1. PRODUCTION PLANNING OF CHEMICAL PROCESSES ISA88 STANDARD
Moisès Graells, Canan Dombayci
International Society of Automation

2. Outline
ISA (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

3. ISA-88.01-1995 (R2006), Batch Control Part 1: Models and Terminology
The Big Picture – ISA88
ISA (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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

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

14. 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

15. 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

16. Ontology View of ISA88
PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

17. 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

18. 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

19. 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.
PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88

20. 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

21. What have we learnt?
ISA (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

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

23. References
ISA. Batch control, part 1: Models and terminology, isa 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, , 1993.
PRODUCTION PLANNING OF CHEMICAL PROCESSES - ISA88