to 128 Characters long (16 before)
Batch Display can now run many instances parallel, with specific focus on certain C/L/B through command line

46. InBatch 9.5 – What’s New?
A NEW (stateless) API… that follows the design pattern introduced with Wonderware MES

47. InBatch 9.5 – What’s New?
System Platform using InBatch’s Stateless API in scripts

48. InBatch 9.5 – What’s New?
Under the hood: More accurate use of Quality Status Messages for any I/O communication
The Batch Manager waits for an I/O with non-initializing quality to determine if a tag failure has occurred. An I/O with initializing quality is not considered for tag failure by the Batch Manager. For status tags of bad quality, a Bad Quality Received message is sent to the operator displays and the batch is not put on hold. For parameter tags of bad quality, a ??? message is displayed on the operator displays. When the Batch Manager reads the parameter tags that have bad quality even at the end of the phase, it retries the read operation for a configurable amount of time (See Parm Timeout (sec) on page 62). If the parameter tags do not return to good quality during the retry period, an error message is sent to the operator displays and the batch is put on hold.

49. InBatch 9.5 – What’s New?
Under the hood: More accurate use of Quality Status Messages for any I/O communication
The Batch Manager waits for an I/O with non-initializing quality to determine if a tag failure has occurred. An I/O with initializing quality is not considered for tag failure by the Batch Manager.
For status tags of bad quality, a Bad Quality Received message is sent to the operator displays and the batch is not put on hold. For parameter tags of bad quality, a ??? message is displayed on the operator displays.
When the Batch Manager reads the parameter tags that have bad quality even at the end of the phase, it retries the read operation for a configurable amount of time (See Parm Timeout (sec) on page 62).
If the parameter tags do not return to good quality during the retry period, an error message is sent to the operator displays and the batch is put on hold.

50. InBatch v10 – What’s Next?

51. Q & A Any Batch Related Questions? THANK YOU!