PRODUCTION PLANNING OF CHEMICAL PROCESSES ISA88 STANDARD Moisès Graells, Canan Dombayci moises.graells@upc.edu, canan.dombayci@upc.edu International Society of Automation

Outline ISA-88.01-1995 (R2006) Batch Control, Part 1: Models and Terminology Batch Processes E-R (Entities-Relationship) Diagrams Sequential Function Charts and Documenting a Recipe Operation by Using a Sequential Function Chart Ontology and ISA88 Physical Model in ISA88 PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

ISA-88.01-1995 (R2006), Batch Control Part 1: Models and Terminology The Big Picture – ISA88 ISA-88.01-1995 (R2006), Batch Control Part 1: Models and Terminology ISA is international society for automation ISA88 is addressed both for standard S88 and committee SP88 ISA88 is an ANSI standard and global basis for modern batch control system. PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

ISA88, Part 1: Models and Terminology This standard (Part 1, Models and Terminology) is intended for people who are involved in designing and/or operating batch manufacturing plants, responsible for specifying controls and the associated application programs for batch manufacturing plants, involved in the design and marketing of products in the area of batch control. Part 1 standard on Batch Control defines reference models for batch and related procedure-oriented manufacturing as used in the process industries, and terminology that helps explain the relationships between these models and terms. Other parts (2-3-4) Data Structures and Guidelines for Languages General and Site Recipe Models and Representation Batch Production Records PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

What is ISA88 Standard? This standard provides a batch control unification for users in order to use standard definitions. The reasons for this standard: A universal model for batch control did not exist, Difficulty communicating requirements, Difficulty integrating solutions from different vendors , Comprehensive implementation was not practical with available tools. PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Continuous, Discrete and Batch Processes-I In a continuous process materials are passed in a continuous flow through processing equipment. Once established in a steady operating state, the nature of the process is not dependent on the length of time of operation. Start-ups, transitions, and shutdowns do not usually contribute to achieving the desired processing. Discrete processes involve the production of things. A part or a specific quantity of parts in a group moves from one workstation to another, gaining value at each location as work is performed. In a discrete process, each thing or part maintains its unique identity. Continuous processes example: The production of gasoline is often thought of as a prime example of a continuous process. Once started, refineries do not want to shut down. When looking at a continuous process, you’ll see pumps, valves, instrumentation, and larger processing equipment (such as a cracking tower). Discrete processes example: car production PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Continuous, Discrete and Batch Processes-II The batch processes addressed in this standard lead to the production of finite quantities of material (batches) by subjecting quantities of input materials to a defined order of processing actions using one or more pieces of equipment. Batch processes are neither discrete nor continuous; however, they have characteristics of both. PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Some Definitions From ISA88 3.5 batch: 1.) The material that is being produced or that has been produced by a single execution of a batch process. 2.) An entity that represents the production of a material at any point in the process. 3.7 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. 3.6 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. PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

E-R (Entities - Relationship) Diagrams - I One and only one association Zero or one association One or more association Unicycle Wheel Car Hatchback House Bathrooms PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

E-R (Entities - Relationship) Diagrams - II Zero, one or more association Student Homework Surfer Surfboards owns Procedure Operator Instructions consist of an ordered set of PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Example: Pasteurizing Ice Cream Mix Milk Liquid Sugar Eggs Batch Tank Powder Liquefier H2O Powders Balance Tank Pasteurized Mix Storage Tanks Homogenizer Press Holding Tubes PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Sequential Function Charts Add Milk Add Cream TRUE Milk Addition Complete Cream Addition Complete When Transition 1 fires, Step 1 becomes active. When Transition 2 fires, Step 2 becomes active. When Transition 3 the procedure ends. This translation immediately fires and Add Milk step becomes active When Add Milk step is complete, this transition fires and the Add Cream step becomes active When the Add Cream step is complete, this transition fires and the procedure ends. Transition 1 Step 1 Transition 2 Step 2 Transition 3 PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

A recipe operation documented using a sequential function chart Redrow this one!!! PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

HOW? Ontology Where are we in ISA88? 3.50 recipe operation: An operation that is part of a recipe procedure in a master or control recipe. 3.49 recipe management: The control activity that includes the control functions needed to create, store, and maintain general, site, and master recipes. Control Activity Model: HOW? Ontology PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

What About Ontology? An ontology can be defined as 'an explicit specification of a conceptualization' Purpose is developing of domain ontology for Process Systems Engineering ISA88 which is a technical standard is chosen because of clear definite terminology and models How? Use of the semi-automatic ontology development Automatic part has been done using with linguistic analyzer, pattern matching tool and grammar parser for ISA88 PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Ontology View of ISA88 PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Hierarchy of Physical Model - I Enterprise 4.2 Physical model: … a physical model that can be used to describe the physical assets of an enterprise in terms of enterprises, sites, areas, process cells, units, equipment modules, and control modules. 3.13 enterprise: An organization that coordinates the operation of one or more sites. 3.55 site: A component of a batch manufacturing enterprise that is identified by physical, geographical, or logical segmentation within the enterprise. NOTE – A site may contain areas, process cells, units, equipment modules, and control modules. 3.3 area: A component of a batch manufacturing site that is identified by physical, geographical, or logical segmentation within the site. may contain Site may contain Area may contain Process Cell must contain Unit may contain Equipment Modul may contain may contain Control Module may contain PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Hierarchy of Physical Model - II Enterprise Ben & Jerry’s may contain Site Springfield St. Albans Waterbury may contain Area Ingredients Reciving & Storage Mix Making Pasteurized Mix Storage Fill Room may contain Process Cell Batching Mix-making batch tank must contain Unit Pasteurizing Pasteurizer may contain Equipment Modul may contain may contain Control Module may contain PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Please draw a recipe operation documented using a sequential function chart. Homemade Toothpaste Recipe Natural Homemade Toothpaste Ingredients About 1/2 cup coconut oil 2-3 Tablespoons of baking soda 2 small packets of stevia powder 15-20 drops of peppermint How to Make Natural Homemade Toothpaste Melt coconut oil. Mix other ingredients (baking soda, stevia powder and peppermint) and stir well. Mix other ingredients and melted coconut. Put mixture into small glass jar (in our case it should be tubes) Let cool completely. http://wellnessmama.com/1772/natural-toothpaste/ PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Bonus Slide 3.48 recipe: The necessary set of information that uniquely defines the production requirements for a specific product. NOTE – There are four types of recipes defined in this standard: general, site, master, and control. 3.34 phase: The lowest level of procedural element in the procedural control model. 3.16 equipment module: A functional group of equipment that can carry out a finite number of specific minor processing activities. Batch size: A reference value for the size of the batch generated by the execution of the recipe. PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

What have we learnt? ISA-88.01-1995 (R2006) Batch Control, Part 1: Models and Terminology Batch Processes E-R (Entities-Relationship) Diagrams Sequential Function Charts and documenting a recipe operation by using a sequential function chart Ontology and ISA88 Physical Model in ISA88 PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

Thank you for your attention! PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

References ISA. Batch control, part 1: Models and terminology, isa-88.01-1995. Technical report, ISA standard, 2006. Parshall, J. and Lamb, L., Applying S88 Batch Control from a User’s Perspective, ISA, 2000. Gruber, T.R., A translation approach to portable ontology specifications. Knowledge Acquisition, 5, 199-220, 1993. http://wellnessmama.com/1772/natural-toothpaste/ PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88