overview of the ansi

1. Overview of the ANSI/ISA S88.01 Batch Control Standard

3. 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 � to vendors and among themselves� to vendors and among themselves

4. Clarification The 88 number was assigned not due to the year that the committee was established but rather sequentially (next number available for an ISA standard)

5. History of SP88 Purpose: To provide standards and recommended practices for the design and specification of batch control systems The committee was established by ISA for the purpose of ...The committee was established by ISA for the purpose of ...

6. 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 SP88 was chartered with the scope of ...SP88 was chartered with the scope of ...

7. History of SP88 In 1990 it was internationalized after a petition to IEC was accepted - Working Group 11 (WG11) of subcommittee 65A was formed The corresponding international standard is known as IEC-SC65AThe corresponding international standard is known as IEC-SC65A

8. 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

9. 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

10. 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 Meanwhile across the Atlantic...Meanwhile across the Atlantic...

11. 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

12. The ANSI/ISA S88.01 Standard ANY QUESTIONS?ANY QUESTIONS?

13. 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 ...models are modular in nature which promostes re-usability of software...models are modular in nature which promostes re-usability of software

14. 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) S88 is not a cookbook for implementing batch control, there is still a need for control engineering knowledge S88.01 is a good foundation for developing functional specifications for batch control systemsS88 is not a cookbook for implementing batch control, there is still a need for control engineering knowledge S88.01 is a good foundation for developing functional specifications for batch control systems

15. 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 S88 is not a cookbook for implementing batch control, there is still a need for control engineering knowledge S88.01 is a good foundation for developing functional specifications for batch control systemsS88 is not a cookbook for implementing batch control, there is still a need for control engineering knowledge S88.01 is a good foundation for developing functional specifications for batch control systems

16. Main Sections of S88.01 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 � 63 terms are defined in the standard � 63 terms are defined in the standard

17. Main Sections of S88.01 Section 6: Batch control activities and functions - discusses control activities and functions associated with batch processing/manufacturing

18. 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 Some sample definitions as a warm up for discussions to follow...Some sample definitions as a warm up for discussions to follow...

19. Definitions 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

20. Batch Processes and Equipment The process activities which are part of a batch process are defined by a Process Model. The diagram shown here is an Entity Relationship diagram The main elements of this type of diagram are - Entity (represented by the rectangular shape) - Relationship (represented by the chicken leg shaped symbol) The relationship symbols defines how one entity relates to the other. Cardinality symbols at the ends of the relationship indicate how many of one entity correspond to the other - One >Many o None GIVE EXAMPLE The corresponding definitions of the entities are...The process activities which are part of a batch process are defined by a Process Model. The diagram shown here is an Entity Relationship diagram The main elements of this type of diagram are - Entity (represented by the rectangular shape) - Relationship (represented by the chicken leg shaped symbol) The relationship symbols defines how one entity relates to the other. Cardinality symbols at the ends of the relationship indicate how many of one entity correspond to the other - One >Many o None GIVE EXAMPLE The corresponding definitions of the entities are...

21. Batch Processes and Equipment Examples of the entities are...Examples of the entities are...

22. Batch Processes and Equipment The physical aspects of a batch enterprise are defined by a Physical Model of which the top four levels are shown here... DESCRIBE RELATIONSHIPS Definitions for these entities are� The top three entities are shown dashed since the configuration of systems at these levels of the enterprise are beyond the scope of the S88 standard. I�ll let you read the corresponding definitions...The physical aspects of a batch enterprise are defined by a Physical Model of which the top four levels are shown here... DESCRIBE RELATIONSHIPS Definitions for these entities are� The top three entities are shown dashed since the configuration of systems at these levels of the enterprise are beyond the scope of the S88 standard. I�ll let you read the corresponding definitions...

23. Batch Processes and Equipment The lower four levels of the physical model (process cell being repeated) are shown here� DESCRIBE RELATIONSHIPS Definitions for these entities are� The key differences between and equipment module and a control module are that an equipment module can perform procedural control while a control module can only perform basic control. Later I will define the different types of control. The lower four levels of the physical model (process cell being repeated) are shown here� DESCRIBE RELATIONSHIPS Definitions for these entities are� The key differences between and equipment module and a control module are that an equipment module can perform procedural control while a control module can only perform basic control. Later I will define the different types of control.

24. Batch Processes and Equipment Examples of the entities are a resin manufacturing cell with two reactors and a blending/solids adjustment tank... CONTINUES ON THE NEXT OVERHEADExamples of the entities are a resin manufacturing cell with two reactors and a blending/solids adjustment tank... CONTINUES ON THE NEXT OVERHEAD

25. Batch Processes and Equipment An example of equipment module are the reactor overhead system used for distillation/separation... Examples of control modules are the level and temperature control modules which are part of the reactor overhead system... ANY QUESTIONS? An example of equipment module are the reactor overhead system used for distillation/separation... Examples of control modules are the level and temperature control modules which are part of the reactor overhead system... ANY QUESTIONS?

26. Equipment Module or Control Module? Time for a quiz to see if you have been paying attention. Is it an ...Time for a quiz to see if you have been paying attention. Is it an ...

27. 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 The standard defines three types of control...The standard defines three types of control...

28. 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 DESCRIBE We will see more examples about this type of control later...DESCRIBE We will see more examples about this type of control later...

29. 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) Typical methods of allocation include: - selecting the equipment with the least amount of operating time - selecting the next available piece of equipment Typical methods of arbitration include: - First in/first out (FIFO) also referred to as First Come/First Serve - FIFO�s with prioritization schemes - Pre-emptying, where a resource is allocated to upon request overriding any order or priorityTypical methods of allocation include: - selecting the equipment with the least amount of operating time - selecting the next available piece of equipment Typical methods of arbitration include: - First in/first out (FIFO) also referred to as First Come/First Serve - FIFO�s with prioritization schemes - Pre-emptying, where a resource is allocated to upon request overriding any order or priority

30. Batch Control Concepts Procedural Control is further defined by a model... DESCRIBE RELATIONSHIPS The corresponding definitions are... Procedural Control is further defined by a model... DESCRIBE RELATIONSHIPS The corresponding definitions are...

31. Model mapping Mapping the previosly introduced models we can see how process objectives are met by a combination of procedural elements and physical entities� DESCRIBE A MAPPING...Mapping the previosly introduced models we can see how process objectives are met by a combination of procedural elements and physical entities� DESCRIBE A MAPPING...

32. Batch Control Concepts Lets now see some examples of procedural elements. Referring back to the physical entities introduced earlier in our resin process example...Lets now see some examples of procedural elements. Referring back to the physical entities introduced earlier in our resin process example...

33. Batch Control Concepts Expanding the Polymerize Monomer A unit procedure we can see prepare, react and xfer out operationsExpanding the Polymerize Monomer A unit procedure we can see prepare, react and xfer out operations

34. Batch Control Concepts Expanding the React operation we can see � phasesExpanding the React operation we can see � phases

35. Definitions Recipe: The necessary set of information that uniquely defines the production requirements of a specific product When we talk about recipes...When we talk about recipes...

36. 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. DESCRIBE It attempts to answer the questions...DESCRIBE It attempts to answer the questions...

37. 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)? DESCRIBE It attempts to answer the questions...DESCRIBE It attempts to answer the questions...

38. Batch Control Concepts The standard defines four types of recipes� The site recipe is basically the same as the general recipe with the addition of site specific information. For example: - Different raw materials available from local suppliers - Differences in parameters due to altitude changes The control recipe is the working recipe, created at runtime as a copy of the master recipe. It adds items such as ... The standard defines four types of recipes� The site recipe is basically the same as the general recipe with the addition of site specific information. For example: - Different raw materials available from local suppliers - Differences in parameters due to altitude changes The control recipe is the working recipe, created at runtime as a copy of the master recipe. It adds items such as ...

39. Recipe Procedures (Entity - Relationship Diagr.) Procedural elements associated with the four types of recipes are as follows...Procedural elements associated with the four types of recipes are as follows...

40. 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 ...The key is that equipment control is independent from the recipe and that it defines the required equipment/process control....The key is that equipment control is independent from the recipe and that it defines the required equipment/process control.

41. Batch Control Concepts This is most commonly achieved at the phase level. Recipe phases are then associated with a corresponding equipment phase.This is most commonly achieved at the phase level. Recipe phases are then associated with a corresponding equipment phase.

42. Batch Control Concepts Refering back to the reactor previously shown, we see an example of the equipment phase A one to one relationship typically exists between an equipment phase and an equipment module. The type of activities defined in an equipment phase are not defined in the recipe. Refering back to the reactor previously shown, we see an example of the equipment phase A one to one relationship typically exists between an equipment phase and an equipment module. The type of activities defined in an equipment phase are not defined in the recipe.

43. Recipe Phase vs. Equipment Phase Here is an example of the relationship between a Recipe Phase and an Equipment Phase. Notice that a many to one relationship exists. The same equipment phase logic can be used for all three charges by just passing parameters to the software. This is a good example of modularity which promotes re-usability of software.Here is an example of the relationship between a Recipe Phase and an Equipment Phase. Notice that a many to one relationship exists. The same equipment phase logic can be used for all three charges by just passing parameters to the software. This is a good example of modularity which promotes re-usability of software.

44. 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 Are you still awake! Here are more definitions� Modes and states apply to both elements of the Procedural Model and to equipment entities defined in the Physical Model.Are you still awake! Here are more definitions� Modes and states apply to both elements of the Procedural Model and to equipment entities defined in the Physical Model.

45. 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 It is important to note that� Propagation refers to how changes in mode or state propagate to other procedural elements or equipment entities. An example of mode propagation: changing the mode of any phase to manual causing the corresponding operation and unit procedure mode to change to manual. An example of state propagation: aborting the unit procedure when any operation is aborted. This is subjective and very much dependent on the particular application It is important to note that� Propagation refers to how changes in mode or state propagate to other procedural elements or equipment entities. An example of mode propagation: changing the mode of any phase to manual causing the corresponding operation and unit procedure mode to change to manual. An example of state propagation: aborting the unit procedure when any operation is aborted. This is subjective and very much dependent on the particular application

46. States example included in S88.01 This is the example of states included in the standard. This is a state transition diagram whose primay elements are: - States (represented by ellipses) - Transitions (represented by lines with arrows in the direction of the state reached upon transitioning) Text is used to describe the commands which cause the transition to occurr GIVE EXAMPLES This is only an sample specification and not a requirement of all batch control applications. Some processes may not allow state transitions such as these.This is the example of states included in the standard. This is a state transition diagram whose primay elements are: - States (represented by ellipses) - Transitions (represented by lines with arrows in the direction of the state reached upon transitioning) Text is used to describe the commands which cause the transition to occurr GIVE EXAMPLES This is only an sample specification and not a requirement of all batch control applications. Some processes may not allow state transitions such as these.

47. Modes example included in S88.01 This is the example of modes included in the standard. The Behavior column describes how the procedural element or basic control acts while in the given mode. The command column describes what control is permitted to the operator and/or other control functions. GIVE EXAMPLES This is only an sample specification and not a requirement of all batch control applications. Some processes may not permit modes such as semiautomatic or manual.This is the example of modes included in the standard. The Behavior column describes how the procedural element or basic control acts while in the given mode. The command column describes what control is permitted to the operator and/or other control functions. GIVE EXAMPLES This is only an sample specification and not a requirement of all batch control applications. Some processes may not permit modes such as semiautomatic or manual.

48. 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 I promise this is the last definitionI promise this is the last definition

49. Batch Control Activities and Functions The last section of the standard defines the Control Activity model. This is a Context diagram whose primary elements are: - Control activites represented by rectangles with rounded eges - Information flows represented by the connecting lines The Personnel and Envir. Protect. control activity is outside the scope of the standard but is shown here to depict some form of interface to process control. BRING IN THE SLIDING TEXT Most of the activies within PP and S and PIM are outside the scope of the standard. Only Batch Scheduling in PP and S and Managing Batch History in PIM are of any concern to the standard. Thus we will not spend much time discussing these activities. The last section of the standard defines the Control Activity model. This is a Context diagram whose primary elements are: - Control activites represented by rectangles with rounded eges - Information flows represented by the connecting lines The Personnel and Envir. Protect. control activity is outside the scope of the standard but is shown here to depict some form of interface to process control. BRING IN THE SLIDING TEXT Most of the activies within PP and S and PIM are outside the scope of the standard. Only Batch Scheduling in PP and S and Managing Batch History in PIM are of any concern to the standard. Thus we will not spend much time discussing these activities.

50. 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 Batch schedules are developed based on� Batch schedules are developed based on�

51. Production Planning and Scheduling Develop Batch Schedules: Allowing revisions on demand based on significant changed in batch progress and cell status Allowing manual intervention Some sample capabilities of the � function areSome sample capabilities of the � function are

52. Production Information Management Manage Batch History: Receive and store batch history information Manipulate historical data Produce reports Some sample capabilities of the � function areSome sample capabilities of the � function are

53. 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) Sample batch information which is recorded includes� CONTINUED ON NEXT SLIDESample batch information which is recorded includes� CONTINUED ON NEXT SLIDE

54. Production Information Management Sample Batch Information Recorded: Calculated parameters Laboratory data Operator interventions Operator ID�s Operator comments Trends of selected process variables

55. Batch Control Activities and Functions Zooming into the Recipe Management control activity we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW We will not talk much about these since they are mainly recipe data management functions.Zooming into the Recipe Management control activity we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW We will not talk much about these since they are mainly recipe data management functions.

56. 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 Some sample capabilities of the � function areSome sample capabilities of the � function are

57. Recipe Management 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 Some sample capabilities of the � function areSome sample capabilities of the � function are

58. 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 END OF GENERAL RECIPE Some sample capabilities of the � function areEND OF GENERAL RECIPE Some sample capabilities of the � function are

59. 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 Some sample capabilities of the � function areSome sample capabilities of the � function are

60. Recipe Management 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 Some sample capabilities of the � function areSome sample capabilities of the � function are

61. Recipe Management Define Master Recipe Procedural Elements: Maintaining inventory of procedural elements Managing changes to procedural elements END OF DEFINE MASTER RECIPE...END OF DEFINE MASTER RECIPE...

62. Batch Control Activities and Functions Zooming into the Process Management control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW Zooming into the Process Management control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW

63. 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 The scope of Process Management is the Process Cell Some sample capabilities of the � function are CONTINUED ON NEXT SLIDEThe scope of Process Management is the Process Cell Some sample capabilities of the � function are CONTINUED ON NEXT SLIDE

64. Process Management 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 CONTINUED ON NEXT SLIDECONTINUED ON NEXT SLIDE

65. 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

66. 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 Some sample capabilities of the � function are CONTINUED ON NEXT SLIDESome sample capabilities of the � function are CONTINUED ON NEXT SLIDE

67. 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 Some sample data collected by the � function areSome sample data collected by the � function are

68. Process Management Collect Batch and Process Cell Information: Time of commands sent to Unit Supervision and Process Control Delays due to lack of equipment availability Time of allocation, reservation and release of resources Requests and results for equipment allocation and reservation Status changes in unallocated equipment

69. Batch Control Activities and Functions Zooming into the Unit Supervision control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW Zooming into the Unit Supervision control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW

70. 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 The scope of Unit Supervision is the Unit Some sample capabilities of the � function are CONTINUED ON NEXT SLIDEThe scope of Unit Supervision is the Unit Some sample capabilities of the � function are CONTINUED ON NEXT SLIDE

71. 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 Some sample capabilities of the � function are CONTINUED ON NEXT SLIDESome sample capabilities of the � function are CONTINUED ON NEXT SLIDE

72. Unit Supervision 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 Some sample data collected by the � function are CONTINUED ON NEXT SLIDESome sample data collected by the � function are CONTINUED ON NEXT SLIDE

73. Unit Supervision 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

74. Batch Control Activities and Functions Zooming into the Process Control control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOWZooming into the Process Control control activitiy we see the following functions... DESCRIBE IN TERMS OF IN-FLOW --> ACTIVITY --> OUTFLOW

75. 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 The scope of Process Control is the Equipment and Control Modules Some sample capabilities of the � function areThe scope of Process Control is the Equipment and Control Modules Some sample capabilities of the � function are

76. 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 Some sample capabilities of the � function are Some sample data collected by the � function areSome sample capabilities of the � function are Some sample data collected by the � function are