overview of the ansi/isa s88.01 batch control standard © 1996

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

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History of SP88 In 1990 it was internationalized after a

petition to IEC was accepted - Working Group 11 (WG11) of subcommittee 65A was formed

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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

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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

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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

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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

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The ANSI/ISA S88.01 Standard

© 1996

Characteristics of S88.01

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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

Characteristics of S88.01

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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)

Usability of S88.01

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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

Batch Processes and Equipment

ProcessProcess

Process Model (Entity - Relationship Diagram)

Process StageProcess Stage

consists of an ordered set of

A sequence of chemical, physical, or biological activities for the conversion, transport, or storage of material or energy

Process OperationProcess Operation


Process ActionProcess Action


A part of a process that usually operatesindependently from other process stages and that usually results in a planned sequence of chemical and physical changes in the materialbeing processed

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A major processing activity that usuallyresults in a chemical or physical change in thematerial being processed and that is definedwithout consideration of the actual target equipment configuration

Minor processing activities that are combined tomake a process operation


ProcessProcess

Process Model (Entity - Relationship Diagram)

Process StageProcess Stage


Example:Polymerization of vinyl chloride monomer

Process OperationProcess Operation


Process ActionProcess Action


Example:PolymerizeRecoverDry

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Example (Polymerize stage):Prepare reactorChargeReact

Example (React operation):Add monomerAdd catalystHeat to 55-60 deg CHold at 55-60 deg C until press. decreases


EnterpriseEnterprise

Physical Model (Entity - Relationship Diagram of upper levels)

SiteSite

may contain

An organization that coordinates the operationof one or more sites

AreaArea

may contain

Process CellProcess Cell

may contain

A component of a batch manufacturing enterprisethat is identified by physical, geographical, or logicalsegmentation within the enterprise

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A component of a batch manufacturing site that isidentified by physical, geographical, or logicalsegmentation within the site

A logical grouping of equipment that includes theequipment required for the production of one ormore batches

Batch Processes and EquipmentPhysical Model (Entity - Relationship Diagram of lower levels)

UnitUnit

must contain

Equipment ModuleEquipment Module

may contain

Control ModuleControl Module

may contain

A collection of associated control modules and/orequipment modules and other process equipment in which one or more major processing activitiescan be conducted. Examples: Kettles, Reactors, Fermenters, Crystallyzers, etc.

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A functional group of equipment that can carry afinite number of specific minor processing activities. Examples: Reactor Jacket System, Material Charge Equipment, etc.

The lowest level of grouping of equipment in thephysical model that can carry out basic control.Examples: Regulatory Control Loops, Discrete Device Loops, etc.


may contain

may contain

Batch Processes and EquipmentPhysical Model (Entity - Relationship Diagram)

UnitUnit

must contain


may contain


may contain

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may contain

may contain

Reactor B

Blend/AdjustTank

Reactor A

Batch Processes and EquipmentPhysical Model (Entity - Relationship Diagram)

UnitUnit

must contain


may contain


may contain

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may contain

may contain

M

TIC

LIC

FQIC

LITIC

Reactor B

Equipment Module or Control Module?

FQIC

Can be either depending on implementation:- If separate basic control functions are used for the valve, totalizer, and discrete/sequential control, itcould be construed as an Equipment Module (i.e. multiple control modules carry out a minor processingactivity - 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)

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MaterialCharge Module

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

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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

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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)

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Batch Control Concepts

ProcedureProcedure

Procedural Control Model (Entity - Relationship Diagram)

Unit ProcedureUnit Procedure


The strategy for carrying out a process. Inthe context of S88, it refers to the strategy for making a batch in a process cell.

OperationOperation


PhasePhase


A strategy for carrying out a contiguous processwithin a unit. It consists of the contiguousoperations and the algorithm necessary for theinitiation, organization, and control of thoseoperations.

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A procedural element defining an independentprocessing activity consisting of the algorithm for initiation, organization, and control of phases

The lowest level of procedural element in theprocedural control model

Model mapping

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Procedure(s)

Procedural Control Model

UnitProcedure(s)

Operation(s)

Phase(s)

Phase(s)

Process Cell(s)

Physical Model

Unit(s)

Unit(s)

Unit(s)

Equipment Module(s)

Process

Process Model

Process Stage

Process Operation

Process Action

Process Action

combined with a

combined with a

combined with a

combined with a

combined with a

provides process functionality to carry out a






ProcedureProcedure

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Reactor B

Blend/AdjustTank

Reactor A

Blend Resin

PolymerizeMonomer A

Polymerize Monomer B



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TransferOut

PrepareReactor

React

Polymerize Monomer A

M

TICLI

FQIC

Reactor A

FQIC

Monomer


OperationOperation

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Catalyst

M

TICLI

FQIC

Reactor A

FQIC

Monomer

React

Charge Monomer

Charge Catalyst

AgitatorON

Heat

Hold Temperature

AgitatorOFF

Definitions Recipe:

– The necessary set of information that uniquely defines the production requirements of a specific product

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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.

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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)?

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General RecipeGeneral Recipe

Recipe Types (Entity - Relationship Diagram)

Site RecipeSite Recipe

may be transformed into

Master RecipeMaster Recipe

may be transformed into

Control RecipeControl Recipe

is the basis for

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Product - specificprocessing information

Product - specificprocessing information

includes

Site - specificinformation

Site - specificinformation

includes

Process cell - specificinformation

Process cell - specificinformation

includes

Batch ID, batch size, in-process, operator- and/or system-

generated information

Batch ID, batch size, in-process, operator- and/or system-

generated information

includes

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



ProcedureProcedureControl Recipe must be linked to

Equipment control at some procedural element level (e.g. Phase)



OperationOperation


PhasePhase


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EquipmentPhase

EquipmentPhase

references

Batch Control ConceptsEquipment

Phase

EquipmentPhase

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M

TICLI

Reactor A

FQICFQIC

Catalyst

EquipmentModule

Charge Monomer

Reset Totalizer

Open Valve

Charge Target Amount

Close Valve andStop Pump

Start Pump

Monomer

Recipe Phase vs. Equipment Phase

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Raw MaterialsHeader

M

FQIC

A

B

C

Recipe Phases

Charge A

Charge B

Charge C

Equipment Phase

Charge RM

- Independent of Recipe- Receives RM as parameter

EquipmentModule

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

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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

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States example included in S88.01

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Hold

Start

Restart

StopAbort

Reset

Reset

Reset

Restarting Holding

Running

StoppingAborting

Pausing

Resume

Pause

Aborted Stopped

Paused

HeldComplete

Final States

Quiescent States

Transient States

Idle(Initial

State)

Modes example included in S88.01

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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.

Batch Control Activities and Functions

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Outside the scopeof SP88

RecipeManagement

ProductionPlanning andScheduling

ProductionInformationManagement

ProcessManagement

UnitSupervision

ProcessControl

Personnel andEnvironmental

Protection

Control Activity Model

(Context Diagram)

Most functionsinside these activitiesare outside the scope

of SP88

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

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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)

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Production Information Management Sample Batch Information Recorded:

– Calculated parameters– Laboratory data– Operator interventions– Operator ID’s– Operator comments– Trends of selected process variables

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Recipe Management (Data Flow Diagram)

Manage GeneralRecipe

Manage Site

Recipe

General Recipe

Manage MasterRecipe

Define GeneralRecipe Proced.

Element

Define MasterRecipe Proced.Element

General Recipe

MasterRecipe

ProcessManagement

General RecipeProcedural

Element

Procedural Element

Procedural Element

Master Recipe

GeneralRecipe

ProceduralElement

Information

Site Recipe


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CollectBatch and

Process CellInformation

ManageBatches

ManageProcess CellResources

UnitSupervision

RecipeManagement

ProductionPlanning andScheduling


Unit Recipes,Commands, and Batchand Status Information

Batch InformationCommands and

Status Information

Process CellInformation

Batch andResource

Information

BatchScheduling

Information

MasterRecipe

Batch andProcess CellInformation

Batch Progressand Process Cell

Status Information

Process Management

(Data Flow Diagram)

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

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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

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CollectBatch and Unit

Information

Acquire and ExecuteProcedural Control

Elements

ManageUnit

Resources

ProcessControl

ProcessManagement


Commands and Status Information

Batch InformationCommands and

Status Information

UnitInformation

Batch andResource

Information

Batch and Unit Information

Unit Recipes,Commands and

Status Information

Unit Supervision

(Data Flow Diagram)

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

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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

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CollectData

Execute Equipment

Phases

ExecuteBasic

Control

UnitSupervision


Data

Commands andStatus Information

DataCommands and Status

Information

Process Control

(Data Flow Diagram)Personnel andEnvironmental

Protection


DataCommands and

Status Information


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

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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

overview of the ansi/isa s88.01 batch control standard © 1996

Documents

batch control slide

batch control standard

definitions u batch

batch control activities

standard u section

batch control concepts

specification u

future of s88 u