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Table of contents
1 What is S88? .......................................................................................................................... 3 1.1 Types of manufacturing operations ................................................................................ 3 1.1.1 Batch processes....................................................................................................... 3 1.1.2 Continuous processes.............................................................................................. 3 1.1.3 Discrete processes ................................................................................................... 4 1.2 Why S88?........................................................................................................................ 4 Strategy of S88....................................................................................................................... 5 2.1 S88 and automation......................................................................................................... 5 2.2 3-system-elements........................................................................................................... 6 2.3 Preparation ...................................................................................................................... 6 2.4 Market segments ............................................................................................................. 7 Physical model....................................................................................................................... 7 3.1 Physical model in general ............................................................................................... 7 3.2 Process cell...................................................................................................................... 8 3.3 Types of trains.............................................................................................................. 9 3.4 Unit ............................................................................................................................... 10 3.5 Equipment module ........................................................................................................ 10 3.6 Control Module............................................................................................................. 11 3.7 Equipment- or control module? .................................................................................... 11 3.8 Design physical model.................................................................................................. 11 Recipes and procedures...................................................................................................... 12 4.1 Procedures and equipment ............................................................................................ 12 4.2 Different demands, different recipes............................................................................. 12 4.3 Recipes and process model ........................................................................................... 14 4.4 Recipes and procedure model ....................................................................................... 15 4.5 Recipes: 5 categories..................................................................................................... 15 4.6 Phases and commands................................................................................................... 17 Linking recipes to equipment control ............................................................................... 17 5.1 Types of equipment controls......................................................................................... 17 5.2 Relations of S88 models ............................................................................................... 18 5.3 Communications ........................................................................................................... 19 5.4 The lower the link, the higher flexibility ...................................................................... 20 Modes and States................................................................................................................. 21 6.1 Modes............................................................................................................................ 21 6.2 States ............................................................................................................................. 21 6.3 Exception handling ....................................................................................................... 22 6.4 Allocation and arbitration ............................................................................................. 23 System specification ............................................................................................................ 23 References ............................................................................................................................ 24
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1 What is S88?
S88 is a model and methodology for the design and running of flexible production control. The maintainability is improved because of a better and universal structure. Originally, the S88 standard is made for the batch industry, but it is applicable in discrete and continuous processes as well. S88 is a standard to improve handling production processes. But before we can introduce the standard, we will explain the different types of manufacturing operations we know.
work than maintaining the production flow. Sometimes people choose to keep a continuous product running 24h/24h.
Examples of continuous processes: Production of drinkable water Oil refinery Production of electricity Production of plastic tubes Also here flexibility is requested quite often. Water can be for example hard or soft, drinkable or not. The composition of diesel has to be different during the winter than in during the summer. Sometimes plastic tubes has to be made of alternative raw materials for different qualities, or the thickness of the tube has to be different etc In these cases the S88 standard can help for a good management of flexibility.
Except finding solutions for these problems, the S88 also wanted to reduce the cost of automation systems. A shorter time to market and a higher flexibility would make the production installation more competitive. The reliability of operations can be improved. A higher process How To Apply ISA 88 Dirk van der Linden Scientific Researcher 4
quality and a faster development of batch recipes could help the factories to serve their customers better. The S88 standard provides a set of models. Although the first target was batch control, the design of the models are universal, so that they can be used for continuous and discrete processes as well. A clear terminology makes communication between vendors, systems integrators and endusers better. With this terminology, less misunderstandings are possible during discussions about the processing requirements. Data structures helps to integrate solutions in a multi-vendor environment. Parameter guidelines makes configuration of batch solution easier.
2 Strategy of S88
Experts on different fields have to cooperate, but think in another way. Process engineers focus on how to handle the material flow to meet the specs of the end-product. Control system experts focus on how to control equipment. S88 makes a separation of recipes and equipment. Recipes are to be developed by process engineers, and control system experts will have to let the equipment run, following the parameters and procedures of the recipes. Programming the normal operation is often a small part of the job. More code is written for abnormal events or exceptions. Non-structured handling of these unexpected events or workaround makes code difficult to read and to maintain. S88 provides guidelines for exception handling. When there is a problem with a end-product and someone wants to know the circumstances of the production, S88-aware software can track the state of the batch. Sometimes this is integrated in historian software. The terminology and models makes it easier to write system requirements and to communicate with customers and vendors. Collect all the necessary unequivocal information to produce product and installation documentation is easier if based on a standard terminology. For large companies it can be handsome to reproduce the same installation on another site when the installation is based on standard models. Overall validation procedures will be more generic.
2.2 3-system-elements
To develop a control system as a good engineering project, you should define three important elements: How to make the product (recipes) What physical tools are needed (equipment) How to run the equipment (control activities)
2.3 Preparation
Before starting developing a control system, you should collect detailed requirements information. The first step has to do with the desired flexibility, or more concrete: a list of all the product variants needed. The different product variants are listed in recipes. This is a question of management. There a more limits than only production flexibility. Even if a system is for example able to produce both soft drinks and beer, a manager will rather decide what the company is going to sell in stead of making things more flexible than needed. Besides, in general the more flexible a system is, the more complex it will be. For the maintenance and usability, it is better not to make a system more complex than needed.
With this list there should come a meeting with PLC or DCS programmers and process experts. In this meeting, the previewed product variants, the knowledge of process experts and equipment experts should be converted to a recipe structure and equipment procedures, operations and phases. The recipe structure should match the equipment control elements with an unequivocal interface. This interface corresponds with the control recipe.
3 Physical model
3.1 Physical model in general
Equipment is modularized by using the Physical Model. This model has a hierarchy of seven levels . It gives an overview of what equipment is available in the company. Based on this overview, people can define the possibilities of an installation. The three highest levels, Enterprise, Site and Area are important for the administration, but less important for the design of a production installation. More details about these levels can be found in the standard S95.
The four lowest levels, Process Cell, Unit, Equipment Module and Control Module are important for the production installation. Every physical component of an automated control should match one of these levels.
In a multi path trains the material flow can pass different alternative units, depending on the recipe.
In a network path train the sequence in which the material flow passes different units can have a lot of variations. The recipe needs a structure which can handle these complex variations.
3.4 Unit
The term unit is more or less abstract with respect to the equipment associated with it. The unit can perform activities which provides an added value to the product. In other words, a unit is a manufacturing tool together (or not) with instrumentation and associated equipment. While designing a production installation, you have to find the units. If the equipment needs a recipe to run, it is a unit. If the equipment do not needs a recipe to run, then it belongs to a unit. With this, you decide the flexibility. A unit is performing a major processing activity. A unit is active on a part or on the entire batch. No two batches can be handled simultaneous in the same unit, a unit can only be active on one batch at a time. Every unit works independent of other units, based on their proper unit procedures and formula parameters. A unit contains an amount of equipment modules and control modules.
An equipment module contains all the equipment and control functions needed to carry out his process function. Several units can share equipment modules, eg several tanks can share the same pipeline and pump. If an equipment module can work with only one unit at a time, it is called an exclusive use resource. If it can act simultaneous for more than one unit, it is called a shared use resource. In spite of the above, an equipment module belongs in general to one unit. This applies also for control modules.
The lower levels can be found if you concentrate on material flow, and look at your plant layouts and process and instrumentation drawings (P&IDs). You have to determine the process cell boundaries. Remember that a train or line may not exceed these boundaries. Use this rule to check intuitive design. The material flow is passing trough one or more units in a train or line. Each unit is a functional group of equipment which runs recipes-tasks. The physical model is collapsible. A process cell must contain at least one unit. Other levels may contain something. Take care that the physical model is designed in function of the equipment.
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A master recipe is targeted to a process cell and maybe derived from either a general or a site recipe. The master recipe can contain product-specific information required for detailed scheduling, such as equipment requirements. The master recipe takes into account the type of equipment. But unlike the general and site recipe, S88 control requires a master recipe. A master recipe is the template for control recipes used to create individual batches. A control recipe is used to create a single, specific batch. It starts as a copy of a master recipe and is modified as necessary to create a batch. The modifications may account for batch size, characteristics of raw materials on-site, or actual equipment to be used.While several batches may be derived from the same master recipe, every batch has a single control recipe to that batch and that batch alone. Two control recipes may be indentical in ingredients, quantities, or equipment used, but they are identified individually nonetheless. This allows product tracking and tracing.
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Process operation
Process action
The general and site recipes are based on the process model, this model is used in an R&D environment. With this model, the necessary steps to make a product can be defined.
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Operation Phase
The master and control recipes are based on the procedure model. This model is specific for a process cell.
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Process Parameters
Process
Process Outputs
A process input is the identification and quantity of a raw material or other resource required to make the product. It can also include energy or human labour. A process parameter details information such as temperature, pressure or time that is pertinent to the product. Process parameters can be measured values, or set points in PID loops. A process output is the identification and quantity of a material (product) that results from one execution of the recipe. Equipment requirements: the equipment category constrains the choice of the equipment that will be used to implement a specific part of the procedure. In the general and site recipes, the equipment requirements are typically described in general terms. At the master recipe level, the equipment requirements specifies allowable equipment in process cells. The control recipe may include specific allocations of process cell equipment. Recipe procedures: sequence or strategy to execute the process. The general and site recipe procedures are structured using the levels described in the process model since these levels allow the process to be described in non-equipment specific terms. The master and control recipe procedures are structured using the procedural elements of the procedural control model, since these recipes deal with equipment classes or specific pieces of equipment. Other information: everything what is not included in the other categories like safety information, packaging or labelling information.
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batches, and arbitrates requests for equipment allocation in case more than a single procedure needs the equipment simultaneously. When a procedural element comes in hold, a coordination control can propagate the hold state up and down the procedural chain.
A procedure is taking place in the process cell. This corresponds with the process of the process model. Each of the lower procedural elements can take place in a unit, and corresponds with a similar level in the process model. A phase can also take place in an equipment module, and corresponds in this case with a process action. A control module cannot receive commands directly from a recipe procedure, but is commanded via an equipment module.
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5.3 Communications
In an automation project, pretty often different systems has to operate in a multi-vendor environment. An S88 based system needs a lot of communication to let the relations between the models work. OPC is a very successful standard in industrial communication to help commercial hard- and software products communicate smoothly. We highlight some typical communications needed in an S88 based system.
Process equipment is connected to a PLC, often with a fieldbus. The control modules are not only hardware, very often the hardware corresponds with a function block in the PLC. The basic controls of these control modules are connected via OPC to an HMI or SCADA software on a PC. In this SCADA system, every control module is visualised with a dynamic symbol. Software faceplates are often used to let the operator interact on the commands and settings of the control module, while the states and actual values are used to change the colour or size of the visual object. The control module in the PLC is supervised by SCADA, but also by an equipment module, which corresponds with a PLC function block too. Like the control module, the basic controls of the equipment module is also corresponding with a dynamic object in HMI or SCADA software. The recipe in the PC can call a phase in the PLC via the Phase Logic Interface, which is a set of parameters to control the equipment. How To Apply ISA 88 Dirk van der Linden Scientific Researcher 19
For batch processes, the most common link is the phase level link. But the linking does not have to be done at the phase level. In general, the lower the link, the more flexibility the recipe manager can have. Keep in mind that flexibility makes things more complex too. Some commercial batch management software packages do not allow linking on another level than phase level. In this case, it is easy to workaround this because collapsing recipes is allowed following S88. Skipping levels can always be done(eg definition of one operation which contains one phase in a unit procedure).
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6.1 Modes
A mode determines how procedural elements (such as unit procedures and phases) and equipment entities (such as equipment modules and control modules) respond to commands and how they will operate. S88 suggest 3 modes for procedural elements: Automatic: The transitions within a procedure are carried out without interruption as appropriate conditions are met. Semi-automatic: The procedure requires manual (operator) approval to proceed after the appropriate conditions are fulfilled. Manual: the procedure elements and their order of execution are completely specified by the operator. S88 suggest 2 modes for equipment entities: Automatic: Equipment entities could be under the control of a procedure or some control algorithm. Manual: equipment entities are under the control of an operator.
6.2 States
S88 suggests a common set of states and transition commands for procedural elements. The standard does not require any particular set of states and commands, but remember the S88 committee members have a lot experience, and the examples procedural states and commands they chose probably will work in more than 95 percent of the cases. The most elementary states are Idle-Running-Complete. This is what is called normal operation.
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The other states and commands are suggested to use for exception handling.
7 System specification
S88 is not a compliance document. That is, you do not have to follow every letter of the standard to say you are S88-aware. But neither do S88 software vendors. This is why there are such a wide variety of S88 implementations in industry. Use this to your advantage by balancing the concepts in S88 against what is practical and economically for you operations. The result of this exercise should become a system specification document. First, you should document the physical equipment needed or available if you are retrofitting an S88 solution into an existing system. Collect all the P&IDs (process and instrumentation diagrams), electrical drawings and information system requirements. Find your units, determine where your equipment modules and control modules are, and determine which independent tasks equipment entities are performing. Second, you should design master recipes using S88 definitions: header, equipment requirements, procedure, formula, and other information. If you already decided to use a particular S88 commercial software package, it may be easier to specify recipes based on the capabilities of that package. A very large part of the documentation work is describing equipment control. The definitions of phase logic, modes and states, allocation and arbitration, exception handling, etc. are very important, because it determines at the end how the equipment will physically run. Other documents may describe scheduling, production history, data collection, reports, etc.. Finally, the more control engineers and IT professionals communicate, the better off. It is often found that basic problems arise because of misunderstandings over terms. Just as S88 has helped define common terminology for batch manufacturing, another ISA committee, SP95, is defining How To Apply ISA 88 Dirk van der Linden Scientific Researcher 23
models and terminology for the purpose of integrating control systems with information systems. For a totally integrated system, the S88 and S95 systems should match. Developing a clear, detailed documentation is a good start.
8 References
Applying S88 : Batch Control from a Users Perspective, Jim Parshall and Larry Lamb, ISBN 1-55617-703-8, Printed in the USA, August 2005 [2] S88 implementation guide: strategic automation for the process industries, Darrin W. Fleming, Velumani A. Pillai, ISBN 0-07-021697-5, Printed in the USA, 1999. [3] Applying ISA S88 to Small, Simple Processes, Clark Case, Rockwell Automation, World Batch Forum conference 13-15 nov 2006, Zemst, Belgium [4] S88 for Researchers and Scientists, Zofia Verwater-Lukszo, Delft University of Technology. White paper written for World Batch Forum June 2004. [5] Using Basic Control to Make Recipes Simple, Francis Lovering, ControlDraw Ltd, World Batch Forum conference 13-15 nov 2006, Zemst, Belgium [6] ANSI/ISA-S88.01-1995, Batch Control, Part 1: Models and Terminology, ISBN: 1-55617-562-0, Printed in the USA, 1995 [7] OPC Data Access Custom Interface Specification 3.0, OPC Foundation, March 2003 [8] OPC Fundamentals, Implementation, and Application, 3rd rev. Ed., Frank Iwanitz, Jrgen Lange, Printed in Germany, 2006, Hthig GmbH & Co. KG Heidelberg, ISBN 3-7785-2904-8 [9] www.S88.nl [10] www.isa.org [1]
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