Automatic Adaptation of Batch Logic to Changing Levels of Field Automation

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As batch processes are automated, it is common to leave certain less essential field devices without automatic actuators. Thus, the initial control design must accommodate both automated and manual activities. Later, the manual field devices may be automated, either one-at-a-time or in related groups as equipment modules. These field changes, often occurring over a period of years, each require rework of the batch control logic, which can easily exceed the cost of the actuator. In response to this undesirable situation, a technique has been developed which permits the batch design to automatically modify itself, or evolve, to accommodate changes in field automation. This approach yields significant benefits: • Initial design treats all field devices as if they are automated, • Recipe includes logic for both automatic and manual devices, • Batch Journal logs manual device actions, • Field devices may be automated over any time period, • Virtually zero modification time for batch logic, • No redesign, patches, or work-around, • No dead code or wasted engineering. This paper describes the problem, illustrates a practical solution, and explores the resulting benefits.