Abstract: A process control system includes a controller that executes a control routine which performs a series of unit procedures within a process. The control routine is written or created to specify the class of unit to be used for each unit procedure, but not the actual unit itself. At the start of each unit procedure of the control routine, a dynamic unit selection routine selects a particular unit as the unit to be used during operation of that unit procedure. When called, the dynamic unit selection routine determines a set of possible units to be used, determines if each of the set of possible units is suitable for use during that unit procedure of the control routine based on a suitability criterion, prioritizes the units that meet the suitability criterion based on a priority criterion and selects the particular unit from the prioritized list of suitable units in order of priority.

Abstract: A hierarchical failure management technique uses an integrated equipment hierarchy to automatically pass failure information from control modules to unit modules. Each control module collects failure information and generates a composite failure code by mathematically combining the failure information collected by that module. Modules which are currently needed by a phase of the unit module to carry out a process automatically send respective failure codes to the unit module. The unit module selects the worst failure code from a list of failure codes within the unit module and compares the selected worst failure code to a predetermined threshold value to determine whether the process should continue.

Abstract: A generic process control routine for a process control system is written to include alias names and dynamic reference parameters. Before execution of a process control function on a particular unit of the process control system, an instance of the generic routine is created, in which the alias names are replaced by parameters defined in an alias resolution table for the particular unit. The controller then executes the instantiated version of the generic routine to control operation of the unit. The generic routine can have multiple algorithms associated therewith, wherein each of the algorithms is designed to control different units having somewhat different hardware, even though these different units perform essentially the same function within the process control system. The generic routine may also be used with multiple classes of hardware that perform different functions within the process control system.

Abstract: Methods and apparatus for batch process control in which a Phase Logic Module operable in accordance with the state machine model of the batch server program is embedded within a programmable controller. More specifically, a phase executed by the batch server program in a data processing device is operable in accordance with a pre-defined state machine model (typically compliant with the ISA S88.01 standard). A Phase Logic Module (PLM) is implemented within a programmable controller in accordance with the same state machine model so as to mirror the state machine operation of the batch server process within the programmable controller. The PLM is pre-implemented and standardized. Specific state logic for performing desired control in accordance with the desired batch processing is defined by a control engineer using well known languages and tools and integrated with the standard PLM state machine.