【Weekly Question 20090518】Please list the current mainstream batch systems and their characteristics.

The original poster, please introduce one first; it will also help us gain some knowledge in this area, as it’s a rather specialized subject.

1# qiaopeng1231: The people upstairs are going too far; they should have points deducted from them. This is a question meant for every Monday! ABB’s batch functionality is part of the 800xA software suite, with the AC800M as the underlying hardware platform. It is used in various pharmaceutical and chemical industries. One of its main customers is Dow. Other hardware platforms such as 800F require the 800xA system in order to utilize batch functionality.

This post was last edited by qiaopeng1231 on 2009-5-19 18:42. The ABB AC800F once had a batch called DigiBatch. It’s actually quite useful and relatively cheap as well. . . Because originally, Openbatch was controlled by ABB. However, later on, the shares of OpenBatch were sold, and the company changed its name. I’ve forgotten what the new name was, but the system is still called OpenBatch. It focuses on quietly providing OEM services for batch processing systems in the background. Currently, the Batch version of 800XA is also developed based on Openbatch. However, unlike in the past when Openbatch was purchased directly, the 800XA Batch version was developed independently on that foundation. It integrates more closely with ABB’s 800XA system. ABB’s Batch is mainly used in industries such as pharmaceuticals, fine chemicals, and food hygiene. The pharmaceutical industry has a well-known achievement despite a relatively small contract value – GE Healthcare is a strategic partner and major client of ABB-PA. The 800XA batch has a history of being used to support GE Healthcare’s pharmaceutical projects on multiple occasions. For batch systems used in fine chemicals, in the domestic market PA has not managed to establish a strong presence; as a result, what is seen most often are Emerson-DeltaV batch systems. In industries such as food and beverages, Siemens is more commonly used in China, while ABB’s batch systems are not widely adopted. In Europe, ABB Batch has many customers in the food industry. Currently, the 800F still has a Batch interface; users can see the relevant options in the software menu of the 800F. But this is no longer a batch from the past of 800F. . . This is an interface designed to work with the 800XA batch. To use Batch with 800F, it is necessary to purchase the corresponding Batch interface component license, which is not expensive. It is also necessary to use the 800XA system, and then the 800XA batch system as well, which makes it quite expensive.

I can’t keep bearing the burden all by myself, can I? General HMI software manufacturer. A. Wonderware InBatch. Inbatch is Wonderware’s Batch system; it has been around for a long time as well, but its upgrades are slow. The current version is V8.1, and an upgrade to V9.0 is likely to take place soon. In China, several shampoo production lines, detergent production lines owned by Procter & Gamble, as well as those used for Trident chewing gum, all utilize Inbatch. It is said that Procter & Gamble’s implementation of this system has been very successful, as it was based on the model used in their factories in the United States. Apart from these typical domestic factories of North American companies, it seems that Inbatch has very few major applications. Inbatch is available in a Premium version and a Fle*ble version. It can be understood as a professional version and a streamlined version. Version P can support processes with changing workflows, while Version F cannot support such processes. The price of Inbatch is extremely high; it seems to be more expensive than the batch versions of many well-known DCS systems. As I recall, 1 pair of redundant Batch Servers plus 1 Batch development station cost around RMB 1.1 million or more. According to Wonderware, to fully utilize the capabilities of InBatch, it is best to deploy a Batch system on the IAS platform. The stand-alone version of Intouch Horror can deliver the same effects as InBatch. . . B. GE Fanuc-Intellution iBtach. It should now be called Proficy Batch. I don’t have any immediate impression of this software; I only know that it’s a product acquired by GE, and it seems to have a very good reputation. The price is not too outrageous either. C. RockwellAutomation-AB RSBatch. Currently, it’s popular to rebrand concepts by changing their names. Thus, RSBatch has been renamed FT Batch, just as iBatch was renamed Proficy Batch. In reality, it’s difficult to grasp the essence of Batch without using it in depth. Therefore, I simply installed RSBatch and gave it a try. Therefore, I don’t have any deep insights either. According to external evaluations, RSBatch is easy to use; although its features are not extremely powerful, it is simple to get started with. Stable in use. Moreover, it bears the renowned AB brand name. D. Siemens WinCC batch. Originally, Siemens’ batch functionality was available only in PCS7; however, starting from version 08, this feature was separated from PCS7 and made available for use independently with WinCC. It is designed primarily for small-scale processes that require batch control, and it works well in conjunction with the S7-300. ----PCS7 requires CPUs of at least 414-3. According to the description, it is compatible with non-Siemens controllers, but there are currently no records of performance with such controllers. The performance in conjunction with its own S7 controllers is not very significant, mainly in the tobacco industry. There are a large number of 317 CPUs. Part of it was used in conjunction with WinCC batch.E. Citect. Citect Batch is even less well-known. After acquiring Citect, Schneider didn’t carry out many batch projects either. Advantech’s SmartPro V3 HMI software is an OEM of Citect. The only batch project achievement of so-called domestic DCS is the one carried out with HollySys. It used the OEM version of Batch from Citect. I can’t remember the project name. I’m not sure whether it’s Basf or Qinghai Alkali Industry.

Next, we will introduce the batch system from the DCS system manufacturer; active netizens will receive high scores as rewards.

I’m becoming less and less confident. . . Add some information about the batch systems provided by DCS manufacturers. A. The best-reviewed Emerson DeltaV batch system. To date, the DletaV batch system remains the system with the best batch performance. It’s really terrifying if an Emerson DCS system engineer doesn’t know how to work with batch processes or has no understanding of them. In contrast, taking Foxboro, Yokogawa, Honeywell, etc. as examples, it is very rare for these manufacturers to offer Batch functionality. At Foxboro, there seem to be only two people who can handle the batch system properly; moreover, there are no opportunities in China for them to achieve any batch-related results. According to insider information, Yokogawa Xi’an has not had a single batch project in the past two years, and Yokogawa Suzhou has had none in the past three years. I’m digressing… For many manufacturers, the batch functions are acquired externally and then integrated into the DCS system; the integration with their own systems is not very tight. In contrast, the batch functions in DeltaV are tightly integrated with the DCS system – it can almost be said to be a seamless integration. B. Honeywell: All along, Honeywell’s batch processing solutions haven’t seemed to be very well-known. However, for this Shenhua coal direct liquefaction project, the PKS C300 system is used, which includes a batch process. Colleagues within HW still lack a proper understanding of batches. So, it’s still a few foreigners who handle the batches. The GES department in Chongqing also has little experience in debugging batch projects; it’s still feeling its way forward. C.ABB: ABB has many batches, and they are chaotic. The AC800F already comes with a batch function; although its capabilities aren’t extremely powerful, it is easy to use. Unfortunately, ABB eliminated it on its own; then for the AC800F model, a batch process is required, and the 800XA batch has to be used. The 800XA batch currently offers the highest level of integration, but its performance isn’t that great either. It turns out that the Symphony system used in Bailey’s department also has a batch system. Although Bailey mainly focuses on power plant DCS systems, Symphony-Info90 has achieved significant success in the petrochemical industry as well. Its Batch is quite well-known. After focusing on electricity, there was no demand for batches in the electricity sector, which led to the decline of batches. D. Siemens PCS7 batch. This is something I’ve had some basic experience with in terms of debugging. It feels pretty okay too. It isn’t difficult to understand. Currently, the latest version of the PCS7 batch system comes with well-translated manuals that look good. However, it is important to note that batch processing needs to be carried out in conjunction with SFC. The issue is that SFC blocks consume too much memory; 414H can basically not be used for this purpose. Although 417H can have a memory capacity of 30M, its cost is indeed too high. When choosing the PCS7 batch, pay special attention to the grade of the main controller. . . Furthermore, in line with Siemens’ usual practice, there are currently many Version D installations of PCS7 batch in use on site. As for the batches of other DCS systems, almost no non-official versions have been seen. E. Other batches. The Batch system of DCS is no different from the Batch system of general-purpose HMI software. Most of the time, software CDs aren’t available. It’s not possible to install software; and even if software is installed, there is no encryption lock, so configuration and simulation are not feasible. So, relatively speaking, it is still a bit closed to engineers from system integrators. Furthermore, at some manufacturers’ own Chinese headquarters, there are hardly any people who understand Batch. So these manufacturers all use non-mainstream batch systems. For example, Yokogawa, Honeywell, Foxboro. Because there was no opportunity to use it, no chance to test it, and even due to the limited volume of work done, there was no way to see firsthand how the batch processing was carried out. As a result, it’s impossible to provide an objective evaluation. It is recommended that engineers from system integrators give up. . .