Transcript XYZ Polymer Process - University of Pannonia

Overview of the ANSI/ISA
S88.01 Batch Control Standard
© 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
© 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
© 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
© 1996
The Future of S88
 Part
two:
– 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
© 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
© 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)
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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
© 1996
Batch Processes and Equipment
Process Model (Entity - Relationship Diagram)
Process
consists of an
ordered set of
Process Stage
consists of an
ordered set of
Process Operation
consists of an
ordered set of
Process Action
A sequence of chemical, physical, or
biological activities for the conversion,
transport, or storage of material or energy
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
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
Minor processing activities that are combined to
make a process operation
© 1996
Batch Processes and Equipment
Process Model (Entity - Relationship Diagram)
Process
consists of an
ordered set of
Process Stage
consists of an
ordered set of
Process Operation
consists of an
ordered set of
Process Action
Example:
Polymerization of vinyl chloride
monomer
Example:
Polymerize
Recover
Dry
Example (Polymerize stage):
Prepare reactor
Charge
React
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
Area
A component of a batch manufacturing site that is
identified by physical, geographical, or logical
segmentation within the site
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
Unit
may contain
Equipment Module
may 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.
A functional group of equipment that can carry a
finite number of specific minor processing
activities. Examples: Reactor Jacket System,
Material Charge Equipment, etc.
may contain
Control Module
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.
© 1996
Batch Processes and Equipment
Physical Model (Entity - Relationship Diagram)
Process Cell
must contain
Unit
may contain
Equipment Module
Reactor
A
Reactor
B
may contain
may contain
Control Module
Blend/Adjust
Tank
may contain
© 1996
Batch Processes and Equipment
Physical Model (Entity - Relationship Diagram)
Process Cell
TIC
Reactor B
FQIC
must contain
Unit
M
LI
may contain
LIC
TIC
Equipment Module
may contain
may contain
Control Module
may contain
© 1996
Equipment Module or
Control Module?
FQIC
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)
- 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
© 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
© 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)
© 1996
Batch Control Concepts
Procedural Control Model (Entity - Relationship Diagram)
Procedure
consists of an
ordered set of
Unit Procedure
consists of an
ordered set of
Operation
consists of an
ordered set of
Phase
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.
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.
A procedural element defining an independent
processing activity consisting of the algorithm for
initiation, organization, and control of phases
The lowest level of procedural element in the
procedural control model
© 1996
Model mapping
Physical
Model
Procedural
Control Model
Procedure(s)
Unit
Procedure(s)
Operation(s)
combined
with a
combined
with a
combined
with a
combined
with a
Phase(s)
Phase(s)
combined
with a
Process
Cell(s)
provides process
functionality
to carry out a
provides process
functionality
to carry out a
Unit(s)
Unit(s)
Unit(s)
Equipment
Module(s)
provides process
functionality
to carry out a
provides process
functionality
to carry out a
provides process
functionality
to carry out a
Process
Model
Process
Process
Stage
Process
Operation
Process
Action
Process
Action
© 1996
Batch Control Concepts
Procedure
Reactor
A
Polymerize
Monomer B
Polymerize
Monomer A
Reactor
B
Blend/Adjust
Tank
Blend
Resin
© 1996
Batch Control Concepts
Polymerize Monomer A
Unit Procedure
FQIC
FQIC
Monomer
Prepare
Reactor
M
LI
TIC
React
Reactor A
Transfer
Out
© 1996
Batch Control Concepts
React
Operation
FQIC
Charge
Monomer
FQIC
Catalyst
Charge
Catalyst
Monomer
M
LI
TIC
Heat
Reactor A
Agitator
ON
Hold
Temperature
Agitator
OFF
© 1996
Definitions
 Recipe:
– The necessary set of information that uniquely
defines the production requirements of a
specific product
© 1996
Recipe contents
 Header:
– 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.
© 1996
Recipe contents
 Formula:
– 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)?
© 1996
Batch Control Concepts
Recipe Types (Entity - Relationship Diagram)
General Recipe
includes
Product - specific
processing information
includes
Site - specific
information
includes
Process cell - specific
information
may be
transformed into
Site Recipe
may be
transformed into
Master Recipe
is the basis for
Control Recipe
includes
Batch ID, batch size, in-process,
operator- and/or systemgenerated information
© 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
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
consists of an
ordered set of
Phase
references
Equipment
Phase
© 1996
Batch Control Concepts
Equipment
Phase
FQIC
Charge Monomer
FQIC
Equipment
Module
Catalyst
Reset Totalizer
Monomer
Open Valve
M
LI
TIC
Start Pump
Reactor A
Charge Target
Amount
Close Valve and
Stop Pump
© 1996
Recipe Phase vs. Equipment Phase
Raw
Materials
Header
A
B
Equipment
Module
Recipe Phases
Equipment
Phase
FQIC
Charge A
C
M
Charge B
Charge RM
Charge C
- Independent of Recipe
- Receives RM as parameter
© 1996
Definitions
 State:
– 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
© 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
© 1996
States example included in S88.01
Restart
Complete
Held
Restarting
Holding
Reset
Hold
Idle
(Initial
State)
Start
Abort
Aborting
Pause
Running
Pausing
Resume
Stop
Stopping
Paused
Final States
Aborted
Stopped
Reset
Reset
Quiescent States
Transient States
© 1996
Modes example included in S88.01
Mode
Behavior
Command
Automatic
The transitions within a procedure are
Operators may pause the progression, but
(Procedural)
carried out without interruption as
may not force transitions.
appropriate conditions are met.
Equipment entities are manipulated by
The equipment cannot be manipulated
their control algorithm.
directly by the operator.
Transitions within a procedure are
Operators may pause the progression or
carried out on manual commands as
re-direct the execution to an appropriate
Only)
appropriate conditions are fulfilled.
point. Transitions may not be forced.
Manual
The procedural elements within a
Operators may pause the progression or
procedure are executed in the order
force transitions.
Automatic
(Basic Control)
Semi-automatic
(Procedural
(Procedural)
specified by an operator.
Manual
(Basic Control)
Equipment entities are not manipulated by Equipment entities may be manipulated
their control algorithm.
directly by the operator.
© 1996
Batch Control Activities and Functions
Recipe
Management
Production
Planning and
Scheduling
Process
Management
Control Activity Model
Unit
Supervision
Production
Information
Management
Most functions
inside these activities
are outside the scope
of SP88
(Context Diagram)
Process
Control
Personnel and
Environmental
Protection
Outside the scope
of SP88
© 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
© 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)
© 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
Manage
General
Recipe
General Recipe
Manage
Site
Recipe
General Recipe
Procedural Element
General Recipe
Procedural
Element
Define General
Recipe Proced.
Element
General
Recipe
Procedural
Element
Information
Site Recipe
Manage
Master
Recipe
Master Recipe
Procedural Element
Define Master
Recipe Proced.
Element
Master
Recipe
Process
Management
Recipe Management
(Data Flow Diagram)
© 1996
Batch Control Activities and Functions
Production
Planning and
Scheduling
Recipe
Management
Master
Recipe
Batch
Scheduling
Information
Batch and
Resource
Information
Commands and
Status Information
Unit Recipes,
Commands, and Batch
and Status Information
Batch Progress
and Process Cell
Status Information
Manage
Process Cell
Resources
Manage
Batches
Production
Information
Management
Process Cell
Information
Batch
Information
Unit
Supervision
Batch and
Process Cell
Information
Collect
Batch and
Process Cell
Information
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
© 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
© 1996
Batch Control Activities and Functions
Production
Information
Management
Process
Management
Unit Recipes,
Commands and
Status Information
Batch and
Resource
Information
Acquire and Execute
Procedural Control
Elements
Manage
Unit
Resources
Commands and
Status Information
Commands and
Status Information
Process
Control
Batch and Unit
Information
Unit
Information
Batch
Information
Collect
Batch and Unit
Information
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
© 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
© 1996
Batch Control Activities and Functions
Production
Information
Management
Unit
Supervision
Commands and
Status Information
Commands and
Status Information
Execute
Equipment
Phases
Commands and
Status Information
Commands and
Status Information
Data
Execute
Basic
Control
Collect
Data
Data
Commands and
Status Information
Personnel and
Environmental
Protection
Data
Process Control
(Data Flow Diagram)
© 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
© 1996
Process Control
 Execute
Basic Control:
– 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
© 1996