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    S88 Lecture Notes ISA S88

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    houstonmath
    S88 is a standard for batch control systems that defines common models, terminology, and principles. It describes manufacturing processes as either continuous, discrete, or batch. Batch processes involve running production in discrete quantities over medium cycle times by running the process in batches that have attributes of both continuous and discrete processes. S88 defines physical and procedural models to describe batch processes. The physical model defines the equipment hierarchy from the enterprise down to control modules. The procedural model defines the recipe and procedure hierarchy from general to control recipes and from procedures down to phases. S88 aims to provide modularity, standardization, and flexibility for batch control systems.

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    S88 Lecture Notes ISA S88

    Uploaded by

    houstonmath
    302 views20 pages
    S88 is a standard for batch control systems that defines common models, terminology, and principles. It describes manufacturing processes as either continuous, discrete, or batch. Batch processes involve running production in discrete quantities over medium cycle times by running the process in batches that have attributes of both continuous and discrete processes. S88 defines physical and procedural models to describe batch processes. The physical model defines the equipment hierarchy from the enterprise down to control modules. The procedural model defines the recipe and procedure hierarchy from general to control recipes and from procedures down to phases. S88 aims to provide modularity, standardization, and flexibility for batch control systems.

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    S88 Lecture Notes ISA S88

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    S88 is a standard for batch control systems that defines common models, terminology, and principles. It describes manufacturing processes as either continuous, discrete, or batch. Batch processes involve running production in discrete quantities over medium cycle times by running the process in batches that have attributes of both continuous and discrete processes. S88 defines physical and procedural models to describe batch processes. The physical model defines the equipment hierarchy from the enterprise down to control modules. The procedural model defines the recipe and procedure hierarchy from general to control recipes and from procedures down to phases. S88 aims to provide modularity, standardization, and flexibility for batch control systems.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    302 views20 pages

    S88 Lecture Notes ISA S88

    Uploaded by

    houstonmath
    S88 is a standard for batch control systems that defines common models, terminology, and principles. It describes manufacturing processes as either continuous, discrete, or batch. Batch processes involve running production in discrete quantities over medium cycle times by running the process in batches that have attributes of both continuous and discrete processes. S88 defines physical and procedural models to describe batch processes. The physical model defines the equipment hierarchy from the enterprise down to control modules. The procedural model defines the recipe and procedure hierarchy from general to control recipes and from procedures down to phases. S88 aims to provide modularity, standardization, and flexibility for batch control systems.

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    S88 Batch Standard

    An esoteric standard, used as a formal communications tool for batch control.


    Manufacturing Operations

    Continuous
    Discrete
    Batch

    Continuous
    Make stuff
    Long cycle time
    Process rarely shut-down
    Few procedural changes
    Example: crude oil refining
    Discrete
    Make things
    Short cycle time
    Process up and down at will
    Lot size of one
    Example: automotive parts, gears, etc
    Batch
    Make discrete quantities of stuff
    Medium cycle time
    Process runs in batches
    Mixes attributes of continuous and discrete
    Example: Pharmaceuticals, food processing, chemical processing
    S88 is a way of thinking of Batch Control, not the hardware, rather a set of terms and
    philosophy.
    Why a standard? To address control problems with batch control:
    No Universal model for batch control
    Difficulty in communicating terms, Example tune
    Difficulty integrating different manufactures
    Batch Control Configurations too difficult
    ISA SP88 Committee
    The First Standard: (American National Standards Institute) ANSI / ISA S88.01-1995
    Identified Common Models and Terminology for Batch Control Systems
    Introduced Concept of Modular Batch Automation (MBA)
    Isolates equipment from recipes
    Track historical data
    Recovery from abnormal events
    Gather requirements
    Provides modularity
    Facilitate validation

    Entity-Relationship Diagrams, describing objects in a system and how they


    interact:

    A has one and only one occurrence of B

    A has zero or one occurrence of B

    A has one or more occurrences of B

    A has zero, one or more occurrences of B

    consists of an
    ordered set of

    Associations: with descriptive labels; A consists of an ordered set of B

    Sequential Function Charts (SFC)


    SFC is a programming language or nomenclature and documentation to represent
    executable procedures. Also called Flowcharting

    Double box is the initial step horizontal line shows transition, with description. Terminator
    is the ground symbol.

    Note: In flow charting, the diamond is generally used as a decision point, yet I
    have not seen it used in any document describing S88.

    Divergence

    When A is complete, select either the path to B or C.

    Convergence

    When A is complete, select either the path to B or C, then execute D.

    Skipping steps: When A is complete, select either the path to B or C, or skip to execute D.

    TRUE

    B complete and C
    complete

    Agitate

    Agitate will stop when B


    and C complete even
    though agitation
    completion is not part of
    the compound transition.

    Simultaneous Convergence

    Mix Making Example


    Tank and Valve diagram; Use a Process flow diagram, make several copies of each
    drawing and highlight the product flow. Very useful for complicated batch processes

    The Physical and the Procedural Models

    Modular Manufacturing

    PHYSICAL MODEL
    Top-Down

    PROCEDURAL MODEL
    Bottom-Up

    PROCESS

    PROCEDURES

    UNITS

    UNIT PROCEDURES

    EQUIPMENT MODULES

    CONTROL MODULES

    OPERATIONS

    PHASES

    How to make the product? (Recipe)


    What is the physical equipment to make the product?
    How the process is run (Control activities)
    S88 defines several Models that describe the equipment and how it operates
    Major division between Physical Model and the Procedural Model

    The Physical Model

    S88.01 says:
    All control related sections of the standard assume that the process cell in question
    (both physical equipment and related control activities) has been subdivided into well
    defined equipment entities such as units, equipment modules, and control modules.
    Effective subdivision of the process cell into well defined equipment entities is a
    complex activity, highly dependent on the individual requirements of the specific
    environment in which the batch process exists. Inconsistent or inappropriate
    equipment subdivisions can compromise the effectiveness of the modular approach to
    recipes suggested by this standard.
    Subdivision of the process cell requires a clear understanding of the purpose of the
    process cells equipment. Such understanding allows the identification of equipment
    entities that must work together to serve an identifiable processing purpose

    Enterprise

    Site

    Area

    Polymerization
    Train

    Process Cell

    Unit

    Reactor
    Unit

    Equipment
    Module
    Control
    Module

    Nitrogen Header
    EM
    Steam Valve Cooling Water Temperature
    CM
    CM
    CM

    The Physical Model

    Bleed Valve
    CM

    XFER Pump
    CM

    A Process Cell defines the span of logical control of one set of process
    equipment within an area that can be used to manufacture batch product
    The domain for a batch control system is the Process Cell
    Sometimes a cell is called a train
    A Unit
    May contain a flexible amount of equipment, equipment modules and
    control modules
    Operates on all or part of the batch
    Only one batch at a time
    Cannot acquire another unit
    May operate independent of other units.
    An Equipment Module
    Consists of equipment, control modules and other equipment modules
    Contain all equipment and control functions necessary to perform its
    process function
    Usually centered around a fixed piece of equipment, for example, Heat
    Exchanger, Weigh Tank, Agitator
    The scope of the equipment module is defined by the finite processing
    activity it is designed to carry out.
    May be part of a Process Cell, Unit, or another Equipment Module.
    A Control Module
    Control modules provide the interface to basic control
    Basic control may include regulatory control, or sequential control.
    Sequential control may involve state based control and exception
    monitoring/handling
    May be part of a Process Cell, Unit, Equipment Module, or another Control
    Module

    Process Cell Class:

    Unit Class:

    VORLAGE

    PRODUKTION

    A150

    Phase Class:

    KOFFEIN

    A200

    V10

    V11

    ZUSAETZE_V11
    ZUCKER_V11
    R20

    WASSER_V

    Area: PRODUCTION

    T60

    T70

    KOFFEIN_V11

    R21

    T80

    RUEHREN_V11

    T90

    Process Cell: A200

    ABLASSEN_V11

    Unit: V11

    In this diagram, the cell is the production train, within the cell are the process units.
    Units are not necessarily chemical unit operations, S88 unit may run many different
    chemical unit operations, Example: Reaction and crystallize within the same vessel.

    The Procedural Model


    Make
    Product A

    Procedure

    Unit
    Procedure

    Reactor
    Make A

    React

    Operation

    Phase

    Load 1

    Mix

    Heat

    XFER_OUT

    Based on the concept of a Recipe

    General
    Recipe

    Product specific processing


    information

    Site
    Recipe

    Site specific
    information

    Master
    Recipe

    Process Cell
    specific information

    Control
    Recipe

    Batch ID, batch size, inprocess, operator, and/or


    system generated
    information

    XFER_IN

    General Recipe Corporate planning investment decisions, Research, Intellectual


    Property
    Site Recipe In local language derived from the general recipe.
    Master Recipe Targeted to a specific cell. Engineering related, specific agitation,
    metering details, control requirements
    Control Recipe Used to create a specific batch, has Batch ID, operator and other
    information unique to that specific batch.
    Example: You can track, through the Lot number on a pill bottle, where and when it was
    made, all the details about manufacturing, operators on duty etc. All the things that
    make the FDA great.

    Recipe Contents
    Header
    Equipment Requirements
    Procedure
    Formula
    Other Information

    Administration information and process summary


    Information about specific hardware to make the batch
    Defines the strategy for carrying out a process
    Recipe formula, chemicals, process parameters and inputs
    MSDS (Material Safety Data Sheets), Regulatory, FDA GMP
    etc.

    Recipe Procedures defined by two models, Process Model and Procedural Control Model
    Procedural Model

    Make
    Product A

    Procedure

    Unit
    Procedure

    Reactor
    Make A

    React

    Operation

    Load 1

    Phase

    WAHR

    ANSATZ:1

    ANSATZ:1.STATUS = FERTIG

    REAKTION:1

    REAKTION:1.STATUS = FERTIG

    Mix

    Heat

    XFER_OUT

    WAHR

    DOSIEREN:1

    WAHR

    RUEHREN:1

    DOSIEREN:1.STATUS = FERTIG

    ABLASSEN:1

    ZUCKER:1.STATUS = FERTIG

    KOFFEIN:1

    ABLASSEN:1.STATUS = FERTIG

    KOFFEIN:1.STATUS = FERTIG

    ZUSAETZE:1

    ZUSAETZE:1.STATUS = FERTIG

    Procedure:
    PRODUCT A

    Unit Procedure:
    Make Mix

    XFER_IN

    Operation:
    DOSING

    Procedural Control Recipes are grouped as shown above. The Phase not shown
    A phase is the smallest element of control. Usually executed in a PLC or DCS.
    A phase can operate one or more pieces of equipment.

    When
    combined
    with a
    Procedure

    Produces a
    Process Cell

    Unit
    Procedure

    Operation

    Process

    Process Stage

    Unit

    Process Operation

    Phase
    Process Action
    Phase

    Procedural

    Equipment Module

    Physical

    Linking the Physical, Procedural Control and Process Models

    Process

    Modes of Operation
    The manner in which the transitions of sequential functions are carried out within a
    procedural element or the accessibility for manipulating the states of equipment manually
    or by other types of control.

    States and Commands


    A State completely specifies the current condition of a procedural element or equipment
    entity.
    A Command is a method of moving a procedural element or equipment entity from one
    state to another.

    The present participle form, ___ing, is usually a separate block of code in a phase.
    The execution of this code is transitory. Completing this state results in placing the
    system in a quiescent or final state. Note that running is considered transitory.

    General Comments, Experience


    When designing these systems, the database or noun, the Physical Model description is the
    most important. It is usually easier to change some phase logic than it is to add or delete a
    Control or Equipment module. This is very important when a compiled language is used for
    generating the code.
    Americans tend to emphasize the verbs and not the nouns. Example: German is very noun
    orientated language. This results in descriptive verse that appears foreign to Americans. I
    have found that translation of operating instructions makes control definition more difficult.
    S88, by design, separates the equipment from the recipe, assumes a pots and pan approach.
    Example: Very few cookbooks describe in detail the exact design of a pot or pan. S88 defines
    equipment in a generic form. For many processes, this will not completely describe the whole
    process. In many industries, the processing equipment design is integral and unique to the
    process i.e. it cannot be made any other way. Example Electronic grade silicon makes use of
    very specialized machines and equipment. Design of this equipment is considered intellectual
    property to the company. S88 can be used to describe the batch control description, but it is
    not complete enough to describe the whole process.

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