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Industrial science and technology
How to apply
ANSI/ISA S88 (America) or
IEC 61512 (Europe)
Dirk van der Linden
Industrial science and technology
Hogeschool Antwerpen
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Types of manufacturing
operations
• Discrete processes:
production of ‘things’ with a unique identity (cars)
• Continuous processes:
Continuous flow of material through various
processing equipment (gasoline)
• Batch process:
Production of a limited quantity of material during a
limited time (ice-cream)
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Industrial science and technology
What is S88?
• Universal model for batch control
• Models
• Communication processing requirements
• Terminology
• Integrate solutions in a multi-vendor environment
• Data structures
• Make configuration of batch solutions easiers
• Parameter guidelines
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Industrial science and technology
Strategy S88?
•
•
•
•
Separation of recipes and equipment
Guidelines for abnormal events (exceptions)
Helps to trace historical data
Terminology and models helping to communicate
with the customer
• Improve communication with vendors
• Improve reproducibility of the installation
• Improve validation
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Industrial science and technology
S88 and automation
• Structure for all levels of automation
• Full-automatic systems
• Full-manual systems
• Semi-automatic systems
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Industrial science and technology
3 system-elements
• How to make the product? (recipes)
• What physical tools are needed (equipment)
• How to run the equipment (control activities)
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Industrial science and technology
Preparation
Product
variants
Process
experts
PLC
programmers
Meeting
Interface
≈
Control
recipe
Recipe
structure
Procedures,
Operations,
Phases
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Segment 4
Flexible
Multi-Pathway
processing
Equipment
Flexible
Sequencing
Products
Segment 3
Multiple Products,
Multiple Procedures
Many
Flexible
Formula
Parameters
Segment 2
Multiple products,
same procedure
fte
O
Segment 1
Few
Changes Occur
r
Often to Often to
Formula Procedure
e
ev
Never
E
A qui
rb p
itr me
at n
io t
n
n
Fixed
Fixed Sequencing
N
Industrial science and technology
Market segments
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Industrial science and technology
The physical model
Enterprise
Site
accent on administration,
more details in S95
Area
Process Cell
Unit
Equipment module
important for production
automation.
Control module
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Industrial science and technology
Process cell
• Contains all the units and equipment needed to
make a batch or product.
• Not all equipment necessary for every batch.
• Term ‘train’ is used, for discrete processes ‘line’.
• In one process cell we can have several ‘trains’.
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Industrial science and technology
Types of ‘trains’
1. Single-path
2. Multiple-path
3. Network-path
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Unit
• More or less abstract term
• Provides an added value to the product
• Unit = manufacturing tool together (or not) with
• Instrumentation
• associated equipment
• Does equipment need a recipe to run?
• yes = unit
• No = no unit
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Industrial science and technology
Properties unit
•
•
•
•
Is active on a part or on the entire batch
Is active on one batch at a time
Works independent of other units
Contains an amount of equipment modules and
control modules
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Industrial science and technology
Equipment module
• Functional group physical devices
• Equipment module consist of control modules and
other equipment modules
• Can perform minor processing activities (phases)
• Contains all the necessary processing equipment
to carry out these processing activities
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Industrial science and technology
Sharing equipment
• Several units can share equipment modules.
• E.g. several tanks can share the same pipeline and
pump
• One unit at a time ‘exclusive-use-resource’.
• Simultaneous for several units,
‘shared-use-resource’.
• Mostly an equipement module belongs to one unit
• Applies also for control modules.
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Industrial science and technology
Control Module
• Single entities.
• Belongs to the physical model, but all parts are
not necessary physical.
• A part can be a PLC – subroutine.
• In the most elementary form: device drivers.
• Possible also extra functions like auto/man,
permissions, alarming, simulation, etc..
• Cannot execute recipe procedures
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Industrial science and technology
Control vs Instrumentation
• Instrumentation can be used by several control
modules.
• E.g. Two control modules ‘dose water’ and ‘dose
cream’ uses the same flow meter as a common
instrumentation
• A device (hardware) is controlled by one (and
only one) control module.
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Industrial science and technology
Equipment- or control module?
• Depends on the functionality.
• Control modules may not execute commands
from recipes.
• Equipment modules are the smallest entities on
which a recipe can act.
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Industrial science and technology
Design physical model
• Highest level’s are often easy:
• Company = enterprise
• Establishment = site
• Area = production plant
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Industrial science and technology
Design physical model (2)
• Study from process cell level the P&ID’s of the
production
• Concentrate on material flow
• A ‘train’ or ‘line’ material flow may not exceed
the process cell boundaries
• Use this rule to check intuitive design
• Define units based on the P&ID’s
= functional groups which runs recipe-tasks
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Industrial science and technology
Physical model is collapsible
• 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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Industrial science and technology
Procedures
• R&D group: define properties of a product by
way of a procedure. Equipment not really
important, just has to be suitable for the
procedure-course.
• Engineering group: Strongly involved in the
equipment, but not specific which equipment is
used for a specific batch
• Production team: Large interest in where and
when specific equipment is available
Industrial science and technology
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Different demands,
different recipes
General recipe
raw materials, proportions, actions.
No equipment info
Site recipe
derived from general recipe with
site-specific adjustments.
Master recipe
targeted to (part of) process cell
Takes into account type of equipment
Control recipe
Unique for one batch (ID nr).
Adjusted copy of master recipe.
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Industrial science and technology
Recipes and process model
Process
Process stage
Process operation
• General & Site recipes
are based on the
process model
• Is used by R&D
Process action
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Industrial science and technology
Recipes and procedure model
• Master & Control
recipes are based on the
procedure model
Procedure
Unit Procedure
Operation
• Specific for a process
cell
Phase
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Industrial science and technology
Recipes: 5 categories
• Recipe = “the necessary set of information that
uniquely defines the production requirements for
a specific product”
• 5 categories of information:
• Header: administr. info & process summary
• Equipment requirements
• Procedure: strategy process execution
• Formula: process inputs & outputs, parameters
• Other info: eg safety
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Industrial science and technology
Phases
• A recipe phase is abstract, is managed by recipesoftware (database-software)
• An equipment phase is defined for specific
hardware, is controlled by PLC or DCS software.
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Industrial science and technology
Commands
• Physical entities (equipment, control modules,
units), can get commands of many phases.
• Programmers take care of contradictory
commands for the same equipment
• Sometimes priority management is needed
• This can be parts of a PLC program to manage
(many) phase-commands to one control-modulecommand
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Industrial science and technology
3 types of equipment controls
• Basic Controls – Regulatory
–
–
–
–
Interlocking
Monitoring
Exception handling
Repetitive discrete
• Procedural Controls – Manages sequence
– Not necessary automatic/electronic,
can be manual
• Co-ordination Controls – Allocation
– Arbitration
– Propagation
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Industrial science and technology
Relations of S88 models
Procedural Model
Physical Model
Procedure
Process Cell
consists of an
ordered set of
Unit
Procedure
consists of an
ordered set of
Operation
consists of an
ordered set of
Phase
Process Model
must contain
Unit
may contain
Equipment
Module
may
contain
may contain
Control
Module
may
contain
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Communications
Industrial science and technology
Object
Interface
Interface control module
Interface equipment module
Reports
Setpoints
PC
Commands
States
Commands
States
Settings
Actual
Settings
Actual
Live object model
OPC
Phase Logic Interface
Functions
PLC
Control module
Interface
Equipment module
Control
modules
Proces equipment
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Industrial science and technology
Collapsing recipes
• Collapsing recipes is allowed following S88
• Some software products do not support this
• Skipping levels can always be done
eg
definition of one operation which contains one
phase in a unit procedure.
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Equipment Control
Recipe
Procedure
Equipment
Procedure
Recipe Unit
Procedure
Equipment
Unit Procedure
Recipe
Operation
Equipment
Operation
Recipe
Phase
Equipment
Phase
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Mechanics
Control Recipe Procedure
Flexibility
Industrial science and technology
Linking recipe to equipment
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Modes for procedure
• S88 suggests 3 modes for procedural elements:
• Automatic: no interaction needed for
transitions in procedure.
• Semi-automatic: operator has to acknowledge
every transition
• Manual: The sequence is fully specified by the
operator
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Industrial science and technology
Modes for equipment
• S88 suggests 2 modes for equipment entities:
• Automatic: equipment is controlled by a
procedure or control algoritm
• Manual: equipment is controlled by an
operator
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Industrial science and technology
States
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Industrial science and technology
State matrix
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Industrial science and technology
Exception handling
• Often exceptions are break downs
• Can be also eg an empty tank
• Exceptions has to be handled on the level where
they occur
• If the recipe link is on phase level, then
exceptions on phase level should be handled by
the PLC
• An exception can be handled by an operator, but
sometimes also automatic
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Industrial science and technology
Allocation and arbitration
• Sometimes equipment is expensive
• Can be economic to share equipment
• Allocation means that shared equipment is
allocated by coordination controls.
• If two units wants the same (shared) equipment
on the same moment, then priority management
can be implemented by arbitration
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Industrial science and technology
Information management
• Control activity model (cactus model)
• Recipe management
• Production planning & scheduling
• Production history
• Process management ( in one process cell
many batches can be active)
• Unit supervision (links recipes to equipment)
• Process control (PLC)
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Industrial science and technology
Documentation
•
•
•
•
Document physical equipment
Document master recipes
Document equipment control (phases)
Other documents (scheduling, production-history,
data-collection and reports, etc…)
• Schema’s, text, tables, which are in relation to
each other
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Industrial science and technology
Questions?
• Dirk van der Linden
• Scientific researcher automation
• Hogeschool Antwerpen (Belgium)
• Industrial Science and Techology
• [email protected]
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