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ANSI/ISA S88.01 Batch Standard

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  1. ANSI/ISA S88.01 Batch Standard Greg Skovira President EZSoft Inc. Daren Moffatt Solution Architect Invensys Foxboro (Výběr pro Počítačové řídicí systémy 2012) ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  2. Batch Process Example Material Storage 1 Material Storage 2 Material Storage 3 Minor Additions Mixer ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  3. Processing Overview • A Discrete Process produces finite quantities of discrete parts. • Circuit boards, memory chips, floppy disk, disk drives, computers, cars, car engines, dishwashers, etc... • A Continuous Process produces a continuous flow of free flowing product, usually a liquid or powder. • Bulk chemicals, gasoline, kerosene, natural gas, electricity, wood pulp, etc... • A Batch Process produces a finite quantity of free flowing product, usually a liquid or powder. • Specialty chemicals, paints, pigments, personal care products, food products, pharmaceuticals, etc. ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  4. Batch Process Example Material Storage 1 Material Storage 2 Material Storage 3 Feed Tank 1 Feed Tank 2 Minor Additions Mixer Spray Dryer 2 Spray Dryer 1 BATCH CONTINUOUS Packaging Line 1 Packaging Line 2 DISCRETE ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  5. Batch Processing Characteristics Material Storage 1 Material Storage 2 Material Storage 3 Mixer 2 Mixer 1 Reactor 2 Reactor 1 Storage Tank 1 Storage Tank 2 Storage Tank 3 • Number of Products • Single product • Multiple products • Physical Layout • Single stream • Multi-stream ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  6. Standards & Organizations • ISA S88 Committee • S88.01 • S88.00.02 • S88.00.03 • World Batch Forum • BatchML • B2MML • OPC for Batch www.isa.org www.wbf.org www.opcfoundation.org ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  7. ISA 88.01/ IEC 61512-1 • Terminology and models that apply to all types of control systems • A modular structure that promotes reuse • A structure that applies to both automated and manually-controlled batches • Separates the recipe that describes how the batch is to be made from the equipment used to make the batch ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  8. ANSI/ISA-88.01-1995 / IEC 61512-1 • Standard covers four basic concepts: • How to depict what you have in the plant (physical model) • How to define what you would like to accomplish in the plant (recipe) • Implementation of what you can do in the plant (equipment logic) • How to put the three pieces mentioned above together in an intelligent, reusable and successful way ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  9. Enterprise / Site / Area Process Cell The entire collection of equipment needed to execute a single recipe from start to finish batch Consists of one or more units Unit Usually centered on a major piece of process equipment Frequently operates on or contains the complete batch May operate on or contain only a portion of the complete batch Cannot operate on or contain more than one batch at a time S88.01 Physical Hierarchy Process Cell Unit Equipment Module Control Module ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  10. Equipment Module A collection of control modules or other equipment modules Can carry out a finite number of minor processing activities, i.e., phases Contains all the necessary processing equipment to carry out these processing activities Control Module A collection of sensors, actuators, other control modules, and associated processing equipment Acts as a single entity from a control standpoint Is the direct connection to the process through its sensor and actuators Procedures do not run on control modules S88.01 Physical Hierarchy Process Cell Unit Equipment Module Control Module ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  11. Batch Control Conceptual Example • Equipment=Process that we will sequence • Procedure=order in which we will sequence the process • Batch Journal=Record of what happened to the process Equipment Journal Procedure 12:05 This happened 12:07 That happened 12:10 This and that happened 1. Do this 2. Do that 3. Do this and that “How” “When” “What” ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  12. Batch Control Conceptual Example Equipment Examples Illustration Valve Pump Motor Pressure Controller Control Module ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  13. Batch Control Conceptual Example TIC Equipment Examples Illustration Equipment Module (a set of Control Modules) Temperature Control System consisting of: 1. Recycle pump 2. Chilled water valve 3. Steam valve 4. Temperature Controller Chilled Water Steam ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  14. Batch Control Conceptual Example TIC Equipment Examples Illustration Unit (a set of Equipment Modules) Reactor consisting of: 1. Temperature control system 2. Agitation system 3. Material addition systems 4. Discharge system 5. Analysis system ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  15. The Recipe is the necessary set of information that uniquely defines the production requirements for a specific product Recipe Management General Recipe Processing Information Site Recipe Site-specific Information Master Recipe Process Cell Specific Info Batch Specific Info Control Recipe ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  16. General & Site Recipes One General Recipe per produced material, maintained at the enterprise level (1000 company wide products) One Site Recipe per site and produced material, maintained at the site for local materials, language, or segment of production (10,000 site recipes for 10 sites) One Master Recipe per Process Cell and produced material (50,000 master recipes for 5 cells per site) One Control Recipe per batch that describes the custom options and formula values for one specific batch of product (1,000,000 batches per year) ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  17. Recipe Information Categories Recipe Header Other Information Equipment Requirements Formula Procedure Process Parameters Process Inputs Process Outputs Formula ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  18. Procedure (recipe level) The overall strategy for making a batch Consists of an ordered sequence of unit procedures Unit Procedure The subset of a procedure that occurs within a single unit Consists of an ordered sequence of (one or more) operations S88.01 Procedure Hierarchy Procedure Unit Procedure Operation Phase ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  19. Operation A sequence that causes a significant physical or chemical change within the batch Consists of an ordered sequence of (one or more) phases Phase The smallest element of procedural control, capable of causing one or more actions S88.01 Procedure Hierarchy Procedure Unit Procedure Operation Phase ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  20. Typical Procedure using the Hierarchy Procedure Unit Procedure Unit Procedure Operation Operation Phase Phase Phase Note parent / child relationships as you move down and to the right in this procedure tree ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  21. Batch Control Conceptual Example Recipe procedure Examples Illustration Procedure Make Product A Make Product B Unit Procedure Any set of Operations Unit Operation Filtration Reaction Distillation Solution Preparation Phase Agitate Heat Cool Transfer Charge Recycle Procedure Unit Procedure 2 Unit Procedure 1 Unit Operation 1 Unit Operation 4 Unit Operation 2 Unit Operation 3 Phase 3 Phase 5 Phase 7 Phase 1 Phase 4 Phase 2 Phase 6 Phase 8 ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  22. Recipe/Equipment Control Separation Equipment Control Control Recipe Procedure The only reference to the physical processing equipment occurs here Recipe Procedure ordered set of Recipe Unit Procedure ordered set of Recipe Operation ordered set of Equipment Recipe Phase Phase ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  23. Typy řízení • základní řízení • regulace • blokace nesprávné činnosti (interlocking) • sledování překročení mezí • reakce na alarmy • manuální řízení • procedurální řízení • koordinační řízení • řízení zdrojů zařízení • výběr procedurálních prvků pro běh • propagace režimů ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  24. Supervisory Level Recipe Maintenance/Editing Batch Management Data Acquisition Event based Time based Reporting Operator Interface Real Time Control Key Batch System Components Př.: Wonderware InBatch InTouch PLCs ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  25. Information Level 4 Business Logistics Systems Plant Production Scheduling and Operational Management Planning (MRP II, Financials, etc.) The 10,000 Ft View Level 3 Manufacturing Control Systems Area Supervision, Production Scheduling, Reliability Assurance Manufacturing Execution Integration Levels 2, 1, 0 Batch Control Systems Continuous Control Systems Discrete Control Systems Process Control Control ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  26. Typical System Architecture ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  27. Typical System Architecture ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  28. Process level The Model Unit level control Phase level control Device level control ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  29. The 2,000 Ft View From the Bottom Up ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  30. Equipment Module A collection of control modules or other equipment modules Can carry out a finite number of minor processing activities, i.e., phases Contains all the necessary processing equipment to carry out these processing activities Control Module A collection of sensors, actuators, other control modules, and associated processing equipment Acts as a single entity from a control standpoint Is the direct connection to the process through its sensor and actuators Procedures do not run on control modules S88.01 Physical Hierarchy Process Cell Unit Equipment Module Control Module ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  31. Typical Process Model - Device Level MTR-002 MTR-001 007 008 009 010 M XCV-005 Device Control MTR-003 XCV-006 XCV-004 ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  32. Mode (Auto, Manual, Test…) Commands (Start, Stop, Reset, …) Status ( Running, Faulted…) Interlocks and Permissives (blokování a povolení) Faults/Alarms Messages Device Level Properties ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  33. Device Level ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  34. Equipment Module A collection of control modules or other equipment modules Can carry out a finite number of minor processing activities, i.e., phases Contains all the necessary processing equipment to carry out these processing activities Control Module A collection of sensors, actuators, other control modules, and associated processing equipment Acts as a single entity from a control standpoint Is the direct connection to the process through its sensor and actuators Procedures do not run on control modules S88.01 Physical Hierarchy Process Cell Unit Equipment Module Control Module ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  35. Operation A sequence that causes a significant physical or chemical change within the batch Consists of an ordered sequence of (one or more) phases Phase The smallest element of procedural control, capable of causing one or more actions S88.01 Procedure Hierarchy Procedure Unit Procedure Operation Phase ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  36. - Material Selection Material Charging Mix Discharge and Recirc Phase Operation Pump Device & Regulatory Control Typical Process Model - Phase Level FT MTR-002 MTR-001 007 008 009 010 M XCV-005 FT MTR-003 XCV-006 XCV-004 ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  37. Mode (Auto,Manual,…) Commands (Start, Stop, Reset, …) Status ( Running, Faulted, Paused…) Interlocks and Permissives Faults/Alarms Messages Phase Level Properties ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  38. S88.01 State Transition Diagram Complete Paused Held Restart Reset Hold Start Pause Idle (Initial State) Resume Holding Running Aborting Stopping Restarting Pausing Abort Stop Final States Aborted Stopped Quiescent States Reset Transient States Reset State Transition Diagram for Example States for Procedural Elements ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  39. Phase Level ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  40. Operation A sequence that causes a significant physical or chemical change within the batch Consists of an ordered sequence of (one or more) phases Phase The smallest element of procedural control, capable of causing one or more actions S88.01 Procedure Hierarchy Procedure Unit Procedure Operation Phase ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  41. - Material Selection Material Charging Mix Unit Sequence Discharge and Recirc Phase Operation Pump Device Control Typical Process Model - Unit Level FT MTR-002 MTR-001 007 008 009 010 M PT TT XCV-005 FT MTR-003 XCV-006 XCV-004 ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  42. Mode (Auto, Manual, Test…) Commands (Start, Stop, Reset, …) Status ( Running, Faulted…) Interlocks and Permissives Faults/Alarms Messages Unit Level ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  43. Unit Level ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  44. Typical Procedure using the Hierarchy Procedure Unit Procedure Unit Procedure Operation Operation Phase Phase Phase Note parent / child relationships as you move down and to the right in this procedure tree ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  45. Unit Operation Phase Device Control Typical Process Model - Line Level Process Cell ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  46. Process Cell ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  47. Recipe/Equipment Control Separation Equipment Control Control Recipe Procedure The only reference to the physical processing equipment occurs here Recipe Procedure ordered set of Recipe Unit Procedure ordered set of Recipe Operation ordered set of Equipment Recipe Phase Phase ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  48. S88.01 State Transition Diagram Complete Paused Held Restart Reset Hold Start Pause Idle (Initial State) Resume Holding Running Aborting Stopping Restarting Pausing Abort Stop Final States Aborted Stopped Quiescent States Reset Transient States Reset State Transition Diagram for Example States for Procedural Elements ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  49. Dávkový řídicí systém The Control Activity Model – CACTUS model ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004

  50. CACTUS model • Správa receptur • Plánování a rozvrhování výroby • Správa informací o výrobě • Správa procesů • Řízení jednotek • Řízení procesů ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004