Overview of the ANSIISA S88'01 Batch Control Standard

1
Overview of the ANSI/ISA S88.01 Batch Control
Standard
2
Clarification

• SP88 is the ISA committee responsible for
  developing the batch control standard
• S88 is the standard developed by such a committee

3
History of SP88

• Established by ISA in October 1988 to address the
  following needs of industry
• No universal model for batch control systems
• Difficult for users to communicate batch control
  requirements
• Batch control is difficult to configure
• Integration of different vendors equipment is
  difficult

4
Clarification

• The 88 number was assigned not due to the year
  that the committee was established but rather
  sequentially (next number available for an ISA
  standard)

5
History of SP88

• Purpose
• To provide standards and recommended practices
  for the design and specification of batch control
  systems

6
History of SP88

• Scope
• To define terminology that will encourage
  understanding between manufacturers and users
• To provide a standard batch control language
• To provide a standard data structure for
  communications within the system architecture
• To determine a standard batch control
  architecture that defines both physical and
  functional models

7
History of SP88

• In 1990 it was internationalized after a petition
  to IEC was accepted - Working Group 11 (WG11) of
  subcommittee 65A was formed

8
History of S88

• Early on, the standard was split in two parts
• Part 1 (S88.01) covering
• Models
• Terminology
• Part 2 covering
• Data Model and Exchange Formats
• Language Guidelines for Data Exchange and
  Procedural Control

9
History of S88

• The draft of S88.01 was submitted to ISA and IEC
  for balloting for adoption as a standard on the
  spring of 1994
• ISA ballots were completed in October 1994. ISA
  approved the standard in early 1995
• The standard was published as an ANSI standard in
  the summer of 1995

10
History of S88

• IEC ballots were not completed until December
  1995 - IEC requested extensive editorial changes
  to make the standard look more like a
  specification
• After negotiation and meetings in Europe, IEC
  approved a reworded version of the standard on
  April 18, 1996

11
The Future of S88

• Part two
• Work began in December 1994
• Publication of a draft is expected in early 1997
• An object based model is being used
• Endorsing organizations have been formed
• Europe Batch Forum
• World Batch Forum
• Japan Batch Forum

12
The ANSI/ISA S88.01 Standard
13
Characteristics of S88.01

• Universal terminology and models - applicable to
  all types of control systems
• Modular structure - breaks up complex concepts
  into smaller elements promotes reusability
• Non-excluding/binding - not suggesting that there
  is only one way to do batch control nor to force
  users to abandon current methods

14
Characteristics of S88.01

• Collapsible model - elements which are not
  applicable to particular users needs can be
  omitted (except for unit, master recipe and
  control recipe entities)
• Expandable model - elements may be added to meet
  specific needs (as long as the integrity of the
  original relationship is maintained)

15
Usability of S88.01

• Not a cookbook for designing batch control
  systems - Provides a framework still requires
  experienced control systems engineers
• Great for Functional Specifications - Models and
  terminology can be used to define requirements
  for batch control

16
Main Sections of S88.01

• Section 3 Definitions - provides dictionary of
  terms used in the standard
• Section 4 Batch process and equipment - provides
  overview of batch processes and batch
  manufacturing plants
• Section 5 Batch control concepts - discusses
  control concepts to address batch
  processing/manufacturing

17
Main Sections of S88.01

• Section 6 Batch control activities and functions
  - discusses control activities and functions
  associated with batch processing/manufacturing

18
Definitions

• Batch
• The material that is being produced or that has
  been produced by a single execution of a batch
  process
• An entity that represents the production of a
  material at any point in the process

19
Definitions

• Batch Process
• A process that leads to the production of finite
  quantities of material by subjecting quantities
  of input materials to an ordered set of
  processing activities over a finite period of
  time using one or more pieces of equipment

20
Batch Processes and Equipment
Process Model (Entity - Relationship Diagram)
A sequence of chemical, physical, or biological
activities for the conversion, transport, or
storage of material or energy
Process
A part of a process that usually
operates independently from other process stages
and that usually results in a planned sequence
of chemical and physical changes in the
material being processed
consists of an ordered set of
A major processing activity that usually results
in a chemical or physical change in the material
being processed and that is defined without
consideration of the actual target equipment
configuration
Process Operation
Minor processing activities that are combined
to make a process operation
21
Batch Processes and Equipment
Process Model (Entity - Relationship Diagram)
Example Polymerization of vinyl chloride
monomer
Process
Example Polymerize Recover Dry
consists of an ordered set of
Example (Polymerize stage) Prepare
reactor Charge React
Process Operation
Example (React operation) Add monomer Add
catalyst Heat to 55-60 deg C Hold at 55-60 deg
C until press. decreases
22
Batch Processes and Equipment
Physical Model (Entity - Relationship Diagram of
upper levels)
Enterprise
An organization that coordinates the operation of
one or more sites
may contain
A component of a batch manufacturing
enterprise that is identified by physical,
geographical, or logical segmentation within the
enterprise
Site
may contain
A component of a batch manufacturing site that
is identified by physical, geographical, or
logical segmentation within the site
Area
may contain
A logical grouping of equipment that includes
the equipment required for the production of one
or more batches
Process Cell
23
Batch Processes and Equipment
Physical Model (Entity - Relationship Diagram of
lower levels)
Process Cell
must contain
A collection of associated control modules
and/or equipment modules and other process
equipment in which one or more major processing
activities can be conducted. Examples Kettles,
Reactors, Fermenters, Crystallyzers, etc.
Unit
may contain
A functional group of equipment that can carry
a finite number of specific minor processing
activities. Examples Reactor Jacket System,
Material Charge Equipment, etc.
Equipment Module
may contain
The lowest level of grouping of equipment in
the physical model that can carry out basic
control. Examples Regulatory Control Loops,
Discrete Device Loops, etc.
Control Module
may contain
24
Batch Processes and Equipment
Physical Model (Entity - Relationship Diagram)
Process Cell
must contain
Unit
may contain
Equipment Module
may contain
Control Module
may contain
25
Batch Processes and Equipment
Physical Model (Entity - Relationship Diagram)
Process Cell
Reactor B
must contain
Unit
may contain
Equipment Module
may contain
Control Module
may contain
26
Equipment Module or Control Module?
Material Charge Module
Can be either depending on implementation
- If separate basic control functions are used
for the valve, totalizer, and discrete/sequential
control, it could be construed as an Equipment
Module (i.e. multiple control modules carry out
a minor processing activity - charging)
- If FQIC is a regulatory control function block
which controls the valve based on target and
totalized values, it could be construed as a
Control Module (i.e. single entity performing
basic control)
27
Three types of control

• Basic control
• Control that is dedicated to establishing and
  maintaining a specific state of equipment or
  process condition
• May include regulatory control, interlocking,
  monitoring, exception handling, and discrete or
  sequential control

28
Three types of control

• Procedural control
• Control that directs equipment-oriented actions
  to take place in an ordered sequence in order to
  carry out some process-oriented task

29
Three types of control

• Coordination control
• Control that directs, initiates, and/or modifies
  the execution of procedural control and the
  utilization of equipment entities
• Includes allocation (obtaining resources) and
  arbitration (which requester is granted the
  resources)

30
Batch Control Concepts
Procedural Control Model (Entity - Relationship
Diagram)
The strategy for carrying out a process. In the
context of S88, it refers to the strategy for
making a batch in a process cell.
Procedure
consists of an ordered set of
A strategy for carrying out a contiguous
process within a unit. It consists of the
contiguous operations and the algorithm necessary
for the initiation, organization, and control of
those operations.
Unit Procedure
consists of an ordered set of
Operation
A procedural element defining an
independent processing activity consisting of the
algorithm for initiation, organization, and
control of phases
consists of an ordered set of
Phase
The lowest level of procedural element in
the procedural control model
31
Model mapping
Process Model
Physical Model
Procedural Control Model
Process
Process Cell(s)
Procedure(s)
combined with a
Process Stage
Unit(s)
Unit Procedure(s)
combined with a
Process Operation
Unit(s)
Operation(s)
combined with a
Process Action
Unit(s)
Phase(s)
combined with a
Process Action
Equipment Module(s)
Phase(s)
32
Batch Control Concepts
Procedure
33
Batch Control Concepts
Unit Procedure
34
Batch Control Concepts
React
Operation
Catalyst
35
Definitions

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

36
Recipe contents

• Header
• Information about the purpose, source and version
  of the recipe such as recipe and product IDs,
  creator and issue date
• Equipment Requirements
• e.g. allowable materials of construction,
  processing characteristics, selected train,
  specific units, etc.

37
Recipe contents

• Formula
• Process inputs, process parameters, and the
  resulting process outputs
• What, how much, for how long?
• Recipe procedure
• The strategy for producing a batch
• What and when (in what order)?

38
Batch Control Concepts
Recipe Types (Entity - Relationship Diagram)
General Recipe
may be transformed into
Site Recipe
may be transformed into
Master Recipe
is the basis for
Control Recipe
39
Recipe Procedures (Entity - Relationship Diagr.)
40
Batch Control Concepts

• The control recipe does not contain sufficient
  information to operate the process cell by itself
  - it must be linked to equipment control
• Equipment control
• Equipment-specific functionality that provides
  the actual control capability for an equipment
  entity, including procedural, basic, and
  coordination control, and that is not part of the
  recipe

41
Batch Control Concepts
Procedure
consists of an ordered set of
Control Recipe must be linked to Equipment
control at some procedural element level (e.g.
Phase)
Unit Procedure
consists of an ordered set of
Operation
consists of an ordered set of
Phase
42
Batch Control Concepts
Equipment Phase
Equipment Module
Monomer
Reactor A
43
Recipe Phase vs. Equipment Phase
Raw Materials Header
A
B
C
44
Definitions

• State
• The condition of an equipment entity or
  procedural element at any given time
• Mode
• The manner in which the transition of sequential
  functions are carried out within a procedural
  element or the accessibility for manipulating the
  states of equipment entities manually or by other
  types of control

45
Modes and States

• S88.01 only provides definitions and examples for
  modes and states
• Mode and state propagation is up to the users and
  thus not specified by S88.01

46
States example included in S88.01
Restart
Holding
Restarting
Reset
Hold
Start
Idle
Pause
Pausing
Running
(Initial

State)
Abort
Resume
Stop
Stopping
Aborting
Final States
Quiescent States
Reset
Transient States
Reset
47
Modes example included in S88.01
48
Definitions

• Batch control
• Control activities and control functions that
  provide a means to process finite quantities of
  input materials by subjecting them to an ordered
  set of processing activities over a finite period
  of time using one or more pieces of equipment

49
Batch Control Activities and Functions
Production Planning and Scheduling
Production Information Management
Recipe Management
Process Management
Unit Supervision
Control Activity Model (Context Diagram)
Process Control
Outside the scope of SP88
Personnel and Environmental Protection
50
Production Planning and Scheduling

• Develop Batch Schedules
• Based on source information and a scheduling
  algorithm
• Using resource availability as input
• Taking into account target equipment capacities
• With a method for batch sizing and organizing

51
Production Planning and Scheduling

• Develop Batch Schedules
• Allowing revisions on demand based on significant
  changed in batch progress and cell status
• Allowing manual intervention

52
Production Information Management

• Manage Batch History
• Receive and store batch history information
• Manipulate historical data
• Produce reports

53
Production Information Management

• Sample Batch Information Recorded
• Batch IDs
• Timing (start and end of all procedural elements)
• Equipment utilized
• Control recipe utilized
• Actual process values (measured and manual)
• Events and alarms (time stamped)

54
Production Information Management

• Sample Batch Information Recorded
• Calculated parameters
• Laboratory data
• Operator interventions
• Operator IDs
• Operator comments
• Trends of selected process variables

55
Batch Control Activities and Functions
56
Recipe Management

• Manage General Recipes
• Selecting and combining procedural elements to
  create general recipe
• Incorporating formula information
• Specifying equipment requirements
• Maintaining the general recipe
• Managing changes to general recipes

57
Recipe Management

• Define General Recipe Procedural Elements
• Naming individual procedural elements
• Specifying parameter variables
• Describing intended process functionality
• Combining lower level elements and specifying a
  sequence for execution
• Creating, modifying and archiving procedural
  elements

58
Recipe Management

• Define General Recipe Procedural Elements
• Maintaining inventory of procedural elements
• Managing changes to procedural elements
• Manage Site Recipes
• Same functions as managing general recipes
  combined with site specific information

59
Recipe Management

• Manage Master Recipes
• Selecting and combining procedural elements to
  create master recipe
• Incorporating formula information
• Specifying equipment requirements
• Creating, modifying and archiving master recipes
  and maintaining recipe headers
• Maintaining inventory of master recipes
• Managing changes to master recipes

60
Recipe Management

• Define Master Recipe Procedural Elements
• Naming individual procedural elements
• Specifying parameter variables
• Describing intended process functionality
• Combining lower level elements and specifying a
  sequence for execution
• Creating, modifying and archiving procedural
  elements

61
Recipe Management

• Define Master Recipe Procedural Elements
• Maintaining inventory of procedural elements
• Managing changes to procedural elements

62
Batch Control Activities and Functions
Production Planning and Scheduling
Production Information Management
Recipe Management
Batch Scheduling Information
Batch Progress and Process Cell Status Information
Batch and Process Cell Information
Master Recipe
Batch and Resource Information
Manage Process Cell Resources
Process Cell Information
Collect Batch and Process Cell Information

Manage Batches
Batch Information
Commands and Status Information
Unit Recipes, Commands, and Batch and Status
Information
Unit Supervision
Process Management (Data Flow Diagram)
63
Process Management

• Scope is the Process Cell
• Manage Batches
• Creating control recipe from master recipe,
  schedule and operator input
• Assigning unique batch ID
• Verifying control recipe as it is created
• Sizing control recipe to meet batch quantity
  needed
• Distributing unit recipes in a timely manner

64
Process Management

• Manage Batches
• Maintaining current control recipes until batches
  are completed
• Assigning start batch conditions (as soon as unit
  available, based on operator, etc.)
• Modifying control recipe as needed to handle
  processing exceptions
• Requesting and releasing units and other equipment

65
Process Management

• Manage Batches
• Monitoring and controlling the execution of
  control recipes
• Processing state and mode change requests
• Allowing temporary suspension of batches
  including subsequent re-introduction into the
  Process Cell
• Maintaining batch status information
• Updating information on batches

66
Process Management

• Manage Process Cell Resources
• Obtain scheduling information
• Allocate and reserve equipment
• Arbitrating multiple requests for equipment
• Receiving status information from Unit
  Supervision and Process Control
• Updating batch progress information to scheduling

67
Process Management

• Manage Process Cell Resources
• Updating resource information
• Managing unallocated equipment
• Collect Batch and Process Cell Information
• Mode and state changes
• Copies of control recipes
• Time that unit recipes were distributed
• Operator intervention

68
Process Management

• Collect Batch and Process Cell Information
• Time of commands sent to Unit Supervision and
  Process Control
• Delays due to lack of equipment availability
• Time of allocation, reservation and release of
  resources
• Requests and results for equipment allocation and
  reservation
• Status changes in unallocated equipment

69
Batch Control Activities and Functions
Production Information Management
Process Management
Unit Recipes, Commands and Status Information
Batch and Unit Information
Manage Unit Resources
Batch and Resource Information
Unit Information

Acquire and Execute Procedural Control Elements
Collect Batch and Unit Information
Batch Information
Commands and Status Information
Commands and Status Information
Process Control
Unit Supervision (Data Flow Diagram)
70
Unit Supervision

• Scope is the Unit
• Acquire and Execute Procedural Elements
• Determining which procedural elements are to be
  executed
• Verifying that procedural elements exist
• Executing unit procedures, operations, and phases

71
Unit Supervision

• Acquire and Execute Procedural Elements
• Associating recipe procedural elements with
  equipment procedural elements
• Initiating and parameterizing equipment phases
• Manage Unit Resources
• Interfacing with arbitration functions
• Ensuring propagation of unit and procedural
  element modes and states

72
Unit Supervision

• Manage Unit Resources
• Enabling collection of batch relevant production
  information from external equipment
• Collect batch and unit information
• Mode and state changes
• Timing of commands to Process Control
• Timing of execution of unit recipe procedure
  events

73
Unit Supervision

• Collect batch and unit information
• Timing and sequence of allocation, reservation,
  and release of equipment entities
• Equipment status changes
• Values derived during execution of the unit recipe

74
Batch Control Activities and Functions
Production Information Management
Commands and Status Information
Commands and Status Information
Data

Execute Equipment Phases
Collect Data
Data
Data
Commands and Status Information
Commands and Status Information
Commands and Status Information
Process Control (Data Flow Diagram)
75
Process Control

• Scope is the Unit, Equipment Module, and Control
  Module
• Execute Equipment Phases
• Executing phases as directed by Unit Supervision
• Propagating modes and states between procedural
  elements, equipment entities, and units
• Handling manual intervention into the execution
  of equipment phases

76
Process Control

• Execute Basic Control
• Executing control functions (regulatory,
  interlocks, sequential, etc.)
• Propagating of modes and states between any
  equipment entities and/or procedural elements
• Handling manual intervention into basic control
• Collect data
• From sensors, derived values, and events within
  the domain of Process Control