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slide 1ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
ANSI/ISA S88.01 Batch Standard
Daren Moffatt
Solution Architect
Invensys Foxboro
Greg Skovira
President
EZSoft Inc.
(Výběr pro Počítačové řídicí systémy 2012)
slide 2ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Batch Process Example
MaterialStorage 1
MaterialStorage 2
MaterialStorage 3
Minor Additions
Mixer
slide 3ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
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.
slide 4ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Batch Process Example
MaterialStorage 1
MaterialStorage 2
MaterialStorage 3
Minor Additions
Packaging Line 1
Packaging Line 2
FeedTank 1
FeedTank 2
SprayDryer 1
SprayDryer 2
Mixer
BATCH
DISCRETE
CONTINUOUS
slide 5ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Batch Processing Characteristics
Number of Products Single product Multiple products
Physical Layout Single stream Multi-stream
MaterialStorage 1
MaterialStorage 2
MaterialStorage 3
StorageTank 2
Mixer 1
Reactor 1
Mixer 2
Reactor 2
StorageTank 3
StorageTank 1
slide 6ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Standards & Organizations
ISA S88 Committee S88.01 S88.00.02 S88.00.03
World Batch Forum BatchML B2MML
OPC for Batch
www.opcfoundation.org
www.wbf.org
www.isa.org
slide 7ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
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
slide 8ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
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
slide 9ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Physical Hierarchy
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
Control Module
Equipment Module
Unit
Process Cell
slide 10ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Physical Hierarchy
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 modulesControl Module
Equipment Module
Unit
Process Cell
slide 11ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Batch Control Conceptual Example
“What”
Equipment
•Equipment=Process that we will sequence
Procedure
1. Do this2. Do that3. Do this and that
“How”
•Procedure=order in which we will sequence the process
Journal
12:05 This happened12:07 That happened12:10 This and that happened
“When”
•Batch Journal=Record of what happened to the process
slide 12ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Equipment Examples Illustration
Control Module ValvePumpMotorPressure Controller
Batch Control Conceptual Example
slide 13ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Equipment Examples Illustration
TIC
Temperature Control
System consisting of:
1. Recycle pump2. Chilled water
valve3. Steam valve4. Temperature
Controller
Steam
ChilledWater
EquipmentModule(a set of ControlModules)
Batch Control Conceptual Example
slide 14ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Equipment Examples Illustration
Unit(a set of Equipment Modules)
Reactorconsisting of:
1. Temperature control system
2. Agitation system
3. Material addition systems
4. Discharge system
5. Analysis system
TIC
Batch Control Conceptual Example
slide 15ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
GeneralRecipe
SiteRecipe
Recipe Management
The Recipe is the necessary set of information that uniquely defines the production requirements for a specific product
MasterRecipe
ControlRecipe
ProcessingInformation
Site-specificInformation
Process CellSpecific Info
BatchSpecific Info
slide 16ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
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)
slide 17ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Recipe Information Categories
Recipe
EquipmentRequirements
HeaderOther
Information
FormulaProcedure
ProcessInputs
ProcessParameters
ProcessOutputs
Formula
slide 18ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Procedure Hierarchy
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
Phase
Operation
Unit Procedure
Procedure
slide 19ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Procedure Hierarchy
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
Phase
Operation
Unit Procedure
Procedure
slide 20ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Typical Procedure using the Hierarchy
Note parent / child relationships as you move down and to the right in this procedure tree
Unit Procedure
Procedure
Unit Procedure
Operation
Operation
PhasePhase
Phase
slide 21ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Recipe procedure Examples Illustration
Procedure
Unit Procedure 1 Unit Procedure 2
Phase 1
Unit Operation 1 Unit Operation 4
Unit Operation 2 Unit Operation 3
Phase 2
Phase 3
Phase 4
Phase 5
Phase 6
Phase 7
Phase 8
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
Batch Control Conceptual Example
slide 22ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Recipe/Equipment Control Separation
Recipe UnitProcedure
Operation
Phase
ordered set of
Control RecipeProcedure
ordered set of
ordered set of
RecipeProcedure
EquipmentPhase
Recipe
Recipe
EquipmentControl
The only reference to the physical processing equipment occurs here
The only reference to the physical processing equipment occurs here
slide 23ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Typy řízení
základní řízení regulaceblokace nesprávné činnosti (interlocking)sledování překročení mezí reakce na alarmymanuální řízení
procedurální řízení koordinační řízení
řízení zdrojů zařízenívýběr procedurálních prvků pro běhpropagace režimů
slide 24ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Key Batch System Components
Supervisory Level
Recipe Maintenance/Editing
Batch Management
Data Acquisition
Event based
Time based
Reporting
Operator Interface
Real Time Control
Př.: Wonderware InBatch InTouch PLCs
slide 25ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
The 10,000 Ft View
Planning (MRP II, Financials, etc.)
Process Control
Manufacturing Execution
InformationInformation
ControlControl
Inte
gra
tion
Inte
gra
tion
Business Logistics SystemsPlant Production Scheduling
and Operational Management
Manufacturing Control SystemsArea Supervision, Production
Scheduling, Reliability Assurance
BatchControlSystems
ContinuousControlSystems
DiscreteControlSystems
Level 4
Level 3
Levels2, 1, 0
slide 26ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Typical System Architecture
slide 27ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Typical System Architecture
slide 28ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
The Model
PROCESS CELL
PH
AS
ECONTROLBUILDER - DESIGN M ODEL
Device
DE
VIC
E
Device Device Device Device
UNIT SEQUENCE UNIT SEQUENCE
Device Device
PHASE OPERATION PHASE OPERATION
Device Device Device Device
PHASE OPERATION
Device Device
PHASE PHASE
Device Device Device Device
PHASE
UNIT SEQUENCE UNIT SEQUENCE
Device Device
PHASE PHASE
Device Device Device Device
PHASE
UN
ITL
INE
Example:-Valves, Motors,Sensors, etc.
Example:- Add W ater, Agitate,- Hand Addition, etc.
Example:- Run Batch on Tank 1- CIP Tank 2
Example:- Production Area 1
EZSoft Inc. , 1999-2003c
EZSoft & C ontro lBuilder are reg istered tradem arks of EZSoft, Inc.
®
Process level
Unit level control
Phase level control
Device level control
slide 29ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
The 2,000 Ft View
From the Bottom Up
slide 30ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Physical Hierarchy
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 modulesControl Module
Equipment Module
Unit
Process Cell
slide 31ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
M
DeviceControl
Typical Process Model - Device Level
MTR-001
007
MTR-002
MTR-003
XCV-005
XCV-006
XCV-004
008 009 010
slide 32ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Device Level Properties
Mode (Auto, Manual, Test…)
Commands (Start, Stop, Reset, …)
Status ( Running, Faulted…)
Interlocks and Permissives
(blokování a povolení)
Faults/Alarms
Messages
slide 33ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Device LevelDESIGN M ODEL
Device
DE
VIC
E
Device Device Device DeviceExample:-Valves, Motors,Sensors, etc.
EZSoft Inc., 1999-2004cEZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.
slide 34ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Physical Hierarchy
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 modulesControl Module
Equipment Module
Unit
Process Cell
slide 35ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Procedure Hierarchy
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
Phase
Operation
Unit Procedure
Procedure
slide 36ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Mix
DischargeandRecirc
Material Charging-
Material Selection
M
FT
PumpDevice &
RegulatoryControl
FT
Typical Process Model - Phase Level
MTR-001
007
MTR-002
MTR-003
XCV-005
XCV-006
XCV-004
008 009 010
PhaseOperation
slide 37ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Phase Level Properties
Mode (Auto,Manual,…)
Commands (Start, Stop, Reset, …)
Status ( Running, Faulted, Paused…)
Interlocks and Permissives
Faults/Alarms
Messages
slide 38ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 State Transition Diagram
State Transition Diagram for Example States for Procedural Elements
Restarting Holding
Running
Aborting Stopping
Pausing
Aborted
Complete
Stopped
Held
Paused
Restart
Hold
Pause
Resume
StopAbort
Reset
Reset
Reset
Start
Final States
Quiescent States
Transient States
Idle (Initial State)
slide 39ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Phase Level
PH
AS
E
DESIGN M ODEL
Device
DE
VIC
E
Device Device Device Device
Device Device
PHASE PHASE
Device Device Device Device
PHASE
Example:-Valves, Motors,Sensors, etc.
Example:- Add W ater- Agitate- Hand Addition, etc.
EZSoft Inc., 1999-2004c
EZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.
slide 40ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 Procedure Hierarchy
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
Phase
Operation
Unit Procedure
Procedure
slide 41ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Mix
DischargeandRecirc
Material Charging-
Material Selection
M
FT
Pump
DeviceControl
FT
Typical Process Model - Unit Level
MTR-001
007
MTR-002
MTR-003
XCV-005
XCV-006
XCV-004
008 009 010
PhaseOperation
UnitSequence
TTPT
slide 42ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Unit Level
Mode (Auto, Manual, Test…)
Commands (Start, Stop, Reset, …)
Status ( Running, Faulted…)
Interlocks and Permissives
Faults/Alarms
Messages
slide 43ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Unit Level
PH
AS
E
DESIGN M ODEL
Device
DE
VIC
E
Device Device Device Device
UNIT OPERATION UNIT OPERATION
Device Device
PHASE PHASE
Device Device Device Device
PHASE
Device Device
PHASE PHASE
Device Device Device Device
PHASEUN
IT
Example:-Valves, Motors,Sensors, etc.
Example:- Add W ater- Agitate- Hand Addition, etc.
Example:- Run Batch on Tank 1- CIP Tank 2
EZSoft Inc., 1999-2004c
EZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.
slide 44ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Typical Procedure using the Hierarchy
Note parent / child relationships as you move down and to the right in this procedure tree
Unit Procedure
Procedure
Unit Procedure
Operation
Operation
PhasePhase
Phase
slide 45ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
DeviceControl
Phase
UnitOperation
Process Cell
Typical Process Model - Line Level
slide 46ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Process Cell
LINE
PH
AS
E
DESIGN M ODEL
Device
DE
VIC
E
Device Device Device Device
UNIT OPERATION UNIT OPERATION
Device Device
PHASE PHASE
Device Device Device Device
PHASE
Device Device
PHASE PHASE
Device Device Device Device
PHASE
UNIT OPERATION UNIT OPERATION
Device Device
PHASE PHASE
Device Device Device Device
PHASE
UN
ITP
roce
ss C
ell
Example:-Valves, Motors,Sensors, etc.
Example:- Add W ater- Agitate- Hand Addition, etc.
Example:- Run Batch on Tank 1- CIP Tank 2
Example:- Production Area 1- Production Area 2
EZSoft Inc., 1999-2000cEZSoft & C ontro lBuilder are registered tradem arks of EZSoft Inc.
slide 47ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Recipe/Equipment Control Separation
Recipe UnitProcedure
Operation
Phase
ordered set of
Control RecipeProcedure
ordered set of
ordered set of
RecipeProcedure
EquipmentPhase
Recipe
Recipe
EquipmentControl
The only reference to the physical processing equipment occurs here
The only reference to the physical processing equipment occurs here
slide 48ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
S88.01 State Transition Diagram
State Transition Diagram for Example States for Procedural Elements
Restarting Holding
Running
Aborting Stopping
Pausing
Aborted
Complete
Stopped
Held
Paused
Restart
Hold
Pause
Resume
StopAbort
Reset
Reset
Reset
Start
Final States
Quiescent States
Transient States
Idle (Initial State)
slide 49ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Dávkový řídicí systém
The Control Activity Model – CACTUS model
slide 50ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
CACTUS model
• Správa receptur• Plánování a rozvrhování výroby• Správa informací o výrobě• Správa procesů • Řízení jednotek• Řízení procesů
slide 51ANSI/ISA S88.01 Batch Standard - ISA Philadelphia - Sept 15, 2004
Other S88.01 Topics
Batch control activities and functions Allocation and arbitration Production planning and scheduling Production information management Process management Unit supervision Process control Personnel and environmental protection