An Introduction to Advanced

Batch Process Control

through ISA S88
Russell Czolgosz (Chōl·gŏsh)
MTU ChE class of 1999
Lead Automation and Controls Engineer
Dow Corning Corp
Edited by DWC 1-18-2012
for CM4120
 Outline
„ What is WBF and ISA?
„ ISA S88 – the standard
„ Manufacturing Challenges lead to
establishment of SP88
„ The S88 Model definitions
„ Physical Model
„ The Cactus Model

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 World Batch Forum
Now called: WBF-The Organization for Production
Technology
First conference in 1994
Global, volunteer, non-profit organization formed by
members of the ISA SP88 committee

What WBF does:

„ Professional Networking
„ Sharing Ideas
„ Publish whitepapers and articles
„ Host annual conferences
„ Under new title, covers all areas of production
automation
www.wbf.org professional membership is $50
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 International Society for Automation
Founded in 1945
Global non-profit organization
Research Triangle Park, NC

What ISA does:

„ Publish books and technical papers
„ Provide education and training
„ Certify industry professionals
„ Host conferences
„ Develop standards

www.isa.org
$10/yr. virtual student membership

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 ISA S88 is...
„ S88 (or ISA 88) Batch Control Standard
Currently 4 parts
z Part 1 Models and Terminology (ANSI/ISA-88.01)
z Part 2 Data Structures & Guidelines for Languages
(ANSI/ISA-88.00.02)
z Part 3 General and Site Recipe Models & Representation
(ANSI/ISA-88.00.03)
z Part 4 Batch Production Records (ANSI/ISA-88.00.04)
z Part 5 is in draft
„ SP88 is the Batch Control Standards Committee

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 Spirit of S88
„ Not just a standard for software, equipment, or
procedures
z A new way of thinking – a design philosophy

„ Suggests standardized modular design

concepts
z Reusable design components
z Similar to object-oriented computer programming

„ Understanding S88 will help you design better

processes and manufacture better products

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 Challenges in Manufacturing
Need Predictable Product Quality… but:

„ Poor control of manufacturing processes

„ Variation in feedstocks
„ Differences between processing locations
„ Human error

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 Challenges in Manufacturing
High Costs… caused by:

„ Low equipment utilization – scheduling difficulties

„ Using old processing/ control technologies
„ Poor flow of material and information
„ Labor intensive
„ High cost of energy

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 Challenges in Manufacturing
Must expand into New Markets/ New
Products… but:

„ Have a dedicated system or process

„ Traditional design methods create long product and
process development times

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 Traditional Design Process
1. Design equipment for a specific product
2. Implement process control to meet the product
processing requirements
3. Develop procedures (an SOP) to make a single
product
4. Make one product using the SOP with that
equipment.
This type of implementation:
Hinders Process Improvement
Prohibits Manufacturing Agility, and
Prevents Asset Optimization
The goal of S88 is to eliminate these roadblocks.

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 Specific goals of S88:

„ Use best practices for design/ operation

„ Modularity and flexibility in design
„ Common concepts, framework, models, and
language
„ Improved efficiency and control of mfg.
plants (batch, semi-continuous, and
continuous)

It is a guideline, NOT a compliance standard

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 Benefits of an S88 Solution?

1. Modularity allows for easier replication and

better ROI
2. Design concepts make validation easier
3. S88-aware solutions help track product and
process data
4. Gathering requirements from customers/
conveying requirements to vendors is easier
5. Safer operations – Provides guidelines on
recovery from abnormal events

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 Improved Batch Processing

Improve Throughput Reduce Cost

z Reduced batch cycle z Reduced raw material
time loss
z Increased production z Improved batch
rate consistency
z Faster changeover z Better equipment
z More scheduled recipes utilization
z Reduced downtime z Less time to add/modify
z Faster process recipes
development z Lower engineering cost
z Quicker product z Lower data capture cost
launches z Better data availability

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 S88: A New Design Philosophy
Physical Equipment Design Activities:
„ Equipment Modules selected or built from a
capability perspective
„ Basic Control of each equipment module is
implemented based on equipment capability
Process Development Activities:
„ Recipes are used to specify req’d processing
steps
„ Procedural control is developed to make
equipment do what needs to be done in the right
order

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 Applying S88 to existing processes:
1. Learn the terminology
2. Break the process down into appropriate
physical components
3. Identify the steps necessary to produce the
product
4. Identify recipe parameters
5. Tie the recipe to the procedures
6. Map the procedure to the processing
equipment

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 Applying S88 – 4 Models Defined

1. Physical Model

2. Process Model

3. Procedural Control Model

4. Control Activity Model

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 S88
The Physical Model

Physical Equipment that functions to produce

a product plus the Basic Control that makes
it function.

Physical Model defines a hierarchy of the

equipment.

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 Physical Model
Hierarchy of the corporation’s PHYSICAL ASSETS

MTU Enterprise Consists of all the

production and supporting
Process equip necessary to make a
Cell PSCC
batch
A major piece of
Houghton Site PDMS Reactor
equipment within a process
Unit
cell that makes something
Unit Solvent
Recovery all by itself
Unit
Grouping of equipment
ChemSci
Building
Area Agitator & control modules that
Equipment Temp together perform a
Feed minor task
Module Discharge

Agitator Basic discrete and analog

Controls control (output) devices
Control Control Outlet valve
Module Module Temp Controller

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 An Example Process Cell
Material Selection Material
Pressure
Process Charging
Mix Control
Cell FT
M

Temperature PT
TT
Unit Control

Discharge
and
Equipment Recirc
Module

Pump
Control FT
Module

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 Process
Cell

Defining a Unit
Unit

Equipment
Module

Control
Module

„ Batching cannot occur without units

z Batching occurs in units
z Units perform one or more major processing activities
z A unit is used on only one batch at a time
„ Units are built up of (control and equipment)
modules – adds reusability, flexibility
„ A Unit runs a recipe
z Combine ingredients, perform a reaction, cause a
separation
z Adds value to your product or intermediate
„ Units function independently of each other

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 Examples of Units:
Is a Is Not
Unit a Unit
Mix-making batch tank 
Pasteurizer 
Reactor 
Pump 
Ingredient storage tank 
Washing machine 
Kitchen blender 
Refrigerator 
Dishwasher 

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 Process
Cell

Equipment Modules Unit

Equipment
Module

Control
Module

„ Equipment modules group devices for performing one or

more specific minor processing activities
„ Equipment modules run portion(s) of a recipe

FT
Mix

M
Material Charging
Equipment Module

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 Control Modules
„ Contain the actuators and sensors
„ Connect software to the process through sensors and
actuators
„ Commanded by their Unit to maintain a condition and when
to do it
„ Act as a single entity from a control standpoint
„ Carry out Basic Control – they do not contain procedural
control
Material
Selection
Temperature TT
Control

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 Review: Process Cell
Material Selection Material
Pressure
Process Charging
Mix Control
Cell FT
M

Temperature PT
TT
Unit Control

Discharge
and
Equipment Recirc
Module

Pump
Control FT
Module

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 S88
The Control Activity Model
“Cactus Model”

Shows relationships between control activities

Describes flow of information throughout the

enterprise

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 Control Activity Model
Master
Recipe
Master Batch
Recipe Production Schedule Production
Recipe
Planning and Information
Management
Scheduling Management
Batch Schedule Batch Progress
Master Process Batch and Process
Recipe Management Cell Information
Unit Recipes and Commands Batch Status
Unit Batch and Unit
Supervision Information

Commands
Statuses
Process Process
Control Data

Commands Below this line is outside S88 Scope

Statuses
Personnel and
Environmental
Protection

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 Overall Value of S88
„ Permits easy product customization
z Color, level of impurities, packaging, viscosity, composition,
etc.

„ Facilitates rapid product change-over

„ Helps identify suitable assets at different sites

„ Allows for easy recipe conversion into local

languages

Remember: S88 is only one element in a system of

manufacturing
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 References

„ Applying S88 Batch Control from a User’s

Perspective, Jim Parshall and Larry Lamb, ISA,
Research Triangle Park, NC, 2000.
„ ISA S88.01-1995 (R2006) Batch Control Part
1: Models and Terminology, ISA, Research
Triangle Park, NC, 2006.
„ WBF – The Organization for Production
Technology, www.wbf.org
„ International Society of Automation,
www.isa.org

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