CENTUM VP Batch

Industry: Specialty Chemical, Pharmaceutical

Product: VigilantPlant Solutions
Automation
CENTUM Batch Automation • Highly Reliable Controllers
• Effortless Integration with Other Systems
The CENTUM VP Distributed Control System (DCS)
provides scalable and powerful solutions for Modular Engineering
continuous, batch and hybrid applications. CENTUM • Hierarchical and Modular Configuration
VP Batch is the ISA-88 (IEC-61512) batch control • Object Oriented Phase Logic Structure
package, which provides recipe management and • Easy Testing Environment
process management functions interfaced to the
CENTUM VP DCS. CENTUM VP is unique in Powerful and Advanced Unit Supervision
performing unit supervision functions in • User Configurable Unit State Matrices
completely redundant real-time controllers offering • Plug-in Exception Handling and Monitoring
an availability of 99.99999 percent, or “seven-9s”. Routines
CENTUM Batch VP recipe management, scheduling • Support for Audit Trails, Electronic Records
and production information management functions can and Signatures
also be easily integrated into Manufacturing
Operations Management (MOM/MES), supply chain Easy Operation
and enterprise management systems to meet the
• Intuitive View of Batch and Equipment Control
increasing demands for leaner and more agile
• Integration of Automated Control and Manual
manufacturing operations.
Operations
• FDA’s 21 CFR Part 11 Support
CENTUM VP Batch offers flexible and scalable batch
management software for centralized recipe and
Electronic Batch Records
process management combined with distributed unit
supervision. CENTUM VP Batch is field proven, having • Flexible Batch Reporting
been used to automate a wide range of batch • Complete Batch Production Information
processes from simple, single product/single unit Management System
processes to flexible and complex multi-product/multi-
path processes, with ease of use, outstanding Intelligent Solution Suite
reliability, and sophisticated functionality. • Recipe Management
• Production Planning and Scheduling
Using CENTUM VP Batch users benefit from: • Batch Production Information Management
• Reduced lifecycle engineering costs
• Shortened time to market Scalable and Reliable System Architecture
• Improved plant performance
• Reduction in unexpected control failures Batch processes often require complex, modular and
advanced resource management regardless of the
Features of the CENTUM VP Batch System scale. This is, especially true when multiple products
include: require flexible combinations of equipment modules,
units, lines and trains. CENTUM VP provides solutions
Scalable and Reliable System Architecture for batch control irrespective of process scale.
• Scalable Solution from Unit Control to Site

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CENTUM VP Batch controls plants of any scale Hierarchically structured logic allows intuitive
with a single architecture. engineering.
The smallest CENTUM VP Batch system consists of a Hierarchically structured unit instruments and modular
single PC, with operation, monitoring and engineering Sequential Function Charts (SFC) offer concise and
functions, integrated with a compact field control intuitive engineering making control strategies easy to
station. The system can be expanded online as your modify and less costly to maintain. The single
plant grows. integrated engineering tool and database further
reduces engineering costs by making the initial
Unit procedures are executed in highly reliable development and maintenance of control strategies
controllers. less costly.
In CENTUM VP Batch, the unit supervision function,
which is the ISA-88 activity requiring the highest Only one set of phase logic and graphics needs to be
reliability, runs on ultra-reliable controllers. This means configured for similar equipment. In CENTUM VP
all unit procedures, operations, and phases are loaded Batch, a unit instrument is assigned to each batch unit
and executed in controllers which can be fully (e.g. reactor, centrifuge, filter dryer etc). A unit
redundant. It was the first system to completely instrument comprises hierarchically structured
execute unit recipes, including unit procedures and modules using Sequential Function Charts (SFCs).
unit formula, in the controllers, thus, leading to Operations, phases, and graphics can be written using
increased system reliability. This allows a control generic names (aliases), thus making the logic
recipe to be able to run to completion without regard to independent of equipment. For example, a generic
the state of other PCs, servers or any other hardware. name such as “Valve” can be used to express a tag in
Furthermore, a completely integrated database is logic instead of the actual tag name. For many batch
provided to simplify system configuration with units, only one set of operations and graphics need to
automatic backup of configuration data a standard be developed. Multiple reactors can run concurrently
feature. without needing equipment specific operations.

Simple Interfacing Easy Testing and Simulation Environment

CENTUM VP is able to communicate with any OPC Applications can be tested using Yokogawa’s unique
enabled control or information system using OPC Virtual Test Function add-in without the actual
interfaces that are integral components of the system. controller or I/O. For all types of processes,
Connection with PLCs, skid based controls, laboratory development and testing of control applications can be
information systems, electrical facilities, machining done without dedicated hardware. With just a PC,
equipment, automated vehicle systems, and system engineering, testing, and verification can be
warehouse control systems have been field-proven in performed anywhere. The Virtual Test Function
many projects. CENTUM VP’s integral OPC interfaces simulates the complete controller function, including
enable effortless connectivity to hundreds of different the downloaded unit supervision functions, as well as
systems via OPC. The integrated functions permit data providing a simple loop back simulation for all I/O,
from OPC enabled systems to be displayed and used without requiring any engineering. Virtual Test
in CENTUM VP the same as field I/O signals. Function is started simply from a pull-down menu and
you can run batches, debug phase logic, verify unit
Modular Engineering coordination and test exception handling as if the
process controller was connected to the process. This
Yokogawa’s wealth of batch control experience is enables accelerated project schedules, reduces
evident in the CENTUM VP Batch package, which is development and testing bottlenecks on projects and
based on the ISA-88 batch control standard. contributes to the lower TCO (Total Cost of
Ownership) that is experienced with CENTUM VP
This modular, hierarchical package supports reusable controlling your batch processes.
components and libraries for easy engineering.
Configurations can also be tested by simulating field Powerful and Advanced Unit Supervision
control stations in a PC.

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Traditionally, operation and monitoring have been routines can be simply plugged into your control
performed individually for each piece of equipment, but strategies. It usually takes many engineering man-
centralized supervision of unit instruments can greatly hours to develop sequence control for exception
simplify plant operations. handling and interrupt processing for batch control.
The unit supervision function in CENTUM VP allows
A state transition matrix is built into unit instruments these routines to be easily plugged-in as required by
enabling each unit to have a unique set of states, the process.
commands and state transitions. CENTUM VP
provides a fully integrated operation and monitoring Easy Operation
environment that allows operation and monitoring to
be tailored to equipment configurations. The control of batch processes often involves many
manual operations such as manual additions,
A batch process typically consists of multiple pieces of starting/stopping equipment, and activities operators
equipment (e.g., reactor, mixing tank, or spray dryer). must perform on the production floor. Often it is
Each unit has multiple equipment and control modules difficult to coordinate automatic control system
such as temperature sensors, pumps, and valves, activities and manual operator activities. CENTUM VP
which must be centrally controlled by unit supervision. offers a simple, clear operating and monitoring
In CENTUM VP, unit instruments are used to centrally scheme with hierarchical display windows, interactive
control the various, independent, equipment and guidance for on-site operations, and many other
control modules that make up a unit. features to make life easier for operators.
State Transitions Intuitive view of the statuses of running
Custom state transition matrixes containing process processes:
and industry specific state and command names and Sequential Function Charts (SFC) visually represents
transition logic can be created. The state transition the statuses of individual unit procedures, operations
matrix built into every CENTUM VP unit instrument and phases. Operators can follow the progress of unit
provides a standard set of command, states and procedures, operations and phases in real-time,
transition logic to speed engineering. The default automatically configured displays. The display
commands/states include start/restart/running, windows are hierarchically organized with a navigator
pause/paused, and suspend/suspended. Built-in state window allowing easy access to the desired window.
transition logic is easily configured to allow restarting
unit procedures after exceptions have been handled; System coordination of manual operations and
options include restarting from where the exception automatic sequences:
occurred, from the start of the previous phase or Mobile terminals such as tablets can be used as
operation or from the start of the next phase or production floor terminals to perform the same
operation. operations as if in the central control room. In addition,
using interactive messages (appearing as dialog
When the standard does not fit your needs you may boxes), work instructions can be sent to operators no
simply build your own state transition matrix giving matter their location. These dialog boxes are able to
units unique state and command names and transition provide acknowledgement of received messages as
logic. For example in regulated industries the system well as provide data entry. This functionality lets
can be easily configured so some units have state manual operations be easily coordinated and
names such as “Clean”, “Dirty” and “Expired” with integrated with automatic sequences.
custom transition logic. When this is done, the
system’s standard event log will record unit state
transitions using your terminology, not a generic Audit Trails and Access Control for Regulatory
standard term. Compliance
To comply with regulations, such as the FDA’s 21 CFR
Modular Exception Handling Part 11 applicable to the pharmaceutical industry and
Exception handling, including detection of failures, good engineering and software practices, CENTUM
interrupt processing, and continuous monitoring VP records and retains audit trails for engineering

All Rights Reserved, Copyright © 2005, Yokogawa Electric Corporation

configuration and recipe data. When required and control recipes and changes to the plant
electronic signatures may be used as evidence of who equipment hierarchy using the complete data set for
made the change. automatic analysis of your plant's productivity and
efficiency.
Depending on the operator’s level of security
clearance, security restrictions can be set in detail for As systems become more automated, operational
monitoring, using display windows, display terminals, efficiency and quality are expected to improve, but it is
process equipment, and the like, as well as for actions crucial that managers use this data effectively.
on each equipment and control module. The user Exaquantum/Batch provides a standard set of analysis
name and password must be entered for tools that automatically provides metrics that can be
authentication by electronic signature when logging on used to measure operational excellence for batch
to the system or performing an action on equipment. operations, equipment utilization and product
Double authentication supporting done-by/checked-by development. These critical measurements enable
requirements can be set for critical operations. User quick identification of areas for improvement. With
actions are automatically time-stamped, recorded, and Exaquantum/Batch, the necessary data to be acquired
retained as operational audit trails. Yokogawa is does not need to be defined; instead, batch history
committed to provide customers in regulated industries data is acquired, analyzed and displayed
with products and services to help them comply with automatically. Exaquantum/Batch is ready to go
the FDA’s 21 CFR Part 11 regulation for immediately after installation.
pharmaceutical manufacturing.
Examples of reporting and analytical capabilities
Electronic Batch Records include:
• Integrated batch reports that can be
Control systems produce large amounts of operational customized for each master recipe, or recipe
results that are vital for making business decisions family
concerning productivity, quality, and safety • Unit utilization automatically calculated
improvements. Exaquantum/Batch, a Batch Plant • Events and alarms compared on a batch
Information Management system (Batch PIMS), relative basis
automatically saves all CENTUM VP Batch batch • Gantt charts displaying batch execution in
history information to an open, ISA-88 based, real-time and in batch relative time
relational database. It features functions to • Batch Production performance ratings
automatically log the manufacturing results of process automatically calculated for each batch and
management and unit supervision, consumption of raw rolled up on a master recipe basis
materials, alarms occurring in manufacturing, and • Cycle times with mean and standard deviation
many more, all of which can easily be displayed. automatically calculated and displayed for
each batch and unit recipe
Flexible Batch Reporting
Batch reports can be easily generated using Microsoft CENTUM VP Batch and Exaquantum/Batch provide
Excel. Using the CENTUM VP Report Package (a the basis for a plant and enterprise-wide integrated
plug-in for Microsoft Excel), batch reports can be information system configured to meet the specific
easily generated that include formula target values, requirements of the batch processing industries.
actual values, batch trends, alarm and event logs, Based upon the ISA-95 Enterprise-Control System
including records of operator actions, associated with Integration standard Yokogawa can provide integrated
a batch and much more. Standard report templates Manufacturing Operations Management (MOM/MES)
are provided to facilitate easily building your batch that involve simple integration of Yokogawa or other
reports. manufacturers' products, up to fully integrated
solutions consisting of intelligent field instruments,
Complete Batch Production Information automated batch control integrating manual
Management System operations, recipe management, production planning
Exaquantum/Batch not only automatically collects and and scheduling and batch production information
stores operational batch data it also preserves master management.

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 be managed efficiently. Field devices can be centrally
Intelligent Batch Solution Suite managed thanks to systematic predictive
maintenance, reducing TCO and maximizing process
Recipe Management up time.
CENTUM VP Batch provides recipe management
functions for creating and managing master recipes. Event Analysis Package - Exaplog
The master recipes have the advantage of being unit- Exaplog graphically analyzes historical messages in
independent. With CENTUM VP Batch, process the production control system that contain all the plant
engineers can develop master recipes independently operations, in order to locate nuisance alarms and
of unit configurations and without the aid of a system inefficient operation sequences, and thus improve
engineer. Simply by using a PC, master recipes can production processes.
be tested and verified with Yokogawa’s unique virtual
test function, thus reducing time to market. CENTUM Operation Efficiency Improvement Package -
VP Batch master recipes can be integrated with peer Exapilot
batch control systems, MOM/MES systems and Exapilot improves the operation efficiency by
enterprise systems. standardizing and automating the operation
procedures based on the expertise of experienced
Scheduling operators. Automating the execution infrequent
Batch systems must now be able to manufacture modular procedural operation provides a structured
different products in varying volumes, with frequent and reliable method of implementing SOPs according
interruptions of orders or changes of product being to ISA-106 standards.
manufactured. The systems must, therefore,
accurately comprehend production plans and the Alarm Management - AAASuite
current state of progress, and react quickly to AAASuite is an advanced alarm administrator
changes. The CENTUM VP Batch schedule interface designed to address issues with alarm settings of
enables your preferred scheduling package to be control modules. Specifically with batch process,
integrated with your batch control system. alarm settings need to be dynamically set according to
the status of the batch. AAASuite provides enabling
Batch Production Information Management – and disabling of alarms according to operation and
Exaquantum/Batch phase in order to reduce known nuisance alarming
Exaquantum/Batch is an intelligent ISA-88 based that would be caused by normal operation.
Batch Information System. It provides analysis and
reporting facilities that collect, store and display Summary
current and historical data from batch production, Yokogawa’s batch solutions are field-proven worldwide
equipment and recipe viewpoints. This enables easy in a wide range of batch processes and industries
user access to batch information for decision support, including fine chemicals, pharmaceuticals, food &
production planning, production scheduling, analysis, beverage, and pulp & paper, to name just a few.
process improvement, quality and legislative
compliance purposes including using ISA-95 to Yokogawa works in partnership with users to boost
exchange data with business systems. productivity and profitability, increase reliability and
quality, reduce time-to-market, and increase efficiency.
Complimentary Software Solutions Our experienced staff offers skilled, comprehensive
support encompassing improvements of single units,
Asset Management - Plant Resource Manager updates to existing plants, and design for and
(PRM) operation of new plants. We are not just another
PRM (Plant Resource Manager) collects diagnostic supplier, but your most trusted automation partner and
information from field devices through various fieldbus provider of solutions.
networks, such as Foundation Fieldbus and HART,
and manages the information in unified databases.
With these databases, maintenance schedules can be
planned allowing work procedures and spare parts to

All Rights Reserved, Copyright © 2005, Yokogawa Electric Corporation