Transcript ANSI/ISA S88.01 Batch Standard Its Role in

ANSI/ISA S88.01 Batch Standard
Daren Moffatt
Solution Architect
Invensys Foxboro
Greg Skovira
President
EZSoft Inc.
(Výběr pro Počítačové řídicí systémy 2012)
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 1
Batch Process Example
Material
Storage 1
Material
Storage 2
Material
Storage 3
Minor
Additions
Mixer
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 2
Processing Overview
 A Discrete Process produces finite quantities of
discrete parts.
 Circuit boards, memory chips, floppy disk, disk drives,
computers, cars, car engines, dishwashers, etc...
 A Continuous Process produces a continuous
flow of free flowing product, usually a liquid or
powder.
 Bulk chemicals, gasoline, kerosene, natural gas,
electricity, wood pulp, etc...
 A Batch Process produces a finite quantity of free
flowing product, usually a liquid or powder.
 Specialty chemicals, paints, pigments, personal care
products, food products, pharmaceuticals, etc.
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 3
Batch Process Example
Material
Storage 1
Material
Storage 2
Material
Storage 3
Feed
Tank 1
Feed
Tank 2
Spray
Dryer 1
Spray
Dryer 2
Minor
Additions
Mixer
BATCH
CONTINUOUS
Packaging Line 1
Packaging Line 2
DISCRETE
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 4
Batch Processing Characteristics
 Number of Products
Material
Storage 1
Material
Storage 2
Material
Storage 3
 Single product
 Multiple products
 Physical Layout
Mixer 1
Mixer 2
Reactor 1
Reactor 2
 Single stream
 Multi-stream
Storage
Tank 1
Storage
Tank 2
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Storage
Tank 3
slide 5
Standards & Organizations
 ISA S88 Committee
 S88.01
 S88.00.02
 S88.00.03
www.isa.org
 World Batch Forum
 BatchML
 B2MML
 OPC for Batch
www.wbf.org
www.opcfoundation.org
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 6
ISA 88.01/ IEC 61512-1
 Terminology and models that apply to all
types of control systems
 A modular structure that promotes reuse
 A structure that applies to both automated
and manually-controlled batches
 Separates the recipe that describes how
the batch is to be made from the
equipment used to make the batch
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 7
ANSI/ISA-88.01-1995 / IEC 61512-1
 Standard covers four basic concepts:
 How to depict what you have in the plant
(physical model)
 How to define what you would like to
accomplish in the plant (recipe)
 Implementation of what you can do in the plant
(equipment logic)
 How to put the three pieces mentioned above
together in an intelligent, reusable and
successful way
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 8
S88.01 Physical Hierarchy
 Enterprise / Site / Area
 Process Cell
Process Cell
 The entire collection of equipment
needed to execute a single recipe from
start to finish batch
 Consists of one or more units
Unit
 Unit
 Usually centered on a major piece of
process equipment
 Frequently operates on or contains the
complete batch
 May operate on or contain only a
portion of the complete batch
 Cannot operate on or contain more
than one batch at a time
Equipment Module
Control Module
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 9
S88.01 Physical Hierarchy

Equipment Module
 A collection of control modules or other
equipment modules
 Can carry out a finite number of minor
processing activities, i.e., phases
 Contains all the necessary processing
equipment to carry out these processing
activities

Process Cell
Unit
Control Module
 A collection of sensors, actuators, other
control modules, and associated processing
equipment
 Acts as a single entity from a control
standpoint
 Is the direct connection to the process
through its sensor and actuators
 Procedures do not run on control modules
Equipment Module
Control Module
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 10
Batch Control Conceptual Example
•Equipment=Process that we will sequence
•Procedure=order in which we will sequence the process
•Batch Journal=Record of what happened to the process
Procedure
Equipment
Journal
12:05 This happened
12:07 That happened
12:10 This and that
happened
1. Do this
2. Do that
3. Do this and that
“How”
“When”
“What”
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 11
Batch Control Conceptual Example
Equipment
Examples
Control Module
Illustration
Valve
Pump
Motor
Pressure Controller
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 12
Batch Control Conceptual Example
Equipment
Examples
Equipment
Module
(a set of Control
Modules)
Temperature Control
System consisting of:
1. Recycle pump
2. Chilled water valve
3. Steam valve
4. Temperature
Controller
Illustration
Chilled
Water
TIC
Steam
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 13
Batch Control Conceptual Example
Equipment
Examples
Unit
(a set of
Equipment
Modules)
Reactor
consisting of:
1. Temperature
control system
2. Agitation system
3. Material addition
systems
4. Discharge system
5. Analysis system
Illustration
TIC
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 14
Recipe Management
The Recipe is the
necessary set of
information that
uniquely defines
the production
requirements for a
specific product
General
Recipe
Processing
Information
Site
Recipe
Site-specific
Information
Master
Recipe
Process Cell
Specific Info
Control
Recipe
Batch
Specific Info
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 15
General & Site Recipes
One General Recipe per produced
material, maintained at the enterprise level
(1000 company wide products)
One Site Recipe per site and produced
material, maintained at the site for local
materials, language, or segment of production
(10,000 site recipes for 10 sites)
One Master Recipe per Process Cell and
produced material
(50,000 master recipes for 5 cells per site)
One Control Recipe per batch that
describes the custom options and formula
values for one specific batch of product
(1,000,000 batches per year)
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 16
Recipe Information Categories
Recipe
Equipment
Requirements
Header
Procedure
Process
Inputs
Other
Information
Formula
Process
Parameters
Process
Outputs
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 17
S88.01 Procedure Hierarchy
 Procedure (recipe level)
 The overall strategy for making
a batch
 Consists of an ordered
sequence of unit procedures
Procedure
Unit Procedure
 Unit Procedure
 The subset of a procedure that
occurs within a single unit
 Consists of an ordered
sequence of (one or more)
operations
Operation
Phase
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 18
S88.01 Procedure Hierarchy
 Operation
 A sequence that causes a
significant physical or chemical
change within the batch
 Consists of an ordered
sequence of (one or more)
phases
 Phase
Procedure
Unit Procedure
Operation
 The smallest element of
procedural control, capable of
causing one or more actions
Phase
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 19
Typical Procedure using the Hierarchy
Procedure
Unit Procedure
Note parent / child relationships as you move
down and to the right in this procedure tree
Operation
Phase
Phase
Phase
Operation
Unit Procedure
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 20
Batch Control Conceptual Example
Recipe procedure Examples
Procedure
Unit Procedure
Unit Operation
Phase
Make Product A
Make Product B
Any set of Operations
Filtration
Reaction
Distillation
Solution Preparation
Agitate
Heat
Cool
Transfer
Charge
Recycle
Illustration
Procedure
Unit Procedure 2
Unit Procedure 1
Unit Operation 1
Unit Operation 4
Unit Operation 2
Phase 1
Phase 3
Phase 2
Unit Operation 3
Phase 5
Phase 4
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Phase 7
Phase 6
Phase 8
slide 21
Recipe/Equipment Control Separation
Control Recipe
Procedure
Equipment
Control
Recipe
Procedure
ordered set of
Recipe Unit
Procedure
The only reference to
the physical processing
equipment occurs here
ordered set of
Recipe
Operation
ordered set of
Recipe
Phase
Equipment
Phase
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 22
Typy řízení
 základní řízení
 regulace
 blokace nesprávné činnosti (interlocking)
 sledování překročení mezí
 reakce na alarmy
 manuální řízení
 procedurální řízení
 koordinační řízení
 řízení zdrojů zařízení
 výběr procedurálních prvků pro běh
 propagace režimů
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 23
Key Batch System Components
Supervisory Level
Recipe Maintenance/Editing
Batch Management
Data Acquisition
Event based
Time based
Reporting
Př.: Wonderware
InBatch
InTouch
PLCs
Operator Interface
Real Time Control
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 24
The 10,000 Ft View
Information
Level 4
Integration
Planning (MRP II,
Financials, etc.)
Business Logistics Systems
Plant Production Scheduling
and Operational Management
Level 3
Manufacturing Control Systems
Manufacturing Execution
Area Supervision, Production
Scheduling, Reliability Assurance
Levels
2, 1, 0
Control
Process Control
Batch
Control
Systems
Continuous
Control
Systems
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Discrete
Control
Systems
slide 25
Typical System Architecture
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 26
Typical System Architecture
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 27
The Model
®
CONTROLBUILDER - DESIGN MODEL
LINE
Device
Device
Process level
Device
PHASE
Device
Device
Device
PHASE
UNIT SEQUENCE
PHASE
Example:
- Production Area 1
UNIT SEQUENCE
PROCESS CELL
UNIT
Device
Device
Device
PHASE
Device
PHASE
DEVICE
c
Device
Device
PHASE
Unit level control
Example:
- Run Batch on Tank 1
- CIP Tank 2
UNIT SEQUENCE
Device
PHASE OPERATION
Device
Device
PHASE
UNIT SEQUENCE
Device
Device
Device
Device
PHASE OPERATION
Device
Device
Device
PHASE OPERATION
Device
Example:
- Add Water, Agitate,
- Hand Addition, etc.
Phase level control
Example:
-Valves, Motors,
Sensors, etc.
Device level control
EZSoft Inc. , 1999-2003
EZSoft & ControlBuilder are registered trademarks of EZSoft, Inc.
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 28
The 2,000 Ft View
From the Bottom Up
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 29
S88.01 Physical Hierarchy

Equipment Module
 A collection of control modules or other
equipment modules
 Can carry out a finite number of minor
processing activities, i.e., phases
 Contains all the necessary processing
equipment to carry out these processing
activities

Process Cell
Unit
Control Module
 A collection of sensors, actuators, other
control modules, and associated processing
equipment
 Acts as a single entity from a control
standpoint
 Is the direct connection to the process
through its sensor and actuators
 Procedures do not run on control modules
Equipment Module
Control Module
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 30
Typical Process Model - Device Level
MTR-002
007
008
009
010
MTR-001
M
XCV-005
Device
Control
MTR-003
XCV-006
XCV-004
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 31
Device Level Properties
Mode (Auto, Manual, Test…)
Commands (Start, Stop, Reset, …)
Status ( Running, Faulted…)
Interlocks and Permissives
(blokování a povolení)
Faults/Alarms
Messages
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 32
Device Level
DEVICE
DESIGN MODEL
c
Device
Device
Device
Device
Device
Example:
-Valves, Motors,
Sensors, etc.
EZSoft Inc., 1999-2004
EZSoft & ControlBuilder are registered trademarks of EZSoft Inc.
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 33
S88.01 Physical Hierarchy

Equipment Module
 A collection of control modules or other
equipment modules
 Can carry out a finite number of minor
processing activities, i.e., phases
 Contains all the necessary processing
equipment to carry out these processing
activities

Process Cell
Unit
Control Module
 A collection of sensors, actuators, other
control modules, and associated processing
equipment
 Acts as a single entity from a control
standpoint
 Is the direct connection to the process
through its sensor and actuators
 Procedures do not run on control modules
Equipment Module
Control Module
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 34
S88.01 Procedure Hierarchy
 Operation
 A sequence that causes a
significant physical or chemical
change within the batch
 Consists of an ordered
sequence of (one or more)
phases
 Phase
Procedure
Unit Procedure
Operation
 The smallest element of
procedural control, capable of
causing one or more actions
Phase
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 35
Typical Process Model - Phase Level
Material Selection
-
Material
Charging
MTR-002
007
008
009
010
FT
Mix
MTR-001
M
Discharge
and
Recirc
Phase
Operation
Device &
Regulatory
Control
Pump
MTR-003
XCV-005
FT
XCV-006
XCV-004
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 36
Phase Level Properties
Mode (Auto,Manual,…)
Commands (Start, Stop, Reset, …)
Status ( Running, Faulted, Paused…)
Interlocks and Permissives
Faults/Alarms
Messages
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 37
S88.01 State Transition Diagram
State Transition Diagram for Example States for Procedural Elements
Restart
Restarting
Complete
Held
Reset
Holding
Hold
Idle
(Initial State)
Start
Pause
Running
Pausing
Resume
Abort
Aborting
Stop
Stopping
Paused
Final States
Reset
Aborted
Stopped
Quiescent States
Transient States
Reset
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 38
Phase Level
DEVICE
PHASE
DESIGN MODEL
c
Device
Device
Device
PHASE
Device
Device
Device
PHASE
Device
Device
Device
Device
PHASE
Device
Example:
- Add Water
- Agitate
- Hand Addition, etc.
Example:
-Valves, Motors,
Sensors, etc.
EZSoft Inc., 1999-2004
EZSoft & ControlBuilder are registered trademarks of EZSoft Inc.
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 39
S88.01 Procedure Hierarchy
 Operation
 A sequence that causes a
significant physical or chemical
change within the batch
 Consists of an ordered
sequence of (one or more)
phases
 Phase
Procedure
Unit Procedure
Operation
 The smallest element of
procedural control, capable of
causing one or more actions
Phase
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 40
Typical Process Model - Unit Level
Material Selection
-
Material
Charging
MTR-002
007
Unit
Sequence
008
009
FT
Mix
MTR-001
M
010
PT
TT
Discharge
and
Recirc
Phase
Operation
Pump
Device
Control
MTR-003
XCV-005
FT
XCV-006
XCV-004
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 41
Unit Level
Mode (Auto, Manual, Test…)
Commands (Start, Stop, Reset, …)
Status ( Running, Faulted…)
Interlocks and Permissives
Faults/Alarms
Messages
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 42
Unit Level
UNIT
DESIGN MODEL
Device
Device
Device
PHASE
Device
PHASE
DEVICE
PHASE
UNIT OPERATION
c
Device
Device
Device
Device
Device
PHASE
Device
Device
Example:
- Run Batch on
Tank 1
- CIP Tank 2
PHASE
UNIT OPERATION
PHASE
Device
Device
Device
Device
Device
PHASE
Device
Example:
- Add Water
- Agitate
- Hand Addition, etc.
Example:
-Valves, Motors,
Sensors, etc.
EZSoft Inc., 1999-2004
EZSoft & ControlBuilder are registered trademarks of EZSoft Inc.
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 43
Typical Procedure using the Hierarchy
Procedure
Unit Procedure
Note parent / child relationships as you move
down and to the right in this procedure tree
Operation
Phase
Phase
Phase
Operation
Unit Procedure
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 44
Typical Process Model - Line Level
Process Cell
Unit
Operation
Phase
Device
Control
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 45
Process Cell
Process Cell
DESIGN MODEL
Device
Device
Device
PHASE
Device
Device
PHASE
UNIT OPERATION
Device
Example:
- Production
Area 1
- Production
Area 2
PHASE
UNIT OPERATION
LINE
UNIT
Device
Device
Device
PHASE
Device
PHASE
DEVICE
PHASE
UNIT OPERATION
c
Device
Device
Device
Device
Device
PHASE
Device
Example:
- Run Batch on
Tank 1
- CIP Tank 2
Device
PHASE
UNIT OPERATION
PHASE
Device
Device
Device
Device
Device
PHASE
Device
Example:
- Add Water
- Agitate
- Hand Addition, etc.
Example:
-Valves, Motors,
Sensors, etc.
EZSoft Inc., 1999-2000
EZSoft & ControlBuilder are registered trademarks of EZSoft Inc.
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 46
Recipe/Equipment Control Separation
Control Recipe
Procedure
Equipment
Control
Recipe
Procedure
ordered set of
Recipe Unit
Procedure
The only reference to
the physical processing
equipment occurs here
ordered set of
Recipe
Operation
ordered set of
Recipe
Phase
Equipment
Phase
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 47
S88.01 State Transition Diagram
State Transition Diagram for Example States for Procedural Elements
Restart
Restarting
Complete
Held
Reset
Holding
Hold
Idle
(Initial State)
Start
Pause
Running
Pausing
Resume
Abort
Aborting
Stop
Stopping
Paused
Final States
Reset
Aborted
Stopped
Quiescent States
Transient States
Reset
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 48
Dávkový řídicí systém
The Control Activity Model – CACTUS model
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 49
CACTUS model
• Správa receptur
• Plánování a rozvrhování výroby
• Správa informací o výrobě
• Správa procesů
• Řízení jednotek
• Řízení procesů
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 50
Other S88.01 Topics








Batch control activities and functions
Allocation and arbitration
Production planning and scheduling
Production information management
Process management
Unit supervision
Process control
Personnel and environmental protection
ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
slide 51