S88-Batch-Control-Standard

S88 Batch Control Standard : 

S88 Batch Control Standard Presenter Gary Wedge

Agenda : 

Agenda SP88 & S88 Clarification. History of SP88. The S88 Standard. The S88 Standard Definitions. Batch Processes & Equipment. Equipment Module or Control Module. Three Types of Control. Batch Control Concepts. Model Mapping. Definitions. Recipe Phase Vrs Equipment Phase. Modes and States. States examples included in S88.01.

Agenda : 

Agenda Mode examples included in S88.01. Batch Control Activities and Functions. Production Planning and Scheduling. Production Information Management. Recipe Management. Process Management. Unit Supervision. Process Control. Summary.

SP88 & S88 Clarification. : 

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

History of S88. : 

History of S88. Established by the 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.

History of SP88. : 

History of SP88. Purpose: To provide standards and recommended practices for the design and specification of batch control systems.

History of SP88. : 

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.

History of SP88. : 

History of SP88. In 1990 it was internationalized. Working Group 11 (WG11) of subcommittee 65A was formed. 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 The standard was published as an ANSI standard in the summer of 1995. The IEC approved the standard in 1996 Revised in 2009

The S88 Standard. : 

The S88 Standard. 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.

The S88 Standard. : 

The S88 Standard. 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) 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.

The S88 Standard. : 

The S88 Standard. 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. Section 6: Batch control activities and functions - discusses control activities and functions associated with batch processing/manufacturing.

The S88 Standard Definitions. : 

The S88 Standard 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. 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.

Batch Processes & Equipment. : 

Batch Processes & Equipment. Process Process Model (Entity - Relationship Diagram) Process Stage A sequence of chemical, physical, or biological activities for the conversion, transport, or storage of material or energy. Process Operation Process Action 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. Consists of an ordered set of Consists of an ordered set of Consists of an ordered set of

Batch Processes & Equipment. : 

Batch Processes & Equipment. Process Process Model (Entity - Relationship Diagram) Process Stage Process Operation Process Action Consists of an ordered set of Consists of an ordered set of Consists of an ordered set of 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

Batch Processes & Equipment. : 

Batch Processes & Equipment. Enterprise Physical Model (Entity - Relationship Diagram of upper levels) Site Area Process Cell May contain An organization that coordinates the operation of one or more sites A component of a batch manufacturing enterprise that is identified by physical, geographical, or logical segmentation within the enterprise A component of a batch manufacturing site that is identified by physical, geographical, or logical segmentation within the site A logical grouping of equipment that includes the equipment required for the production of one or more batches May contain May contain

Batch Processes & Equipment. : 

Batch Processes & Equipment. Physical Model (Entity - Relationship Diagram of lower levels) Unit Must contain Equipment Module May contain Control Module May contain Process Cell May contain 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. 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.

Batch Processes & Equipment. : 

Batch Processes & Equipment. Physical Model (Entity - Relationship Diagram) Unit Must contain Equipment Module May contain Control Module May contain Process Cell May contain May contain Blend/Adjust Tank Reactor A Reactor B

Batch Processes & Equipment. : 

Batch Processes & Equipment. Physical Model (Entity - Relationship Diagram) Unit Must contain Equipment Module May contain Control Module May contain Process Cell May contain May contain Reactor B

Equipment Module or Control Module. : 

Equipment Module or Control 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)

Three Types of Control. : 

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. Procedural control: Control that directs equipment-oriented actions to take place in an ordered sequence in order to carry out some process-oriented task. 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).

Batch Control Concepts. : 

Batch Control Concepts. Procedure Unit Procedure Operation Phase Consists of an ordered set of Consists of an ordered set of Consists of an ordered set of Procedural Control Model (Entity - Relationship Diagram) 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

Model Mapping. : 

Model Mapping. Procedure(s) Procedural Control Model Unit Procedure(s) Operation(s) Phase(s) Phase(s) Process Cell(s) Physical Model Unit(s) Unit(s) Unit(s) Equipment Module(s) Process Process Stage Process Operation Process Action Process Action combined with a combined with a combined with a combined with a provides process functionality to carry out a provides process functionality to carry out a provides process functionality to carry out a provides process functionality to carry out a provides process functionality to carry out a Process Model

Batch Control Concepts. : 

Batch Control Concepts. Procedure Reactor B Blend/Adjust Tank Reactor A

Batch Control Concepts. : 

Batch Control Concepts. Transfer Out Prepare Reactor React Polymerize Monomer A Monomer Unit Procedure Reactor A

Batch Control Concepts. : 

Batch Control Concepts. Monomer Unit Procedure Reactor A Catalyst React Agitator ON Heat Hold Temperature Agitator OFF

Definitions. : 

Definitions. Recipe: The necessary set of information that uniquely defines the production requirements of a specific product. 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.

Definitions. : 

Definitions. 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)?

Batch Control Concepts. : 

Batch Control Concepts. Recipe Type (Entity - Relationship Diagram) General Recipe Site Recipe may be transformed into Master Recipe may be transformed into Control Recipe is the basis for Product - specific processing information Includes Site - specific information Process cell - specific information Batch ID, batch size, in-process, operator- and/or system- generated information Includes Includes Includes

Batch Control Concepts. : 

Batch Control Concepts. Recipe Procedures (Entity - Relationship Diagram) Procedure Process Stage is an ordered set of Process Operation Process Action Procedure Unit Procedure Operation Phase is an ordered set of is an ordered set of is an ordered set of is an ordered set of is an ordered set of General and Site Recipes Master and Control Recipes

Batch Control Concepts. : 

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. : 

Batch Control Concepts. Procedure Unit Procedure consists of an ordered set of Operation consists of an ordered set of Phase consists of an ordered set of Equipment Phase references Control Recipe must be linked to Equipment control at some procedural element level. (e.g. Phase)

Batch Control Concepts. : 

Batch Control Concepts. Monomer Equipment Phase Reactor A Catalyst Charge Monomer Reset Totalizer Open Valve Charge Target Amount Close Valve and Stop Pump Start Pump

Recipe Phase Vrs Equipment Phase. : 

Recipe Phase Vrs Equipment Phase. Equipment Module Recipe Phases Charge A Charge B Charge C Equipment Phase Charge RM - Independent of Recipe - Receives RM as parameter Raw Materials Header A B C

Definitions. : 

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.

Modes and States. : 

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.

States examples included in S88.01. : 

States examples included in S88.01. Hold Start Restart Stop Abort Reset Reset Reset Restarting Holding Running Stopping Aborting Pausing Resume Pause Final States Quiescent States Transient States Idle Initial State

Mode examples included in S88.01. : 

Mode examples included in S88.01. Mode Behavior Command Automatic (Procedural) The transitions within a procedure are carried out without interruption as appropriate conditions are met. Operators may pause the progression, but may not force transitions. Automatic (Basic Control) Equipment entities are manipulated by their control algorithm. The equipment cannot be manipulated directly by the operator. Semi-automatic (Procedural Only) Transitions within a procedure are carried out on manual commands as appropriate conditions are fulfilled. Operators may pause the progression or re-direct the execution to an appropriate point. Transitions may not be forced. Manual (Procedural) The procedural elements within a procedure are executed in the order specified by an operator. Operators may pause the progression or force transitions. Manual (Basic Control) Equipment entities are not manipulated by their control algorithm. Equipment entities may be manipulated directly by the operator.

Definitions. : 

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.

Batch Control Activities and Functions. : 

Batch Control Activities and Functions. Outside the scope of SP88 Recipe Management Production Planning and Scheduling Production Information Management Process Management Unit Supervision Process Control Personnel and Environmental Protection Control Activity Model (Context Diagram)

Production Planning and Scheduling. : 

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. Develop Batch Schedules: Allowing revisions on demand based on significant changed in batch progress and cell status allowing manual intervention.

Production Information Management. : 

Production Information Management. Manage Batch History: Receive and store batch history information manipulate historical data produce reports. 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) Calculated parameters Laboratory data Operator interventions Operator ID’s Operator comments Trends of selected process variables

Batch Control Activities and Functions. : 

Batch Control Activities and Functions. Manage General Recipe Manage Site Recipe General Recipe Manage Master Recipe Define General Recipe Proceed. Element Define Master Recipe Proceed Element General Recipe Master Recipe Process Management General Recipe Procedural Element Procedural Element Procedural Element Master Recipe General Recipe Procedural Element Information Site Recipe Recipe Management (Data Flow Diagram)

Recipe Management. : 

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. 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.

Recipe Management. : 

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.

Recipe Management. : 

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. 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

Recipe Management. : 

Recipe Management. Define Master Recipe Procedural Elements: Maintaining inventory of procedural elements. Managing changes to procedural elements.

Batch Control Activities and Functions. : 

Batch Control Activities and Functions. Process Flow Management (Data Flow Diagram) Collect Batch and Process Cell Information Manage Batches Manage Process Cell Resources Unit Supervision Recipe Management Production Planning and Scheduling Production Information Management Unit Recipes, Commands, and Batch and Status Information Batch Information Commands and Status Information Process Cell Information Batch and Resource Information Batch Scheduling Information Master Recipe Batch and Process Cell Information Batch Progress and Process Cell Status Information

Process Management. : 

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. 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.

Process Management. : 

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. 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.

Process Management. : 

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.

Batch Control Activities and Functions. : 

Batch Control Activities and Functions. Unit Supervision (Data Flow Diagram) Collect Batch and Unit Information Acquire and Execute Procedural Control Elements Manage Unit Resources Process Control Process Management Production Information Management Commands and Status Information Batch Information Commands and Status Information Unit Information Batch and Resource Information Batch and Unit Information Unit Recipes, Commands and Status Information

Unit Supervision. : 

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. Acquire and Execute Procedural Elements: - Associating recipe procedural elements with equipment procedural elements. - Initiating and parameterizing equipment phases.

Unit Supervision. : 

Unit Supervision. Manage Unit Resources: - Interfacing with arbitration functions. - Ensuring propagation of unit and procedural element modes and states. 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. 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.

Batch Control Activities and Functions. : 

Batch Control Activities and Functions. Process Control (Data Flow Diagram) Collect Data Execute Equipment Phases Execute Basic Control Production Information Management Data Commands and Status Information Data Commands and Status Information Commands and Status Information Data Commands and Status Information Commands and Status Information

Process Control. : 

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. 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.

Summary. : 

Summary. SP88 is the ISA committee responsible for developing the batch control standard. S88 is the standard developed by such a committee. S88 defines universal terminology and models - applicable to all types of control systems. S88 defines a modular structure - breaks up complex concepts into smaller elements; promotes reusability. S88 is a Non-excluding/binding standard that does not suggest that there is only one way to do batch control and does not force users to abandon current methods. S88 provides a collapsible model - elements which are not applicable to particular users needs can be omitted. (except for unit, master recipe and control recipe entities).

Summary. : 

Summary. S88 provides an 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 designing batch control systems - Provides a framework; still requires experienced control systems engineers. S88 Great for Functional Specifications - Models and terminology can be used to define requirements for batch control.