Batch Control Using the ANSI/ISAANSI/ISA-88 -88 Standard Dennis Brandl BR&L Consulting
What is ISA/S88 ? • An IS ISA A (Th (The e Inte Intern rnat atio iona nall Soc Socie iety ty of Me Meas asur urem emen entt and and Control) standard S88.01 “Batch Control Models and Terminology” • Also IEC 61512-01 standard • SP88 SP88 is th the e com commi mitt ttee ee char charge ged d wit with h dev devel elop opin ing g the the S88 S88 • IE IEC C 65A 65A-W -WG1 G11 1 is th the e IEC IEC over oversi sigh ghtt com commi mitt ttee ee
S88.01 Batch Control • S88. S88.01 01 is no nott abo about ut the the BATC BATCH H Ind Indus ustr trie ies! s! ►
It applies in discrete, continuous, and batch industries
• S88. S88.01 01 is a mo mode dell a and nd me meth thod odol olog ogy y for for designing & operating control systems for Independent of the underlying control system (PLC, DCS, or PC) ► Independent of the underlying basic control algorithms ►
Where S88 Applies • Flexible manufacturing (including batch) • Multiple products manufactured using the same set of equipment • Output is a finite quantity of materials • Built using a defined order of processing actions
Input Materials Storage
Unit 4
Unit 6
Finished Materials Storage
What S88 Does Not Address • Can be applied to, but does not specifically address: ► ►
Discrete parts manufacturing Continuous processing
• But, the concepts and terms have been effectively used is these areas ►
Continuous • tartup - s ut own • Grade change
►
Discrete • Setup - Tear down • Product Change
Benefits of S88.01 • Reduce cost of automating systems • Reduced life cycle engineering effort Reduced time to market ► Improved flexibility rocess ualit ► Im roved ►
• Rapid batch recipe development • Applied today around the world, with proven and identifiable benefits
Three Models • Equipment Model ►
How to effectively organize equipment for flexible manufacturing.
• Procedural & Process Model ►
How to effectively organize process and production rules for flexible manufacturing.
• Activity Model ►
How to effectively organize manual and automatic activities for flexible manufacturing.
Three Models Activity Model Defines all the activities involved in Batch Automation
Equipment Model Defines the equipment capability available to manufacture a product
Executes against
Recipe Model Defines the information required to manufacture a product
Part 1: Recipes and Equipment • Key S88 Concept: • Separate: ► ►
Product Knowledge - kept in Recipes from Equipment Capabilities
• S88.01 goal ►
►
Allow recipe development without the services of a control systems engineer 'No control system programming' required
• Result ►
Same equipment - multiple products
Definition - Recipe • Recipes The necessary set of information that uniquely defines the production requirements of a specific product ► The recipe tells the batch control system how to make the product ► A recipe usually exists for each final product to be produced ► Recipes may exist for different sets of raw materials that can be used to make the same product ►
Recipes and Equipment Recipe Defines the information required to manufacture a product
Runs Against Equipment
Equipment Provides Process Capabilities for Defines the equipment capability
available to manufacture a product
Recipe - Equipment Separation • S88.01 explains the concept that separates the recipe, that describes how a batch is to be made, from the equipment that is actually used to make the batch ►
►
► ► ►
Improves the ability to transport a recipe from one system to another Makes recipes more flexible and reusable Makes equipment control more flexible and reusable Lower first cost Improved long-term maintainability
Recipe vs Equipment • Recipes reference basic equipment capabilities ►
Independent of how the capabilities are actually implemented Recipe Phases
Equipment Phases Add
Agitate
Add Heat
Cool
Heat Cool
Agitate
“Equipment” Includes Manual and Automated Phases • Recipes are independent of how the capabilities are actually implemented Automated in PC, PLC, DCS, … ► Manual documented in SOPs ►
Recipe Phases
Agitate
Add Heat
Cool
Equipment Phases
Add 1. xxx 2. xxx
Heat 1. xxx 2. xxx
Agitate 1. xxxx 2. xxxx
Cool 1. xxx 2. xxx
Part 2: Equipment Model • • • •
Equipment entities Process Cells Units Equipment Phases
Equipment Model • An object approach to organizing equipment • Designed to support the required level of flexibility Equipment Control (or SOP Definitions)
V1 V2
Physical Equipment
+
SP OUT ADD MV
PID
CV
Equipment or Manual Control Capability
Equipment Entities
Physical Model
ENTERPRISE MAY CONTAIN
SITE MAY CONTAIN
Only discussed to place the Process Cell in context within a manufacturing enterprise
AREA MAY CONTAIN
Process Cell MUST CONTAIN
Unit
ISA 88.01 Model
MAY CONTAIN
MAY CONTAIN
MAY CONTAIN
Equipment Module MAY CONTAIN
Control Module
A Control View AddSyrup
Coordination Control in the Process Cell AddWater
Mix-U2
U2
AddSugar Mix-U1
Heat
U1 XferOutHot
Specifies what equipment to use an con ro s e rec pe’s procedural execution
Sends equipment and resource availability to Basiccontrol Control coordination
Procedural Control in Recipe Procedures
in Ladder Logic, SOPs, and PID
V1 V2
ADD
OUT SP PID MV
CV
Send commands to the basic control elements in equipment
Equipment Entities •
Process cell ►
•
Units ►
•
A collection of related control modules and equipment modules that can carry out one or more processing activities
Equipment modules ►
•
A logical grouping of equipment required for production of one or more batches
A functional group of equipment and/or control modules that can carry out a finite number of specific processing activities
Control modules ►
A regulating device, a state oriented device, or a combination of both that is operated as a single device
Process Cell • A logical grouping of equipment required for production of one or more batches • May contain more than one grouping of equipment needed to make a batch • The equipment actually used to comp ete a atc s re erre to as t e path or stream • May contain more than one batch at a time
Unit 1
Unit 2
Unit 3
Process Cell Scope • Defined where the batch maintains its identity • Or, defined for the scope of a recipe • Or, defined for a scope of operator control
Unit 1
Unit 2
Finished Materials Storage
Unit 3
Input Materials Storage
Unit 4
Unit 5
Unit 6
Example of a 22-Unit Process Cell M
Ingredient B
Premixer
Ingredient A
F1 PIC M
PIC
Reactor
Units • Usually centered on a major piece of process equipment • Frequently operates on, or contains the complete batch • Cannot o erate on or contain more than one batch at a time ►
One batch per unit
• May operate on, or contain, only part of the complete batch Multiple units per batch are possible ► Multiple units during transfers ►
Unit • A collection of related control modules and equipment modules that can carry out one or more processing activities • Operates on only one batch at a time
Units • The primary object for automatic control • There will often be multiple units involved in making a batch • A unit is made up of equipment modules and control modules • Provides a direct relationship to unit procedures and associated operations
Example of a Unit Inert Gas
F1 PIC
Vacuum
Ingredient A
M
Waste Air
In
Hot PIC
Cold
Out
Hot Cold
Next Unit
Equipment Modules Inert Gas
INERTING DOSING
F1 PIC
Vacuum
M
Ingredient A
In
Hot PIC
Cold
Out
Hot Cold
TEMPERING
G N I R R I T S
Waste Air
RECYCLE AND PUMP OFF
Next Unit
Equipment Modules – – Equipment Phases Inert Gas
INERTING Dose
DOSING
Set Pressure
F1 PIC
Vacuum
M
Ingredient A
In
Hot PIC
Cold
Set Temp
Out
Hot Cold
TEMPERING
G N I R R I T S
Mix
Waste Air
RECYCLE AND PUMP OFF
Recycle Discharge
Next Unit
Equipment Phases • Equipment phases are the link between the recipes and the equipment • Equipment phases are the actions that the equipment can perform for a recipe ►
Charging materials, transferring materials, heating, cooling, agitating, blending, separating, …
Equipment Phase - Recipe Phase • Recipe phases command equipment phases • Equipment phases are where the work is actually done • Anything a recipe ‘does’, it does through an e ui ment hase
Equipment Phases • The equipment phases of a unit (or equipment module) define the basic processing capabilities of the unit, that are available to recipes • The details of how the programmed is hidden from the recipe • Equipment phases are (generally) product independent
Section 3: Recipes • • • • •
General Site Master/Control Procedure Unit Procedure
Recipe Types • General Recipe ►
Recipe with equipment independent processing descriptions
• Site Recipe ►
Recipe with site specific modifications from the general recipe
• Master Recipe ►
Recipe with process cell specific information
• Control Recipe ►
Recipe with batch specific information.
Recipe Types
General Recipe
Processing information Generally not equipment specific
may be transformed into
Site
Site-specific information In local language ase on oca raw mater a s
may be transformed into
We’re going to be more focused with these types
Master Recipe
Process cell-specific information Based upon equipment types or classes Required in any ISA 88-aware solution
is the basis for
Control Recipe
Equipment-specific information Batch-specific information: batch size, raw materials used & quantities, etc.
A Recipe Explosion Bright White Toothpaste
General Recipe
Site Recipe
Madrid
Master Recipe
Line A
Line 1
Line 2
Phase Phase Lot Mxxx
Phase Phase Lot C1xxx
Phase Phase Lot C2xxx
Control Recipe
Chicago
ISA 88 Recipes Recipe Composition • Formula: Process inputs ► Process outputs ► Process parameters
Recipe
►
• Procedure ►
Control definition
Formula
Safety and Information
• Equipment needs • Header information ►
Identification, version control
• Safety & compliance information
Procedure Header Information Equipment Requirements
Header Information • Administrative information Recipe identification and product identification ► Originator ► Issue date ► Approval status ►
• Process summary
General and Site Recipes • General recipe A type of recipe that expresses equipment, location, and site independent processing requirements ► Separates product knowledge from specific equipment knowledge ►
• Site recipe A type of recipe that is site specific ► May be derived from general recipes recognizing local constraints, such as local languages, available raw materials, and site processing capabilities ► Separates product knowledge from specific equipment knowledge ►
Why General Recipes ? • Centralized control and global distribution of product information ►
Is the way to unambiguously communicate processing requirements to multiple manufacturing locations
• When you must make the same product in different sites, regions, and countries ►
Manufactured where ever is most economical
Why Site Recipes ? • Site control of product information • Process cell independent product formulation • For heterogeneous sites; different control equipment, processing equipment, processing ca abilities Yet all must make the same product ► Separates product knowledge from process cell details ►
Master Recipe • A type of recipe that accounts for equipment capabilities and may include process cell specific information • Is the “template” for executed control recipes • A “re uired” reci e t e in the ISA 88 model • Master recipes may be derived from site recipes
Control Recipe • A type of recipe, which through its execution, defines the manufacture of a single batch of product ►
One control recipe per batch
• A “re uired” reci e t e in the ISA 88 model • Derived from a master recipe
Master/Control Recipe Procedure • Derived from a general or site recipe • Based on the procedural model • Creation of Master Recipe from a Site Recipe may be quite complex! • equipment specific information
Master/Control Recipe Procedure Procedure
A Procedure is made up of an ordered set of one or more Unit Procedures
Unit
A Unit Procedure is made up of an ordered set of one or more O erations
Operation
An Operation is made up of an ordered set of one or more Phases
Phase
Procedure • The highest level in the master/control procedure hierarchy • Defines the detailed strategy for carrying out the processing actions required to make a batch • Defined in terms of an ordered set of unit procedures • Example: “make product phenalfree”
Unit Procedure • Consists of an ordered set of operations that cause a continuous production sequence to take place within a unit • One unit procedure is presumed to be active in a unit at any time • A unit procedure is carried to completion in a single unit
Unit Procedure • Multiple unit procedures or one procedure may run concurrently, each in different units • Examples of unit procedures are: Esterify ► Stri ► Neutralize ► Filter ►
Operation • An ordered set of phases that defines a major processing sequence • Takes the material being processed from one state to another • Usuall involved a chemical or h sical chan e to the material • Operation boundaries are often at points where normal processing can be safely suspended
Operation • Only one operation is presumed to be active in a unit at any time • An operation is carried to completion in a single unit • Exam les for the Esterif unit rocedure are: Initialize ► Charge ► React ► Transfer ►
Phase • The smallest element of procedural control that can accomplish a process-oriented task • The logic or set of steps that make up a phase is equipment specific, and not part of the recipe • Phases for the char e o eration are: Initialize ► Add material A at 20L/min ► Add material B at 20L/min ► Mix for 20 minutes ►
• USUALLY THE LINK TO EQUIPMENT ►
Commands the equipment
ISA 88 Part 2 - Recipe Representation Start Symbol True
Start Parallel Phase Mix
Phase Add A
Phase Wait Complete
Procedural Element Symbol Transition Symbol
Phase Add B A & B Complete
End Parallel
Phase Heat Temperature at 200 Deg F
End Symbol
Procedural Element Relationship • Three levels defined, for three reasons ►
Batch to unit associations, operations of products, manipulations required to perform operations Unit Procedure 11
Unit Procedure 2
Operation 44
Unit Procedure 3
Operation 11
Phase 15
Phase 4
Phase 32
Sample Recipe – – S88 Part 2 Standard
+
Sulfurize Unit Procedure
Initialize + Sulfurize Unit Procedure TRUE +
Sulfurize.state = com lete
Charge pera on
Phase Mix
Phase Add A
Phase Wait Complete
Charge.state = complete
React1 Operation
True
+
Phase Add B A & B Complete
Phase Heat
React1.state = complete +
MoveToStorage Operation Transfer.state = complete
Temperature at 200 Deg F
Batch Manufacturing Methodology Master Recipe defines how to carry out a process cell specific General & Site execution of a processMaster & Control defined in a Site Recipe Recipes Recipes
PROCESS STAGE PROCESS OPERATION PROCESS ACTION
One or More
UNIT PROCEDURE
OPERATION One or More
PHASE One or More
Why a Major Transformation? • Gene Genera rall and and site site reci recipe pes s onl only y des descr crib ibe e processing technology • Gene Genera rall and and site site reci recipe pes s do do no nott ref refer eren ence ce an any y target equipment in the plant ►
But they may specify requirements on the equipment
• Gene Genera rall and and site site reci recipe pes s do do not not ha have ve to de deal al wi with th initial conditions and startup checks ►
Unless they are vital to the product definition
• Gene Genera rall and and site site reci recipe pes s do do not not ha have ve to de deal al wi with th material transfers between units
Why a Major Transformation? • Ma Mate teri rial al ma may y hav have e to to be be tra trans nsfe ferre rred d bet betwe ween en un unit its s • One One act actio ion n may may ma map p to to se severa verall pha phase ses s • In Init itia iall an and d exc excep epti tion ons s pha phase ses s may may ha have ve to be ad adde ded d Master Recipe
Site Recipe
Unit Procedure ADD
Start Unit Procedure MIX
Add Add Material A Material B
Add Mat-A
Add Mat-B
Start Initialize
Add Material C MIX
XfreOut
XferIn Add Mat-C MIX
HEAT HEAT
Formula • The information of a recipe used by the procedure • The formula is used to distinguish the products defined by procedures • The formula conce t sim lifies eneratin different products using an established and proven procedure ►
The term ‘grade’ is often used to describe the recipes using the same procedure logic, but with different formula values
Formula Information
Formula
Process Inputs Identification and quantity of raw materials or other resources required to make the product
Process Parameters
Process Outputs
Everything else
Identification and quantity of materials expected to result from the execution of the recipe
Equipment Requirements • Define the attributes of the equipment needed, such as: Type of equipment needed ► Materials of construction ► Equipment (tag) name ►
• Specific information may vary depending on the recipe level Master and control may be very specific, identify the specific equipment or class ► General and site may just identify equipment characteristics ►
Equipment Requirements • Master recipe Reactor class 1 ► Stripper class 2 ► R-502 reactor ► S-503 stripper ►
• General recipe Charge React
Equipment Requirements HEATING COOLING MATERIAL OF CONSTRUCTION VENTING
Max Temperature Max Heat Load Normal Heat Load
Other Information • Recipe dependent safety comments (Not MSDS) • Recipe dependent compliance comments • Data collection requirements •
Control Separation • ISA 88 model describes alternate places to put the recipe logic, depending on needed flexibility Control Recipe Procedure Procedure
Equipment Control Procedure Is a set of
[Must always exist]
Recipe Unit Procedure Is a set of Recipe Operation Is a set of Recipe Phase
Equipment Phase
Procedure Logic in the Recipe • Typical use Recipe procedure logic in the recipe ► Equipment phase logic in equipment ► Maximum flexibility ►
Control Recipe Procedure
Equipment Control
Recipe Procedure Is a set of Recipe Unit Procedure Is a set of Recipe Operation Is a set of Recipe Phase
References
Equipment Phase
Procedure Logic in the Equipment • Procedure “hard-coded” into the equipment ►
►
Recipe authors can only use pre-defined equipment procedures Less flexibility, but may be required by equipment Control Recipe Procedure Recipe Procedure
Equipment Control References
Equipment Procedure Is a set of Equipment Unit Procedure Is a set of Equipment Operation Is a set of Equipment Phase
Alternate Separation • Operations ‘hard-coded’ into equipment logic ► ►
Recipe authors may only use a set of predefined operations Intermediate flexibility, but may be required due to equipment restrictions Control Recipe Procedure
Equipment Control
Recipe Procedure Is a set of Recipe Unit Procedure Is a set of Recipe Operation
References
Equipment Operation Is a set of Equipment Phase
Procedure Model Collapsibility • Any part of the ISA 88 model may be collapsed or expanded • E.g. expanded model may include “macro phases” • Different “collapsed” recipes PROCEDURE
PROCEDURE
OPERATION
UNIT PROCEDURE
PROCEDURE
PHASE PHASE PHASE PHASE PHASE PHASE
PHASE
PHASE PHASE PHASE PHASE PHASE
PHASE PHASE PHASE PHASE PHASE
Summary: Recipes • • • • •
General Site Master/Control Procedure Unit Procedure
