CitectSCADA Batch Tutorial

CitectSCADA Batch Tutorial Version 1.0.8 Citect Pty Ltd 3 Fitzsimmons Lane Gordon NSW 2072 Australia www.citect.com

2 DISCLAIMER Citect Pty. Limited makes no representations or warranties with respect to this manual and, to the maximum extent permitted by law, expressly limits its liability for breach of any warranty that may be implied to the replacement of this manual with another. Further, Citect Pty. Limited reserves the right to revise this publication at any time without incurring an obligation to notify any person of the revision. COPYRIGHT Copyright 2004 Citect Pty Limited. All rights reserved. TRADEMARKS Citect Pty Limited has made every effort to supply trademark information about company names, products and services mentioned in this manual. Trademarks shown below were derived from various sources. CitectSCADA, CitectHMI/SCADA, CitectFacilities and CitectSCADA Batch are registered trademarks of Citect Pty. Limited. IBM, IBM PC and IBM PC AT are registered trademarks of International Business Machine Corporation. MS-DOS, Windows, Windows 98, Windows 2000, Windows XP and Excel are trademarks of Microsoft Corporation. dbase is a trademark of Borland Inc. General Notice: Some product names used in this manual are used for identification purposes only and may be trademarks of their respective companies. November 2004 Edition for CitectSCADA Batch Manual Revision 1.0.8

3 TABLE OF CONTENTS INTRODUCTION...4 BEFORE YOU START...4 PROJECT OVERVIEW...5 CREATING A NEW BATCH DATABASE (FULL TUTORIAL)...5 CREATING THE EQUIPMENT MODEL...10 LINKING TANKS, PIPES, VALVES AND UNITS...21 CONFIGURING PHASES (HEAD START TUTORIAL)...27 ASSIGNING PHASES TO UNITS...40 CREATING MATERIALS...50 CREATING A RECIPE (EXPRESS TUTORIAL)...57 APPROVAL FOR PRODUCTION...57 ADDITIONAL CONFIGURATION FOR TANKS...58 ASSIGNING USERS TO AREAS...61 CREATING OPERATIONS...63 CREATING A PROCESS ORDER AND CONTROL RECIPES...115 EXECUTING BATCHES...121 WHERE TO FROM HERE?...126 CITECTSCADA BATCH VERSION 1.1 NOTES...126 PASSWORD CONFIGURATION...126 ITEMS NOT APPROVED FOR PRODUCTION...127

4 Introduction This tutorial is designed to step through the creation of a CitectSCADA Batch database, configuration of the Equipment Model (using the Equipment Editor), the creation of a Master Recipe (using the Recipe Editor) and finally the execution of Control Recipes on a Citect project (Batch_Example). Because it can take quite a few hours to complete this Tutorial two additional entry points have been provided. If you undertake the Full Tutorial, these entry points could be a good guide as to when to take a break. The Head Start Tutorial starts at the Configuring Phases section with a batch database that has all Area, Cells, Units, Tanks, Pipes and Valves configured. Most of this configuration is very straight forward and 30 45 minutes can be saved by starting the Tutorial at this point. Starting at this point allows you to skip some fairly mundane configuration but still see how to configure Phases and assign Parameters to Tags. It is worthwhile to review the way Tanks, Pipes, Valves and Units are linked together (page 22) if you start at this point. The Express Tutorial starts at the Creating a Recipe section and probably reduces the time spent on the Tutorial by another 60 minutes. Starting here should make it possible to design a Recipe and execute it is less than an hour. After a Batch system has been initially configured and commissioned this will be the normal starting point for creating new Recipes.. Using an existing Citect project allows the Tutorial to concentrate mainly on CitectSCADA Batch. We are going to Batch Example as the Citect Project. After completing the tutorial you will have completed a simplified version of one of the Recipes in Batch Example. After restoring the full version of the Batch_Example batch database, you will be able to explore some of the more advanced features found in the this project such as interaction with Cicode forms, optional branching in a Recipe at run time, exporting Batch records to MS SQL Server/Crystal Reports and MS Access etc. 1 Before You Start The Tutorial requires that CitectSCADA Batch, Citect 5.50/6.0 are installed and the Batch_Example Citect has been restored along with the CtBInclude project that comes with it. There is a folder on the Tutorial CD called Batch_Tutorial in contains a word document called CitectSCADA Batch Installation.doc that provides instruction on how to install CitectSCADA Batch and restore the Head Start Tutorial backup or the Express Tutorial backup if required. Another Word document called Batch Example Installation Instructions.doc has instructions on how to restore the Batch_Example Citect Project and the CtBInclude Project. It also illustrates the use of the Citect Computer Wizard and the Batch Advanced Setup Wizard, both of which must be run before attempting to execute a Batch. Before commencing this Tutorial you should install Citect 5.50/6.0 and CitectSCADA Batch (that order) in if they are not already installed. You should also install the Head Start or Express Tutorial Batch database backup if you do not want to work through the full tutorial. Lastly, the Batch_Example and CtBInclude Citect Projects should be restored. The two documents mentioned above provided instructions on how to perform these tasks.

5 2 Project Overview The Batch_Example project has three Tanks, two Pipes and two Units. Pipe 1 will be used to control access to Flow Meter 1 and Pipe 2 for Flow Meter 2. The first Recipe will be for Chocolate Milk 3 Creating a New Batch Database (Full Tutorial) Log into the CitectSCADA Batch Recipe Editor (RE) as a Batch Administrator (for example User ID 999 with password batch999). On the File menu click New. Type the name of the new Batch database (Batch_Tutorial).

6 Click the Browse button to choose a location for the database file. The standard location for SQL Server is C:\Program Files\Microsoft SQL Server\MSSQL$BATCH, where "$BATCH is the Batch instance of MSDE (Microsoft Database Engine) installed by CitectSCADA Batch. You can choose another location if you wish. Click OK to close the Get Path form and OK again to create the new database. The Recipe Editor will create the new database and restore an empty database structure to it using the default.bak backup that came with CitectSCADA Batch.

7 This is how the New project form should look after you click OK in the Get Path form. After the new Batch database has been created you will be asked to log in as shown below. Log in with User ID 999 and password batch999

8 If the password has expired you will be immediately asked to enter a new password and confirm it by typing it in a second time. If this happens change the password to batch998. When you click Save to save the new password you will be asked for a User ID and password. Remember to use the OLD password. At the completion of this process you will have an empty Batch database called Batch_Tutorial. Note that three default Users are created including Batch Administrator. It is a good idea to create a second user with Supervisor Rights for use if you happen to get locked out of User ID 999. If you updated Default.bak after installing CitectSCADA Batch this has already been done and you can skip to page 11. Select the Users branch, right click and choose New from the menu.

9 Create a user with User ID 111 and password batch111 (easy to remember) and add the User to the Supervisor Group. Note that the requirement to change the password at the next login is set to false. When you click Save a User ID and password will be requested. This should be User ID 999 with password batch999 of course.

10 With the second Supervisor configured it will be possible to recover User ID 999 should the account become locked. 4 Creating the Equipment Model Start the CitectSCADA Batch Equipment Editor (EE). There is no requirement to login to the Equipment Editor.

11 Select Areas, right click and choose New from the menu. Complete the New area form as shown then click Save.

12 Expand the Areas branch by clicking on the + symbol to the left. The expanded branch looks like this. To add a Cell select Area 1, right click and choose New from the menu.

13 Complete the New cell form as shown and click Save. Expand the Area 1 to reveal Cell 1. To add a Unit, select Cell 1, right click and choose New from the menu.

14 Complete the New unit form as shown below and click Save. Repeat for Unit 2 (optional for this tutorial).

15 The next step is to create three Tanks. To do this, select the Tanks branch, right click and choose New from the menu. Complete the New tank form for Tank 1 as shown below and click Save.

16 Repeat this for Tanks 2 and 3 as shown on the next page.

17 The next items of equipment to be configured are Pipes. Select the Pipes branch, right click and choose New from the menu. Complete the New pipe forms for Pipe 1 and Pipe 2 as shown below. The Citect Tags Pipe1 and Pipe2 are configured in the Batch_Example Citect Project and are used to animate the busy state (true/false) on Citect Pages where required.

18 The next items of Equipment Model to configure are Valves. Select the Valves branch, right click and choose New from the menu.

19 Complete the New valve forms for Valves 4, 5, 6 and 7 as shown below. Note that in the Batch_Example Citect project the Tags BE_Valve4, BE_Valve5, BE_Valve6 and BE_Valve7 do not directly control physical valves. They are internal status bits used by PLC logic to control the physical valves in the plant subject to any plant or safety interlocks that may be required. These valves can be used to detect when a Unit has gained the access to a Pipe and often play an important part the PLC Phase logic. When the PLC logic for a Phase that needs to use a shared Pipe (actually a flow meter in this case), it should wait for the Valve associated with the Unit to which the Phase Logic belongs to be turned on the Batch Engine.

20 All elements of the Equipment Model have now been created. It is now necessary to configure any relationships that exist between the Tanks, Pipes, Valves and Units. Based on the model used in the Batch_Example Citect project, the relationships are as follows. Material A Material B Material C Tank 1 Tank 2 Tank 3 Pipe 1 Pipe 2 Valve 4 Valve 5 Valve 6 Valve 7 Unit 1 Unit 2 Product 1 Product 2 For an explanation of what these relationships mean see the Word document (BatchExample_x.xx.doc which can be found in the OtherFiles directory of the Batch_Example Citect project. There is also a PowerPoint in this directory that illustrates how Pipes are reserved and released.

21 5 Linking Tanks, Pipes, Valves and Units To assign Valves 4 and 5 to Units1, select the Unit 1 branch, right click and choose Edit from the menu.

22 Click the Valves tab, click Add valve button, click the icon for Valve 4 then click OK. Repeat this for Valve 5.

23 Use the same procedure to assign Valves 6 and 7 to Unit 2. The next step is to assign Valves to Pipes. Select the Pipe 1 branch, right click and choose Edit from the menu.

24 Click the Valves tab click the Add valve button, click the Valve 4 icon and click OK. Do the same for Valve 6. Valves for Pipe 2 should be assigned as follows.

25 To complete this part of the configuration, Pipes 1 and 2 should be assigned to Tanks 1, 2 and 3 as appropriate. Select the Tank 1 branch. Right click and choose Edit from the menu. Now select the Pipes tab, click the Add pipes button, click the Pipe 1 icon and click OK.

26 Repeat for Tanks 2 and 3 as shown on the next page.

27 6 Configuring Phases (Head Start Tutorial) If you are starting the Head Start Tutorial here you must first restore the partially configured CitectSCADA Batch database as described in at the beginning of this document under the heading Before You Start. Phases are blocks of PLC Logic that control Batch equipment. A typical Phase involves opening a valve path, waiting for a flow meter to measure a preset quantity of liquid the closing the valves and signaling completion. For this tutorial some of the Phases in the Batch Example project will be configured. Phase Description FM1 Addition The addition of sugar or flavouring though Flow Meter FM1 Release Release Pipe 1 after FM1 Addition FM2 Addition The addition of milk though Flow Meter 2 FM2 Release Release Pipe 2 after FM2 Addition Agitator On Off Turn the agitator on or off Drain Drain the unit at the completion of a Batch Time critical and safety related functions of a Phase are implemented in PLC logic. The Batch Engine (BE) uses the information contained in Control Recipes to Start Phase Logic at the appropriate time passing any Parameters to the Citect Tags. The BE monitors Tags that are referenced in Transitions, and detects when Transition logic evaluates as true. When a Transition becomes true the BE moves on to the next Phase or Phases. The BE also logs and Report Parameters to the database. For example the FM1 Addition Phase will write the scaled set point for the Material to the PLC and start the Phase Logic. When PLC detects that Flow Meter 1 has measured the required

quantity of Material it stops the flow of Material and sets a Citect Tag to tell the BE that the job is done. To create a Phase, select the Phases branch, right click and choose New from the menu. 28 Enter details of the FM1 Addition Phase as shown below. In the Parameters section click the New button and add the first Parameter and enter the details for the 00_Start Parameter as shown below.

NOTE: The numeric prefix for the Parameter names was originally intended to provide a sort order for the Tags. The SubType also does this. The Parameters are sorted but SubType and then by Parameter name. The SubType controls the order in which the Batch Engine processes the Parameters. 29 Click the Set Value button for the 00_Start Parameter to set the value to 1. This becomes the default value when designing Recipes. This bit should always be set to a value of 1 so it it worthwhile to set the default.

30 Proceed with the remaining parameters as follows. Note the additional information for the Set Point to indicate a scaled ingredient. The Recipe Editor will scale the Set Point value to the Batch size when creating Control Recipes later on. Because the value of the Set Point different in each instance there is no benefit is setting a default value.

31 It is probably best to leave the default value at 0 to force the Recipe designer to choose Tank 1 or Tank 2. The value of 0 is appropriate for this parameter so that the bit will be turned off in the PLC. When all 4 Parameters have been entered that Phase form will appear as shown below.

32 Repeat the procedure for the FM2 Addition Phase omitting the 20_Tank_1or2 Parameter. Take care to complete the extra information (checkboxes) for 10_SetPoint Parameter for FM2 Addition, indicating that it is a scaled ingredient.

33 Next create the FM1 Release Phase. Note that the 10_Release Parameter is a special Release data type. Note also the value is set to 1 and the Ingredient addition checkbox is checked. When a Pipe is made Busy it is reserved for an Ingredient (Material) and the same Ingredient has to be specified when releasing it.

34 The 20_Completed Parameter should be left with a value of 0 as it will be used to reset the Completed bit in the PLC.

35 Add the FM2 Release Phase in a similar way to FM1 Release, remembering to make the value of the 10_Release Parameter 1 and to check the Ingredient Addition checkbox.

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37 The next Phase to be created is the Drain Phase.

38 Set the default to 1 to open the Drain Valve. If the fail safe condition is Off (which may well be the case here) it may be better to set the value to 0. This will ensure that the valve will remain closed unless the Recipe Designer explicitly sets the value to 1 in the Recipe.

39 Finally add the Agitator On Off Phase.

40 7 Assigning Phases to Units Now that the Equipment, Phases and Parameters are configured the next step is to assign Phases to Units and Citect Tags to Phase Parameters on each Unit. When creating Control Recipes later, this information allows the late binding of parameters to specific Citect Tags for a Unit. The Master Recipe references Parameters by Parameter Name only and can therefore be applied to any Units to which the Phases have been assigned. When the tutorial is completed you can use the Master Recipe Overview and Control Recipe Overview to confirm that Tags are not assigned until the Control Recipe is created. First the status of all Phases must be changed to Approved for Production in the Recipe Editor. Log into the Recipe Editor as a Batch Administrator (e.g. 999/batch999), select the Drain Phase branch, right click and choose Edit from the menu and change Status from Not Approved to Approved for Production then click the Save button. You will be required to enter a User ID to change the state and again to save the changes.

41 Repeat this procedure for all Phases, FM1 Addition, FM1 Release, FM2 Addition, FM2 Release, Drain and Agitator On Off. Items that are not Approved for Production appear in red in the Recipe Editor and Equipment Editor. IMPORTANT: The Equipment Model is configured in the Equipment Editor but ALL status changes (approval etc) and done in the Recipe Editor. Now return to the Equipment Editor Select the Unit 1 branch, right click and choose Edit from the menu.

42 Click on the Unit phases tab for Unit 1 and then click Add Phase, click the FM1 Addition icon then click OK. If the Add Phase button is disabled, you are probably still in the Recipe Editor.

43 Proceed to add all the remaining Phases (FM1 Release, FM2 Addition, FM2 Release, Drain and Agitator On Off) using the same procedure. When completed as shown below click the Save button. The same should be done for Unit 2 although this can be left until after the tutorial if you wish. The final task in the Equipment Editor is to assign Citect Tags in the Unit Phase and Other Information tabs. Staying for the moment on the Unit Phase tab, select the first parameter and click the Config tags button.

44 It is possible to either type in n a Citect Tag or to search the variable.dbf file for the Citect project (Batch_Example) for a Tag. The second method saves typing and reduces the chance of errors. To select a Tag from varirable.dbf click the Citect Project button then the Get Citect Path button to locate the directory in which the Citect is located and click OK.

45 From the list of Citect Projects, select Batch_Example and click OK.

46 The location on the Citect directory will remain the same for the rest of the Equipment Editor session or until changed. The Search button is used as follows to find the required Tag. Check the Name checkbox; enter the first few characters of the Tag followed by % (the SQL Server wildcard character) and click Search.

47 The last step in to select the Tag and click OK.

48 The Unit1PhaseFM1Addition_Start Tag has now been assigned to FM1 Addition Phase Parameter 00_Start. Repeat these steps for all other Phase Parameters. Note that the Release Parameters do not have Tags as they are internal to the Batch Engine. When all Phase Parameters have been entered, click Save to complete the process. You will be prompted for a User ID and password.

49 Again this has to be repeated for Unit 2 but it can be left until after the tutorial. There are also some useful Tags that can be assigned in the Other Information Tab but this can also wait until after the tutorial if you wish. The basic configuration of the Equipment Editor is now complete.

50 8 Creating Materials Before a Recipe can be created, the Materials must be configured. We will define four ingredients (sugar, milk, chocolate and strawberry) and two products (chocolate milk and strawberry milk). In the Recipe Editor, select the Raw Materials Branch and choose New from the menu. Enter the details for Milk as shown below. When creating a Material it must be saved in the Not Approved state. Do the same for sugar, strawberry and chocolate as shown in the list below. Now open each Material in Edit mode change its Status to Approved for Production and Save it.

51 To create the Chocolate Milk Product, select the Products branch, right click and choose New from the Menu. Enter the basic information for Chocolate Milk as shown below. If the End Product checkbox in unchecked, the Product will be available for selection as a Raw Material for multi-step Batches.

52 To add Milk as a Material, click the Add Material button on the New Product form then the Search button on the Get Material form, click the Search button again on the Materials form to display the list of Materials, Select the Material then click OK.

53 Now enter 75 for the quantity in the Get Material form and click OK. Repeat the procedure for Sugar and Chocolate and Save the Product.

54 The Standardize button can be used to force the total to be 100 but it is not needed in this case. Do the same for Strawberry milk.

55 The list of Ingredients and quantities for each Product is the Bill of Materials (BOM) for the Product. IMPORTANT: Before creating Recipes you should Print out the Product form for each Product so that you can easily look up the Materials and Quantities for each Recipe. To do this, select the Product branch, right click and choose Edit or View from the Menu. Alternatively double click the Product branch to open the Product form in View mode. With the Product form open, click the Print button.

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57 9 Creating a Recipe (Express Tutorial) If you are starting the Express Tutorial here you must first restore the partially configured CitectSCADA Batch database as described in at the beginning of this document under the heading Before You Start. 9.1 Approval for Production Before creating a Recipe, all items used in the Recipe must be Approved for Production and you should assign at least one User to Area 1. The Phases have already been approved so that they could be assigned to Units. For those starting the Express Tutorial, this has already been done, please skip to page 69. Log in to the Recipe Editor as a Batch Administrator (e.g. 999/batch999) and view the various lists to check whether they are approved or not. Items that are not Approved for Production are highlighted in red.

58 You will see that the Area 1, Cell 1, Units 1 & 2 and Tanks 1, 2 & 3 need to be approved. To approve Unit 1, select the Unit 1 branch, right click and choose Edit from the menu. Change the State from Not Approved to Approved for Production the click the Save button to save the change. You will prompted for a User ID and password twice, once when changing the Status and again when saving the change. You should now go on to approve Area, Cell, Unit 2 and Tanks 1, 2 and 3 as well as all Raw Materials and Products. 9.2 Additional Configuration for Tanks When approving Tanks, you should also check the Active checkboxes.

59 It is also a good idea to assign Materials to each Tank at this time as shown.

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61 9.3 Assigning Users to Areas First select a User, right click and choose Edit from the Menu.

62 With the User form open, click on the Groups Tab and click the Add button. The User may already be assigned to a Group but not an Area. In this case Add the Group again and assign an Area. The Group assigned without an Area can then be deleted. Now select Operator from the list. If there was more than one Area defined you would also need to select an Area, but Area 1 is already selected in this case.

63 Multiple Areas can be added if there is more than 1 Area. You should also assign Area 1 to User ID 999 (Batch Administrator) to Area 1 and the Supervisor Group. 9.4 Creating Operations It is now time to create some Operations that use the Phases we have created. Select the Operations branch, right click and choose New from the Menu.

64 Click the Header button, type in the Name of the Operation and click OK then Save the Operation and re-open it.

65 Every Operation must have a Start and End element. To create a Start element, click on the appropriate icon and position the element at the top of the work area by clicking at the desired location. Notice that the Start Element icon on the toolbar is disabled after a Start Element has been created. The must be one and only one Start Element and End Element for each Operation.

66 All elements in an Operation have a Sort Number which is used to control the order it which Phases, Operations etc appear in the Batch Viewer and in the Overview print out. It is best to leave gaps in the Sort Numbers so that elements can be inserted without needing to change other Sort Numbers much as used to be the case in Basic programs. The number 0 is a good choice for the Start Element and 999 for the End Element as the Sort Number has three digits. Next create an End Element at the bottom of the work area.

67 To change the Sort Number for the End Element, double click on the element change the number to 999 can click OK. Our recipe calls for Sugar to be delivered from Tank 1 while Milk is being delivered from Tank 3. To do this we need to begin a Simultaneous Sequence.

68 Click on the Beginning of simultaneous sequence icon then use the mouse to trace out a rectangle in a location not far below the Start Element. We now want to draw a Link between the Start Element and the new Simultaneous Sequence Element. Click on the Link icon then click on the bottom of Start Element, move the mouse to the middle of the Simultaneous Sequence Element and click to draw the Link then right click to terminate the Link.

69 Next we want add an FM1 Addition Phase to add Sugar. To do this click on the Phase icon and draw the outline of a rectangle where the Phase should appear.

70 Next, double click the new Phase rectangle to select and configure the Phase. In the Phase form click the Select button and choose the FM1 Addition Phase.

71 IMPORTANT: If you draw a new Operation and save it without selecting an Operation the Select button will be disabled when you re-open the project and it will be necessary to delete and re-draw the Operation.

72 At this point the Parameters for the Phase are listed. To enter the 10_SetPoint parameter, select the row and click the Configurate button. On the Raw Material form click the Set button to the left of the Raw Materials field. The Get Material form will appear Click search button on this form to show the Materials form. Click the Search button on this form to see the list of Materials, select Sugar then click OK.

73 The illustration below shows the forms that appear while searching for and selecting a Material, the most recent form in on top. IMPORTANT: The Materials form lists no Materials when first opened. To see the entire list, leave the Search text empty and click the Search button. Click OK on the Get Material Form. Now set the Quantity.

74 IMPORTANT: The Quantity can be entered at Operation or Master Recipe level. If the Quantity is entered here you will need to refer the print out for the Product to check the Quantity for each Material. The advantage of entering the Quantity here is that if the Operation is changed at a later date the correct Quantities will be preserved. The Material ID/Name cannot be changed in the Master Recipe however so it must be specified in at Operation Level. The 10_SetPoitnt Parameter is now configured.

75 Now set the 20_Tank_1or2 Parameter to a value of 1 following sequence below.

76 The PH Sugar Addition Phase is now configured. Click OK to return to the main work area.

77 Next we need to add a link between the Simultaneous Sequence Element and the PH Sugar Addition Phase. Click the Link icon, click the start point (left hand, bottom of the Simultaneous Sequence Element), and click the end point (top, center of the PH Sugar Addition Phase. Don t forget to right mouse click to terminate the Link. We now need to set up a Transition to detect when the required quantity of sugar has been delivered. The Phase logic in the PLC accepts the 10_SetPoint Parameter and opens the required valves. When the correct quantity is measured by Flow Meter 1, the PLC Phase Logic shuts the valves and sets the Tag that tells the Batch Engine the Phase has completed. The Transition should monitor this Tag and wait for it to be set to 1. IMPORTANT: It is recommended that after configuring a Phase with Phase Parameters, the Operation should be Saved and re-opened. This causes the Parameters to be named after the instance of the Phase (in this case PH Sugar Addition) rather than the generic name (FM1 Addition) when creating Transitions.

78 Select the Transition icon; click a location below the PH Sugar Addition Phase position the Transition in the correct location.

79 Double click on the Transition and set the Name and Sort Number.

80 To set the Transition condition click on the gray raised rectangle below the header area and set the transition as shown below. The value of the comparison (1) should be entered.

81 When the recipe is executed, the Batch Engine will find Sugar in Tank 1 via Pipe 1 and will reserve Pipe 1 for Sugar. The next Phase is to release Pipe 1 from Sugar. Click the Phase icon and draw a rectangle below the PH Sugar Addition Phase then double click the new Phase and enter the basic information shown below.

82 Now click the Select button, click the FM1 Release Phase and click OK.

83 With the 10_Release Parameter selected, click the Configurate button, then click the Set Material button in the Parameter form followed by the Search button in the Get Material form. Finally select Sugar as the Material and click OK on the Materials, Get Materials and Parameter forms.

84 Note that we want to set the 20_Completed Parameter to 0 so there is no need to change it.

85 It is now time to add Links between the Sugar Addition Phase and the Transition and between the Transition and the Sugar Release Phase. Remember to use right click to terminate each Link. The Operation now looks like this, with the three basic elements for Sugar addition in place.

86 We now want to repeat these three elements for Chocolate (in series, below the Sugar Phases) and Milk (in parallel to the right of Sugar and Chocolate). The following images show the various forms that must be completed and the final result. It is important to remember that the Sugar and Chocolate Phases are based on the Flow Meter 1 Addition and Release Phases and the Milk Phases are based on Flow Meter 2 Phases.

87 IMPORTANT: After you add the Chocolate Addition Phase a second set of FM1 Addition Parameters is added. The Parameters are initially named after FM1 Addition NOT Chocolate Addition which can lead to confusion when configuring the subsequent Transition. For this reason, it is recommended that you Save the Operation configuring each Addition Phase to that when you re-open the Operation the Parameter Names are more meaningful. Notice in that when configuring the Transition for Sugar we selected 99_Completed.FM1 Addition. In the example below this has now become 99_Completed.PH Sugar Addition and we can now select 99_Completed.PH_Choclate Addition.

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89 When adding Phases for Milk, remember to use the FM2 Addition and FM2 Release Phases.

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91 We now want to insert an End of Simultaneous Sequence element and complete the Links to the End Element.. Remember to use right click to terminate each Link. First click on the End of Simultaneous Sequence icon and draw the element below the existing Phases.

92 Next complete the Links as shown and Save the Operation. Remember to use right click to terminate each Link.

93 To save the Operation, click the Save (floppy disk) icon at the top left, you will be required to enter a User ID and password. We will now create an Agitator ON Operation.

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95 Then an Agitator OFF Operation.

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97 The last Operation required is the Drain Operation.

98 Before adding the Transition as shown below, Save and re-open the Operation so the Phase instance name is used in the Parameter Name. While this is not essential in this case, it is good practice.

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100 Notice that the Transition uses a less than comparison for the Unit Level, if an equals comparison was used, the Parameter could pass through the value without ever equaling it. Now add a Close Drain Phase.

101 The Operation looks like this when completed. Next, the four Operations must be Approved for Production so that they can be used in a Unit Procedure. Select the Agitator OFF Operation, right click and choose Edit from the Menu.

102 Before Saving the Operation click the Verify button to confirm Operation has no errors that can be detected by the Recipe Editor. Operations cannot be Verified while their Status is Approved for Production. Save the Operation with the Status changed to Approved for Production.

103 Proceed to Approve the remaining Operations. Unit Procedures are created within a Master Recipe. To create a Master Recipe, select the Master Recipes branch. Right click and choose New from the menu.

104 Click the Header button enter the basic details of the Master Recipe and click OK.

105 Create and number Start and End elements as shown, click on the Unit Procedure icon and draw a Unit Procedure.

106 Double click the new Unit Procedure to open the Unit Procedure work area, click the Header button and complete the details shown below.

107 Add a Start Element, click the Operation icon and draw an Operation Box. Double click on the new Unit Procedure enter the basic details in to for the Unit Procedure then click the Select button, choose the Agitator ON Operation and click OK.

108 The next Unit Procedure is for Chocolate Milk.

109 After selecting the Chocolate Milk Operation all the Parameters for will appear. Select one of the Materials and click the Configure button. Observe that the Quantity for the Product is shown so that it can be compared to the value entered for the Parameter.

110 Add the Agitator OFF Operation.

111 Lastly add the Drain Operation.

112 Now add an End Element, change its Sort Number to 999 and draw the necessary links. Click the gray Unit Procedure Close box (top right of the window) to return the Master Recipe being careful not to click red Recipe Editor close box.

113 Complete the Mater Recipe Links and Save the Master Recipe. Re-Open the Master Recipe double click the Chocolate Unit Procedure then the Chocolate Operation and temporarily change the Chocolate quantity to 15.00001.

114 Return Master Recipe, open the Header and Click the Verify button. An error message appears indicating the Chocolate quantity is not correct. The Recipe Editor verifies Quantities to 5 decimal places. Close the Master Recipe without saving it.. Now open the Master Recipe again (in Edit mode), open the Header, change the Status to Approved for Production, close the Header and Save the Master Recipe.

115 10 11 Creating a Process Order and Control Recipes To use a Master Recipe a Process Order and one or more Control Recipes must be created. When a Process Order is created, the size of the Order is specified and it is targeted to a particular Cell. When Control Recipes are created, they are targeted to one or more Units (within the Cell). If the Quantity specified is larger than the capacity of the Unit, multiple Batches are created. The Recipe Editor takes into account the Minimum and Maximum Batch Size for the Unit when doing this. One Process Order can be used to create Control Recipes for a number of Units. Another important process that happens when a Process Order is created is that the Tag Names for the Phase Parameters (and Global Parameters) are used to make the Control Recipe Unit specific. During the creation of Control Recipes Quantities are scaled to the Batch size. First, confirm that the Master Recipe is Approved for Production.

116 Click on the Process Orders, right click and choose New from the Menu.

117 Complete the New Order form as shown below and Save it. Expand the Process Orders branch, select 000001, right click and choose New Control Recipe from the Menu. Complete the basic information for the Control Recipe form as shown below.

118 Click on the Assign Unit button and select Unit 1 and check the Main unit in Recipe checkbox. Batches will be sized according to the capacity constraints of this Unit. When the Batch or Batches are Released in the Batch Scheduler, they will also be assigned to this Unit.

119 Now click the Create button and observe that 3 Batches have been created.

120 Click the Save button to Save the Batches. At this point it is instructive to view (and even print out) the Master Recipe Overview and the Control Recipe Overview. Observe that the Control Recipe is scaled to the Batch size and that specific Tags have been assigned to the Parameters. One last step remains to execute the Batches; they must be Transferred to the Batch Scheduler. Select Control Recipes, right click and choose Show All from the Menu.

121 Click each Control Recipe (to select it), click Transfer then Close the Control Recipes form. The Control The Control Recipes are now available for Release in the Batch Viewer. 12 Executing Batches The Batch Engine (BE) communicates with the plant via Citect Tags and must run in conjunction with a Citect Project. The Citect Project to be used in this case is Batch_Example. If this Project has not already been restored refer to the Word document Batch Example Installation Instructions.doc which can be found in the Batch_Tutorial folder on the CD. Be sure to also run the Citect Computer Setup Wizard and the Batch Advanced Setup Wizard as described in this document. Batches are executed by the Batch Engine (BE), The Batch Engine uses information from the Batch database to load Parameters at the appropriate times and evaluate Transitions. The BE loads Parameters at the start of a Phase and spends most of its time waiting for Transitions to occur. Important Notes:- 1. The Batch_Example Project uses a particular version of CTBInlcude (Citect Batch Include Project). A backup of this project can be found in the OtherFiles folder in the Batch_Example folder, there is also a Word document that provides more detailed information about Batch_Example. 2. If you have a Citect key plugged into the PC and it has no Batch License, the Batch Engine will not start in Demo mode but will start in licensed mode with 0 Units. The result is that no Batches will run. You must either uses a key that has a CitectSCADA Batch license of it or have not key at all so that both Citect and CitectSCADA Batch will run in demo mode.

3. Check the Users icon at the top left of the Citect Cell page. If it is grayed (disabled) as shown, click on it so that it displays in colour. This will toggle a flag to set the Batch Scheduler in a mode (on Page Entry) to substitute the Citect Operator login for the Batch Operator login. The Citect startup Cicode logs in as the Citect Operator. 122

Start the Batch_Example project, compiling it first if necessary. During start-up there may be warning messages if there is now protection key. Both Citect and the Batch Engine will start in demo mode if there is no key (see Note 3 above). 123 When Citect has started, the screen should appear as shown. Click the Scheduler button to go to the Batch Scheduler. Select the first Batch and click the Release button.

124 Notice that Unit 1 is now green, indicating that it has a Batch assigned to it.

125 Double click the same Batch and Start it. Click the Back button to return to the Batch Scheduler then Double click on the green Unit 1 icon at the top left to view the status of the Batch Phases.

126 You can now observe the progress of the Batch in the Batch Scheduler, the Batch Viewer, the Citect Cell page or the Citect Batch Diagnostics page. 13 Where To From Here? To proceed from here, it is recommended that you read the documentation that comes with Batch_Example and examine the Batch_Example database after restoring it in the Recipe Editor. To create a Strawberry Recipe, copy the Chocolate Operation make the appropriate changes to the Operation and Save it. You can then create a new Master Recipe using the same Operations but substituting the Strawberry Operation for the Chocolate Operation. 14 CitectSCADA Batch Version 1.1 Notes Some new features introduced in CitectSCADA Batch Version 1.1 will cause CitectSCADA Batch to behave differently than id described in the document. Fortunately the changes were made to improve usability so they should not cause any problems. 14.1 Password Configuration This feature is viewed by right clicking on the new Configuration branch, selecting Edit and click the Password Configuration tab.

127 This reveals a matrix to control the circumstances under which the Recipe Editor and Equipment Editor will request User ID and Password. For this Tutorial it can be seen that all such requests have been disabled. 14.2 Items Not Approved for Production In Version 1.1, items that are not Approved for Production are highlighted in red, making it easier to recognise items that need to be Approve for Production before they can be used (see next page).