Overview of the ANSI/ISA S88.01 Batch Control Standard © 1996

Clarification SP88 is the ISA committee responsible for developing the batch control standard S88 is the standard developed by such a committee © 1996

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 … to vendors and among themselves © 1996

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) © 1996

History of SP88 Purpose: To provide standards and recommended practices for the design and specification of batch control systems The committee was established by ISA for the purpose of ... © 1996

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 SP88 was chartered with the scope of ... © 1996

History of SP88 In 1990 it was internationalized after a petition to IEC was accepted - Working Group 11 (WG11) of subcommittee 65A was formed The corresponding international standard is known as IEC-SC65A © 1996

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 © 1996

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 © 1996

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 Meanwhile across the Atlantic... © 1996

The Future of S88 Part two: Endorsing organizations have been formed: 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 © 1996

The ANSI/ISA S88.01 Standard ANY QUESTIONS? © 1996

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 ...models are modular in nature which promostes re-usability of software © 1996

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) S88 is not a cookbook for implementing batch control, there is still a need for control engineering knowledge S88.01 is a good foundation for developing functional specifications for batch control systems © 1996

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 S88 is not a cookbook for implementing batch control, there is still a need for control engineering knowledge S88.01 is a good foundation for developing functional specifications for batch control systems © 1996

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 … 63 terms are defined in the standard © 1996

Main Sections of S88.01 Section 6: Batch control activities and functions - discusses control activities and functions associated with batch processing/manufacturing © 1996

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 Some sample definitions as a warm up for discussions to follow... © 1996

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 © 1996

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 Process Stage consists of an ordered set of 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 The process activities which are part of a batch process are defined by a Process Model. The diagram shown here is an Entity Relationship diagram The main elements of this type of diagram are - Entity (represented by the rectangular shape) - Relationship (represented by the chicken leg shaped symbol) The relationship symbols defines how one entity relates to the other. Cardinality symbols at the ends of the relationship indicate how many of one entity correspond to the other - One >Many o None GIVE EXAMPLE The corresponding definitions of the entities are... Process Action consists of an ordered set of Minor processing activities that are combined to make a process operation © 1996

Batch Processes and Equipment Process Model (Entity - Relationship Diagram) Example: Polymerization of vinyl chloride monomer Process Process Stage consists of an ordered set of Example: Polymerize Recover Dry consists of an ordered set of Example (Polymerize stage): Prepare reactor Charge React Process Operation Examples of the entities are... Process Action consists of an ordered set of Example (React operation): Add monomer Add catalyst Heat to 55-60 deg C Hold at 55-60 deg C until press. decreases © 1996

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 The physical aspects of a batch enterprise are defined by a Physical Model of which the top four levels are shown here... DESCRIBE RELATIONSHIPS Definitions for these entities are… The top three entities are shown dashed since the configuration of systems at these levels of the enterprise are beyond the scope of the S88 standard. I’ll let you read the corresponding definitions... may contain Process Cell A logical grouping of equipment that includes the equipment required for the production of one or more batches © 1996

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 lower four levels of the physical model (process cell being repeated) are shown here… DESCRIBE RELATIONSHIPS Definitions for these entities are… The key differences between and equipment module and a control module are that an equipment module can perform procedural control while a control module can only perform basic control. Later I will define the different types of control. 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 © 1996

Batch Processes and Equipment Physical Model (Entity - Relationship Diagram) Process Cell must contain Reactor B Blend/Adjust Tank A Unit may contain Equipment Module may contain Examples of the entities are a resin manufacturing cell with two reactors and a blending/solids adjustment tank... CONTINUES ON THE NEXT OVERHEAD may contain Control Module may contain © 1996

Batch Processes and Equipment Physical Model (Entity - Relationship Diagram) Process Cell M TIC LIC FQIC LI Reactor B must contain Unit may contain Equipment Module may contain An example of equipment module are the reactor overhead system used for distillation/separation... Examples of control modules are the level and temperature control modules which are part of the reactor overhead system... ANY QUESTIONS? may contain Control Module may contain © 1996

Equipment Module or Control Module? FQIC 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) Time for a quiz to see if you have been paying attention. Is it an ... - 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) © 1996

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 The standard defines three types of control... © 1996

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 DESCRIBE We will see more examples about this type of control later... © 1996

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) Typical methods of allocation include: - selecting the equipment with the least amount of operating time - selecting the next available piece of equipment Typical methods of arbitration include: - First in/first out (FIFO) also referred to as First Come/First Serve - FIFO’s with prioritization schemes - Pre-emptying, where a resource is allocated to upon request overriding any order or priority © 1996

Batch Control Concepts Procedural Control Model (Entity - Relationship Diagram) Procedure 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. 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 Procedural Control is further defined by a model... DESCRIBE RELATIONSHIPS The corresponding definitions are... consists of an ordered set of Phase The lowest level of procedural element in the procedural control model © 1996

Model mapping Process Procedural Physical Model Control Model Model provides process functionality to carry out a combined with a Procedure(s) Process Cell(s) Process provides process functionality to carry out a combined with a Unit(s) Process Stage Unit Procedure(s) provides process functionality to carry out a combined with a Operation(s) Unit(s) Process Operation provides process functionality to carry out a combined with a Phase(s) Unit(s) Process Action Mapping the previosly introduced models we can see how process objectives are met by a combination of procedural elements and physical entities… DESCRIBE A MAPPING... provides process functionality to carry out a combined with a Phase(s) Equipment Module(s) Process Action © 1996

Batch Control Concepts Blend Resin Polymerize Monomer A Monomer B Procedure Reactor B Blend/Adjust Tank A Lets now see some examples of procedural elements. Referring back to the physical entities introduced earlier in our resin process example... © 1996

Batch Control Concepts Transfer Out Prepare Reactor React Polymerize Monomer A Unit Procedure M TIC LI FQIC Reactor A Monomer Expanding the Polymerize Monomer A unit procedure we can see prepare, react and xfer out operations © 1996

Batch Control Concepts Charge Monomer Catalyst Agitator ON Heat Hold Temperature OFF React Operation M TIC LI FQIC Reactor A Monomer Catalyst Expanding the React operation we can see … phases © 1996

Definitions Recipe: The necessary set of information that uniquely defines the production requirements of a specific product When we talk about recipes... © 1996

Recipe contents Header: Equipment Requirements: Information about the purpose, source and version of the recipe such as recipe and product ID’s, creator and issue date Equipment Requirements: e.g. allowable materials of construction, processing characteristics, selected train, specific units, etc. DESCRIBE It attempts to answer the questions... © 1996

Recipe contents Formula: Recipe procedure: 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)? DESCRIBE It attempts to answer the questions... © 1996

Batch Control Concepts Recipe Types (Entity - Relationship Diagram) General Recipe Product - specific processing information includes may be transformed into Site Recipe Site - specific information includes may be transformed into Master Recipe Process cell - specific information includes The standard defines four types of recipes… The site recipe is basically the same as the general recipe with the addition of site specific information. For example: - Different raw materials available from local suppliers - Differences in parameters due to altitude changes The control recipe is the working recipe, created at runtime as a copy of the master recipe. It adds items such as ... is the basis for Batch ID, batch size, in-process, operator- and/or system- generated information includes Control Recipe © 1996

Recipe Procedures (Entity - Relationship Diagr.) Process Stage is an ordered set of Process Operation Process Action Unit Procedure Operation Phase General and Site Recipes Master and Control Recipes Procedural elements associated with the four types of recipes are as follows... © 1996

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 ...The key is that equipment control is independent from the recipe and that it defines the required equipment/process control.

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 This is most commonly achieved at the phase level. Recipe phases are then associated with a corresponding equipment phase. consists of an ordered set of Phase Equipment Phase references © 1996

Batch Control Concepts Equipment Phase Charge Monomer Reset Totalizer Open Valve Charge Target Amount Close Valve and Stop Pump Start Pump Equipment Module FQIC Catalyst FQIC Monomer M LI TIC Reactor A Refering back to the reactor previously shown, we see an example of the equipment phase A one to one relationship typically exists between an equipment phase and an equipment module. The type of activities defined in an equipment phase are not defined in the recipe. © 1996

Recipe Phase vs. Equipment Phase Charge RM - Independent of Recipe - Receives RM as parameter Module Raw Materials Header Recipe Phases Charge A Charge B Charge C A B FQIC C M Here is an example of the relationship between a Recipe Phase and an Equipment Phase. Notice that a many to one relationship exists. The same equipment phase logic can be used for all three charges by just passing parameters to the software. This is a good example of modularity which promotes re-usability of software. © 1996

Definitions State: Mode: 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 Are you still awake! Here are more definitions… Modes and states apply to both elements of the Procedural Model and to equipment entities defined in the Physical Model. © 1996

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 It is important to note that… Propagation refers to how changes in mode or state propagate to other procedural elements or equipment entities. An example of mode propagation: changing the mode of any phase to manual causing the corresponding operation and unit procedure mode to change to manual. An example of state propagation: aborting the unit procedure when any operation is aborted. This is subjective and very much dependent on the particular application © 1996

States example included in S88.01 Restart Complete Restarting Held Holding Reset Hold Idle Start Pause (Initial Running Pausing State) Abort Resume Stop Paused Aborting Stopping This is the example of states included in the standard. This is a state transition diagram whose primay elements are: - States (represented by ellipses) - Transitions (represented by lines with arrows in the direction of the state reached upon transitioning) Text is used to describe the commands which cause the transition to occurr GIVE EXAMPLES This is only an sample specification and not a requirement of all batch control applications. Some processes may not allow state transitions such as these. Final States Aborted Stopped Quiescent States Reset Transient States Reset © 1996

Modes example included in S88.01 This is the example of modes included in the standard. The Behavior column describes how the procedural element or basic control acts while in the given mode. The command column describes what control is permitted to the operator and/or other control functions. GIVE EXAMPLES This is only an sample specification and not a requirement of all batch control applications. Some processes may not permit modes such as semiautomatic or manual. © 1996

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 I promise this is the last definition © 1996

Batch Control Activities and Functions Production Planning and Scheduling Recipe Management Production Information Management Most functions inside these activities are outside the scope of SP88 Process Management Unit Supervision Control Activity Model (Context Diagram) Process Control The last section of the standard defines the Control Activity model. This is a Context diagram whose primary elements are: - Control activites represented by rectangles with rounded eges - Information flows represented by the connecting lines The Personnel and Envir. Protect. control activity is outside the scope of the standard but is shown here to depict some form of interface to process control. BRING IN THE SLIDING TEXT Most of the activies within PP and S and PIM are outside the scope of the standard. Only Batch Scheduling in PP and S and Managing Batch History in PIM are of any concern to the standard. Thus we will not spend much time discussing these activities. Outside the scope of SP88 Personnel and Environmental Protection © 1996

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 Batch schedules are developed based on… © 1996

Production Planning and Scheduling Develop Batch Schedules: Allowing revisions on demand based on significant changed in batch progress and cell status Allowing manual intervention Some sample capabilities of the … function are © 1996

Production Information Management Manage Batch History: Receive and store batch history information Manipulate historical data Produce reports Some sample capabilities of the … function are © 1996

Production Information Management Sample Batch Information Recorded: Batch ID’s Timing (start and end of all procedural elements) Equipment utilized Control recipe utilized Actual process values (measured and manual) Events and alarms (time stamped) Sample batch information which is recorded includes… CONTINUED ON NEXT SLIDE © 1996

Production Information Management Sample Batch Information Recorded: Calculated parameters Laboratory data Operator interventions Operator ID’s Operator comments Trends of selected process variables © 1996

Batch Control Activities and Functions Recipe Management (Data Flow Diagram) Manage General Recipe Site General Recipe Master Define General Recipe Proced. Element Define Master Process Management Procedural Procedural Element Master Recipe Information Site Recipe Zooming into the Recipe Management control activity we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW We will not talk much about these since they are mainly recipe data management functions. © 1996

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 Some sample capabilities of the … function are © 1996

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 Some sample capabilities of the … function are © 1996

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 END OF GENERAL RECIPE Some sample capabilities of the … function are © 1996

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 Some sample capabilities of the … function are © 1996

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 Some sample capabilities of the … function are © 1996

Recipe Management Define Master Recipe Procedural Elements: Maintaining inventory of procedural elements Managing changes to procedural elements END OF DEFINE MASTER RECIPE... © 1996

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 Zooming into the Process Management control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW Unit Recipes, Commands, and Batch and Status Information Unit Supervision Process Management (Data Flow Diagram) © 1996

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 The scope of Process Management is the Process Cell Some sample capabilities of the … function are CONTINUED ON NEXT SLIDE © 1996

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 CONTINUED ON NEXT SLIDE © 1996

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 © 1996

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 Some sample capabilities of the … function are CONTINUED ON NEXT SLIDE © 1996

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 Some sample data collected by the … function are © 1996

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 © 1996

Batch Control Activities and Functions Process Management Production Information 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 Zooming into the Unit Supervision control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW Commands and Status Information Process Control Unit Supervision (Data Flow Diagram) © 1996

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 The scope of Unit Supervision is the Unit Some sample capabilities of the … function are CONTINUED ON NEXT SLIDE © 1996

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 Some sample capabilities of the … function are CONTINUED ON NEXT SLIDE © 1996

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 Some sample data collected by the … function are CONTINUED ON NEXT SLIDE © 1996

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 © 1996

Batch Control Activities and Functions Unit Supervision Production Information Management Commands and Status Information Commands and Status Information Data Execute Equipment Phases Collect Data Data Data Commands and Status Information Execute Basic Control Zooming into the Process Control control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW Commands and Status Information Commands and Status Information Process Control (Data Flow Diagram) Personnel and Environmental Protection © 1996

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 The scope of Process Control is the Equipment and Control Modules Some sample capabilities of the … function are © 1996

Process Control Execute Basic Control: Collect data: 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 Some sample capabilities of the … function are Some sample data collected by the … function are © 1996