Master recipe

One of the main functions of this control activity is to select a master recipe from the recipe management control activity, edit that recipe and transform it into a control recipe suitable for downloading to the equipment-related control activity, downloading the recipe (i.e., initiating the batch), and then to supervise the execution of the recipe. 

The terminology defined by NAMUR (compare [2]) has not been successful, for those readers that are familiar with this terminology we note that a master recipe is the same as a NAMUR base recipe and a process order is the same as a NAMUR control recipe. 

Fig. 12.4 Multipurpose batch chemical plant plant structure and master recipes.

A process order is a request asking production to produce a specific quantity of a material on a specific date. Creation of a process order uses a master recipe that is valid for the specific material and quantity as a template to determine the specific timing and component quantities (material flow). 

For the planning of a multipurpose plant one has to map the structure of a master recipe to the detailed device structure of the plant with regard to a given time in the future. This process can be done automatically, e.g., with the SAP ERP system where it is called convert. The result is a process order as a concretization of a master recipe. A process order tells the production operator at which time and on which device a given batch production step has to be executed. This simple conversion can result in a situation where a selected device is already allocated to a different process order at the given time, thus the production plan may not be feasible. 

All data objects contain an identification key and structured information. Materials and resources can be defined by relatively simple property tables. Master recipes require more complex structures to describe which resources have to be used at which time interval by which operation and with which operation parameters, and which materials are needed or produced at which point in time and in which quantity. 

Material transformations in connection with resource allocations (process orders, concretizations of master recipes with specific quantities, timing and allocation information). 

Changing Shelf Life of Products Reassigning Products Annual Product Review Maintain BOM Master Data Maintain Master Recipes... 

Fig. 1 Catalyst mass in the reactor with feeding shots based on the master recipe (second shot at 310 min, third shot at 460 min).

Fig. 2 Off-line calculated optimal temperature profile (dashed line) and corresponding level (continuous line) based on the master recipe catalvst feedintr nolicv tnominal easet...

There are four standard recipes. These are general recipe, site recipe, master recipe, and control recipe. The definitions of all these have already discussed in Clause 3.1.1. In this connection, also refer to Fig. VI/3.1.3-1 (see also ISA 88 Fig. 8). 

MASTER RECIPE Includes PROCESS CELL. SPECIFIC INFORMATION... 

Master recipe The master recipe, which is targeted to a process cell or a subset of the process cell equipment, can be derived from a general or site recipe. W ith the necessary process and product knowledge, it can be developed as stand-alone recipe also. Based on ISA 88 standard, some characteristics of master recipes include the following ... 

Multiple master recipes are possible when each is derived from a site recipe, to cover part of the recipe implementable in a process cell at the site. 

Sufficient adaptation of the properties of the process cell equipment to ensure the correct processing of the batch, by marrying the master recipe information with the functionality of the specific set of process cell equipment. 

The master recipe may contain product-specific information, for example, process input information or equipment requirements. 

The master recipe is essential, as without it, control recipes cannot be created, hence no batch processing. 

The master recipe exists either as a set of written instructions or as an electronic entity, irrespective of manual or automatic operation of batch manufacturing equipment. 

Equipment requirement Equipment requirements identify the equipment to be used to implement a specific part of the procedure. At the master recipe level, the equipment requirements are specified, as allowable equipment in process cells. Based on guidance from the general or site recipe, it is possible for the master recipe to identify the equipment of the train rather than the full range of equipment in the process cell, [ISA 88]. At the control recipe level, the equipment requirements are the same as, or a subset of, the allowable equipment in the master recipe. 

Master Recipes, which are the specific procedures that actually execute the recipe in a particular manufacturing area, known as a process cell. 

General and site recipes are non-equipment dependent and describe the technique of the process, or how to do it in principle, they may however, specify when known, data that may be required for the equipment, for example, pressure requirements. The general recipe is defined at the level of the enterprise, whilst the site recipe is specific to a particular site. Master and control recipes describe the task, i.e. how to do it with actual resources. The master recipe is the required recipe as without it no control recipe can be created and therefore no batches can be produced. 

The master recipe is more general than the control recipe. In the master recipe eqnipment clauses, for example, are stated and quantities are usually specified normalised. A master recipe can also be used for manufacturing a large number of batches. 

A control recipe is used for manufacturing a single batch only. The control recipe is made from a master recipe by adding batch-specific information. The control recipe is individual for every batch and includes scheduling and operational information specific to the batch. For example the equipment and the exact quantities of ingredients to be used. 

The general structure of a master recipe is illustrated in Table 2, using as an example Recipe 1. It was written omitting the general and site recipes, as is permitted by S88.01 when the recipe creator has the necessary process and product knowledge [10]. 

The master recipe is less specific than the control recipe. Although it is equipment-dependent with the resultant restrictions on the unit procedures, operations and phases, it does not specify the exact vessel that they will be executed in, but describes the equipment that is required in sufficient detail for the control recipe to allocate the resources. The control recipe starts as an exact copy of the master recipe, adding the allocated vessels for the unit procedures, operations and phases, which is required for the running of the batch. Batch specific information is also included, such as batch number and operating information. 

Fig. 13. Information flow across the process originated by the Master Recipe (Phase level).

The pilot plant has a Distributed Control System by ABB Automation, model Sattline. All the sensors and actuators are connected to the DCS. The DCS program has to be developed taking into account the integration architecture framework described in Section 5. Therefore it was necessary to describe the plant following the S88 terminology. Description of the Control Module (only reactor R1 is shown). Equipment Module (only reactor R1 is shown). Master Recipe (full recipe for the two products) and Control Recipes (only product PI and Equipment Eql is shown) are given next. 

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