S88 ISA Presentation

slide 1ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

ANSI/ISA S88.01 Batch Standard

Daren Moffatt

Solution Architect

Invensys Foxboro

Greg Skovira

President

EZSoft Inc.

(Výběr pro Počítačové řídicí systémy 2012)


Batch Process Example

MaterialStorage 1

MaterialStorage 2

MaterialStorage 3

Minor Additions

Mixer


Processing Overview

A Discrete Process produces finite quantities of discrete parts. Circuit boards, memory chips, floppy disk, disk drives,

computers, cars, car engines, dishwashers, etc... A Continuous Process produces a continuous

flow of free flowing product, usually a liquid or powder. Bulk chemicals, gasoline, kerosene, natural gas,

electricity, wood pulp, etc... A Batch Process produces a finite quantity of free

flowing product, usually a liquid or powder. Specialty chemicals, paints, pigments, personal care

products, food products, pharmaceuticals, etc.


Batch Process Example

MaterialStorage 1

MaterialStorage 2

MaterialStorage 3

Minor Additions

Packaging Line 1

Packaging Line 2

FeedTank 1

FeedTank 2

SprayDryer 1

SprayDryer 2

Mixer

BATCH

DISCRETE

CONTINUOUS


Batch Processing Characteristics

Number of Products Single product Multiple products

Physical Layout Single stream Multi-stream

MaterialStorage 1

MaterialStorage 2

MaterialStorage 3

StorageTank 2

Mixer 1

Reactor 1

Mixer 2

Reactor 2

StorageTank 3

StorageTank 1


Standards & Organizations

ISA S88 Committee S88.01 S88.00.02 S88.00.03

World Batch Forum BatchML B2MML

OPC for Batch

www.opcfoundation.org

www.wbf.org

www.isa.org


ISA 88.01/ IEC 61512-1

Terminology and models that apply to all types of control systems

A modular structure that promotes reuse A structure that applies to both automated

and manually-controlled batches Separates the recipe that describes how

the batch is to be made from the equipment used to make the batch


ANSI/ISA-88.01-1995 / IEC 61512-1

Standard covers four basic concepts:How to depict what you have in the plant

(physical model)How to define what you would like to

accomplish in the plant (recipe) Implementation of what you can do in the plant

(equipment logic)How to put the three pieces mentioned above

together in an intelligent, reusable and successful way


S88.01 Physical Hierarchy

Enterprise / Site / Area Process Cell

The entire collection of equipment needed to execute a single recipe from start to finish batch

Consists of one or more units Unit

Usually centered on a major piece of process equipment

Frequently operates on or contains the complete batch

May operate on or contain only a portion of the complete batch

Cannot operate on or contain more than one batch at a time

Control Module

Equipment Module

Unit

Process Cell



Equipment Module A collection of control modules or other

equipment modules Can carry out a finite number of minor

processing activities, i.e., phases Contains all the necessary processing

equipment to carry out these processing activities

Control Module A collection of sensors, actuators, other

control modules, and associated processing equipment

Acts as a single entity from a control standpoint

Is the direct connection to the process through its sensor and actuators

Procedures do not run on control modulesControl Module

Equipment Module

Unit

Process Cell


Batch Control Conceptual Example

“What”

Equipment

•Equipment=Process that we will sequence

Procedure

1. Do this2. Do that3. Do this and that

“How”

•Procedure=order in which we will sequence the process

Journal

12:05 This happened12:07 That happened12:10 This and that happened

“When”

•Batch Journal=Record of what happened to the process


Equipment Examples Illustration

Control Module ValvePumpMotorPressure Controller




TIC

Temperature Control

System consisting of:

1. Recycle pump2. Chilled water

valve3. Steam valve4. Temperature

Controller

Steam

ChilledWater

EquipmentModule(a set of ControlModules)




Unit(a set of Equipment Modules)

Reactorconsisting of:

1. Temperature control system

2. Agitation system

3. Material addition systems

4. Discharge system

5. Analysis system

TIC



GeneralRecipe

SiteRecipe

Recipe Management

The Recipe is the necessary set of information that uniquely defines the production requirements for a specific product

MasterRecipe

ControlRecipe

ProcessingInformation

Site-specificInformation

Process CellSpecific Info

BatchSpecific Info


General & Site Recipes

One General Recipe per produced material, maintained at the enterprise level(1000 company wide products)

One Site Recipe per site and produced material, maintained at the site for local materials, language, or segment of production(10,000 site recipes for 10 sites)

One Master Recipe per Process Cell and produced material(50,000 master recipes for 5 cells per site)

One Control Recipe per batch that describes the custom options and formula values for one specific batch of product(1,000,000 batches per year)


Recipe Information Categories

Recipe

EquipmentRequirements

HeaderOther

Information

FormulaProcedure

ProcessInputs

ProcessParameters

ProcessOutputs

Formula


S88.01 Procedure Hierarchy

Procedure (recipe level) The overall strategy for making

a batch Consists of an ordered

sequence of unit procedures

Unit Procedure The subset of a procedure that

occurs within a single unit Consists of an ordered

sequence of (one or more) operations

Phase

Operation

Unit Procedure

Procedure



Operation A sequence that causes a

significant physical or chemical change within the batch

Consists of an ordered sequence of (one or more) phases

Phase The smallest element of

procedural control, capable of causing one or more actions

Phase

Operation

Unit Procedure

Procedure


Typical Procedure using the Hierarchy

Note parent / child relationships as you move down and to the right in this procedure tree

Unit Procedure

Procedure

Unit Procedure

Operation

Operation

PhasePhase

Phase


Recipe procedure Examples Illustration

Procedure

Unit Procedure 1 Unit Procedure 2

Phase 1

Unit Operation 1 Unit Operation 4

Unit Operation 2 Unit Operation 3

Phase 2

Phase 3

Phase 4

Phase 5

Phase 6

Phase 7

Phase 8

Procedure Make Product A Make Product B

Unit Procedure Any set of Operations Unit Operation Filtration

Reaction Distillation Solution Preparation

Phase Agitate Heat Cool Transfer Charge Recycle



Recipe/Equipment Control Separation

Recipe UnitProcedure

Operation

Phase

ordered set of

Control RecipeProcedure

ordered set of

ordered set of

RecipeProcedure

EquipmentPhase

Recipe

Recipe

EquipmentControl

The only reference to the physical processing equipment occurs here



Typy řízení

základní řízení regulaceblokace nesprávné činnosti (interlocking)sledování překročení mezí reakce na alarmymanuální řízení

procedurální řízení koordinační řízení

řízení zdrojů zařízenívýběr procedurálních prvků pro běhpropagace režimů


Key Batch System Components

Supervisory Level

Recipe Maintenance/Editing

Batch Management

Data Acquisition

Event based

Time based

Reporting

Operator Interface

Real Time Control

Př.: Wonderware InBatch InTouch PLCs


The 10,000 Ft View

Planning (MRP II, Financials, etc.)

Process Control

Manufacturing Execution

InformationInformation

ControlControl

Inte

gra

tion

Inte

gra

tion

Business Logistics SystemsPlant Production Scheduling

and Operational Management

Manufacturing Control SystemsArea Supervision, Production

Scheduling, Reliability Assurance

BatchControlSystems

ContinuousControlSystems

DiscreteControlSystems

Level 4

Level 3

Levels2, 1, 0


Typical System Architecture


Typical System Architecture


The Model

PROCESS CELL

PH

AS

ECONTROLBUILDER - DESIGN M ODEL

Device

DE

VIC

E

Device Device Device Device

UNIT SEQUENCE UNIT SEQUENCE

Device Device

PHASE OPERATION PHASE OPERATION


PHASE OPERATION

Device Device

PHASE PHASE


PHASE

UNIT SEQUENCE UNIT SEQUENCE

Device Device

PHASE PHASE


PHASE

UN

ITL

INE

Example:-Valves, Motors,Sensors, etc.

Example:- Add W ater, Agitate,- Hand Addition, etc.

Example:- Run Batch on Tank 1- CIP Tank 2

Example:- Production Area 1

EZSoft Inc. , 1999-2003c

EZSoft & C ontro lBuilder are reg istered tradem arks of EZSoft, Inc.

®

Process level

Unit level control

Phase level control

Device level control


The 2,000 Ft View

From the Bottom Up












Equipment Module

Unit

Process Cell


M

DeviceControl

Typical Process Model - Device Level

MTR-001

007

MTR-002

MTR-003

XCV-005

XCV-006

XCV-004

008 009 010


Device Level Properties

Mode (Auto, Manual, Test…)

Commands (Start, Stop, Reset, …)

Status ( Running, Faulted…)

Interlocks and Permissives

(blokování a povolení)

Faults/Alarms

Messages


Device LevelDESIGN M ODEL

Device

DE

VIC

E

Device Device Device DeviceExample:-Valves, Motors,Sensors, etc.

EZSoft Inc., 1999-2004cEZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.












Equipment Module

Unit

Process Cell








Phase

Operation

Unit Procedure

Procedure


Mix

DischargeandRecirc

Material Charging-

Material Selection

M

FT

PumpDevice &

RegulatoryControl

FT

Typical Process Model - Phase Level

MTR-001

007

MTR-002

MTR-003

XCV-005

XCV-006

XCV-004

008 009 010

PhaseOperation


Phase Level Properties

Mode (Auto,Manual,…)


Status ( Running, Faulted, Paused…)


Faults/Alarms

Messages


S88.01 State Transition Diagram

State Transition Diagram for Example States for Procedural Elements

Restarting Holding

Running

Aborting Stopping

Pausing

Aborted

Complete

Stopped

Held

Paused

Restart

Hold

Pause

Resume

StopAbort

Reset

Reset

Reset

Start

Final States

Quiescent States

Transient States

Idle (Initial State)


Phase Level

PH

AS

E

DESIGN M ODEL

Device

DE

VIC

E


Device Device

PHASE PHASE


PHASE


Example:- Add W ater- Agitate- Hand Addition, etc.

EZSoft Inc., 1999-2004c

EZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.








Phase

Operation

Unit Procedure

Procedure


Mix

DischargeandRecirc

Material Charging-

Material Selection

M

FT

Pump

DeviceControl

FT

Typical Process Model - Unit Level

MTR-001

007

MTR-002

MTR-003

XCV-005

XCV-006

XCV-004

008 009 010

PhaseOperation

UnitSequence

TTPT


Unit Level

Mode (Auto, Manual, Test…)


Status ( Running, Faulted…)


Faults/Alarms

Messages


Unit Level

PH

AS

E

DESIGN M ODEL

Device

DE

VIC

E


UNIT OPERATION UNIT OPERATION

Device Device

PHASE PHASE


PHASE

Device Device

PHASE PHASE


PHASEUN

IT




EZSoft Inc., 1999-2004c

EZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.


Typical Procedure using the Hierarchy

Note parent / child relationships as you move down and to the right in this procedure tree

Unit Procedure

Procedure

Unit Procedure

Operation

Operation

PhasePhase

Phase


DeviceControl

Phase

UnitOperation

Process Cell

Typical Process Model - Line Level


Process Cell

LINE

PH

AS

E

DESIGN M ODEL

Device

DE

VIC

E



Device Device

PHASE PHASE


PHASE

Device Device

PHASE PHASE


PHASE


Device Device

PHASE PHASE


PHASE

UN

ITP

roce

ss C

ell




Example:- Production Area 1- Production Area 2

EZSoft Inc., 1999-2000cEZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.


Recipe/Equipment Control Separation

Recipe UnitProcedure

Operation

Phase

ordered set of

Control RecipeProcedure

ordered set of

ordered set of

RecipeProcedure

EquipmentPhase

Recipe

Recipe

EquipmentControl




S88.01 State Transition Diagram

State Transition Diagram for Example States for Procedural Elements

Restarting Holding

Running

Aborting Stopping

Pausing

Aborted

Complete

Stopped

Held

Paused

Restart

Hold

Pause

Resume

StopAbort

Reset

Reset

Reset

Start

Final States

Quiescent States

Transient States

Idle (Initial State)


Dávkový řídicí systém

The Control Activity Model – CACTUS model


CACTUS model

• Správa receptur• Plánování a rozvrhování výroby• Správa informací o výrobě• Správa procesů • Řízení jednotek• Řízení procesů


Other S88.01 Topics

Batch control activities and functions Allocation and arbitration Production planning and scheduling Production information management Process management Unit supervision Process control Personnel and environmental protection

Documents

S88 ISA Presentation