ISA APPLYING S88 USER-2000 Applying S88 Batch Control from a User-s Perspective.pdf

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1、APPLYING 588 APPLYING S88 BATCH CONTROL FROM A USERS PERSPECTIVE JIM PARSHALL AND LARRY LAMB SA is the international society for measurement and control Notice The information presented in this publication is for the general education of the reader. Because neither the authors nor the publisher have

2、 any control over the use of the information by the reader, both the authors and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application. Add

3、itionally, neither the authors nor the publisher have investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the in

4、formation presented. Any references to commercial products in the work are cited as examples only. Neither the authors nor the publisher endorse any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the authors nor the

5、publisher make any representation regarding the availability of any referenced commercial product at any time. The manufacturers instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication. Copyright 2000 Instrument Societ

6、y of America. All rights reserved. Printed in the United States of America. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of th

7、e publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park North Carolina 27709 Library of Congress Cataloging-in-Publication Data Parshall, Jim. Applying S88: Batch Control from a users perspective / Jim Parshall and Larry Lamb. p.cm. ISBN 1-55617-703-8 1. Production engineering. 2.

8、Automatic control. I. Lamb, Larry. II. Title. TS178.2 P371999 658.5-dc21 99-042402 For our parents TABLE OF CONTENTS FOREWORD XI ACKNOWLEDGMENTS XIII INTRODUCTION XV CHAPTER 1 BASIC CONCEPTS 1 Batch Manufacturing 1 What Really Is S88? 2 E-R Diagrams 6 Sequential Function Charts 8 A Typical Mix-Makin

9、g System 14 CHAPTER 2 ARE You READY TO Go YET? 19 Gathering Requirements 19 Selling the Concept (Getting Funding) 22 CHAPTER 3 STARTING (WHAT You HOPE WILL BE) A SUCCESSFUL PROJECT 25 Step One of a Successful Project 25 Moving Forward with a Successful Project 27 CHAPTER 4 THE PHYSICAL MODEL 31 Ente

10、rprise and Site Levels 31 Area Level 33 Unit Level 34 Process Cell Level 36 Control Module Level 38 Equipment Module Level 41 Designing the Physical Model 42 CHAPTER 5 RECIPES, PART 1: PROCEDURES 45 Information in a Recipe 45 Types of Recipes 46 General and Site Recipe Procedures 50 Master and Contr

11、ol Recipe Procedures 52 Recipe Collapsibility 58 Converting Site Recipes into Master Recipes 58 Linking the Physical, Procedural Control, and Process Models 59 viii Process Control CHAPTER 6 RECIPES, PART 2: ALL THE OTHER STUFF 61 Information in a Recipe 61 CHAPTER 7 LINKING RECIPES TO EQUIPMENT 67

12、Types of Control 67 Linking Recipes and Equipment Control 70 CHAPTER 8 OTHER IMPORTANT BATCH CONTROL ITEMS 77 Modes of Operation 77 States and Commands Associated with Batch Control 79 Exception Handling 83 Allocating and Arbitrating Equipment Use 85 CHAPTER 9 BATCH ACTIVITIES AND INFORMATION MANAGE

13、MENT (THE CACTUS MODEL) 89 The Control Activity Model 89 Presenting Information to the User 102 CHAPTER 10 SYSTEM SPECIFICATION AND DESIGN (SOME OF IT, ANYWAY ) 105 Creating a Control System Functional Specification 106 Documenting Equipment Control 109 A Sensitive Subject: Working with Your IS/IT D

14、epartment 109 One Final Note 110 CHAPTER 11 SPECIFYING AND DESIGNING EQUIPMENT PHASES 111 A Phase Review 111 Modes and States 117 Allocation and Arbitration 123 Unit-to-Unit Synchronization 123 Exception Handling 125 Data Collection 126 Important Design Notes 126 CHAPTER 12 WRITING PHASE LOGIC 127 U

15、sing Distributed Control Systems 128 Writing PLC Phase Logic 130 Writing Control Modules (Device Drivers) 137 A Design/Code Process 138 Tips 139 The PLI 140 Table of Contents CHAPTER 13 STARTING YOUR SYSTEM RIGHT THE FIRST TIME 141 Validation 141 Start-up Tips 143 CHAPTER 14 FINIS 145 What We Learne

16、d-The Big Picture 145 A Challenge to Think Beyond Manufacturing 147 For More Information 147 One Last Thing 149 INDEX 151 ABOUT THE AUTHORS 157 ix FOREWORD To grossly paraphrase Nietzsche, serving on standards committees either kills you or makes you stronger. After six years of bimonthly internatio

17、nal meetings involving hundreds of batch professionals, costing the sponsoring companies millions of dollars, accommodating thousands of end-user comments, boosting frequent flyer accounts to record highs, and leveling whole forests to produce the twelve intermediate drafts required to reach consens

18、us, the ISA S88 Committee produced ANSI/ISA-S88.01-199S: Batch Control Systems, Part 1: Models and Terminology. The standard promised to unify the world of flexible process manufacturing with a common framework, finally allowing engineering, operations, vendors, and customers to use a common languag

19、e to describe, design, and deliver agile plants. While momentous, clear, and enlightening to the hard-core committee members, the standard proved in practice to be more of a reference than a guide to automation engineers. There were a few who vowed to write application guides to supplement the stand

20、ard, but most approaches cover a superset of the S88.01 material, treating the many aspects of batch automation necessary to successfully architect and manage large teams. However, there is a need for strong examples and case studies that breathe life into the theory. That is where this book comes i

21、n. While attending the Rockwell Consumer Products Roundtable a few years ago, I ran into Jim Parshall for the first time. He was holding court on the finer points of making ice cream, waving his arms, and genuinely having a good time explaining the process to those around him. I was instantly struck

22、 by his outgoing and enthusiastic attitude about applying computers to flexible manufacturing. He moved throughout the crowd, challenging whomever he encountered to a discussion on segmenting a plant, architecting a PLC, or laying out a graphic display. His combination of technical expertise and dyn

23、amic, engaging style appealed to the attendees and helped them understand his message. This book is written in the same style, telling the story of Ben helped us assemble a successful proposal; and worked with us diligently to ensure that the system delivered as promised. Gary Epright, Engineering M

24、anager; Wendy Yoder, Plant Manager; Drake Wallis, Corporate Director of Manufacturing; and Bruce Bowman, Senior Director of Operations, let us use technology to improve plant operations. Sue Ketcham taught us volumes about process manufacturing. We returned the favor by helping her understand the wo

25、rld of modular automation (and linear algebra and logarithms). Shes now supporting the batch control system at St. Albans (among her other many duties). You may have heard it before, but Ben Cohen and Jerry Greenfield are two real guys. We both knew them, and on one occasion Ben and Jerry bought bee

26、rs for us at a local microbrewery. Of course, we must acknowledge our good friend and fellow engineer Roland Wilhelm. (Hes a mechanical engineer, but we dont hold that against him-most of the time.) The three of us made quite a trio at that plant. Rolands unrelenting insistence on perfect project ma

27、nagement, starting with exceptional requirements gathering, kept us on our toes throughout our tenure in St. Albans. Hes truly one of a kind, and we miss working with him. We had help from many people in industry as well. These next four people spent many hours reviewing our manuscript and suggested

28、 many great improvements. (So blame them for any mistakes . ) Michael Saucier, founder of Sequencia, guided us in the principles of S88, always honestly shared his views, and was kind enough to write the books foreword. Tom Fisher, Technology Manager at xiv Applying 888 Lubrizol and considered the “

29、father“ of S88, kept us from straying too far from the intent of the standard. Karen Tipp, Industry Specialist at Rockwell Automation, is always a great source of encouragement and enthusiasm. Her experience implementing OpenBatch helped us clarify issues. Finally, Rick Mergen, Senior Engineer at Lu

30、brizol and the first Chairman of the S88 committee, also provided great insight. Lynn Craig of Manufacturing Automation Associates, and Chairman of the S88 committee when we wrote the book, is a wealth of information and phraseology. He read the manuscript on his own time and provided great feedback

31、. Wayne Cantrell from Siemens helped us with PCS 7 information. Steve Ryan, Dan Hartnett, John Clark, and Chuck Fortner from Rockwell; Bart Winters and Don Clark from Honeywell; Bob Nelson from Siemens; Joe Hancock from Eutech; Bruce Sanchez from AspenTech; Mike Kolba from Foster-Wheeler (and the Ch

32、airman of the World Batch Forum while we wrote this); Roddy Martin from AMR; Asish Ghosh from ARC; Paul Nowicki from Sequencia; and Niels Haxthausen from Novo Nordisk Engineering all lent us a hand in one important way or another. Lou Bendle from Sequencia showed us the light on OpenBatch and how we

33、 much we could benefit from it. John Parraga from Sequencia was the most-excellent consultant who introduced us to the world of phase logic. We also cannot forget the Sequencia product support team, as support can sometimes make or break a product. This group is first class. Thanks Barry, Tamara, Da

34、nny, Mark, and John. In the middle of writing this book, we both ended up leaving Ben were jumping right in. So hang on tight and enjoy the ride. BATCH MANUFACTURING Manufacturing operations can be generally classified into one of three different processes: discrete, continuous, and batch. Discrete

35、processes involve the production of things. A part or a specific quantity of parts in a group moves from one workstation to another, gaining value at each location as work is performed. In a discrete process, each thing or part maintains its unique identity. Often parts are combined to create produc

36、ts or other parts, but each new product or part maintains its unique identity. A great example of a discrete manufacturing process is the production of automobiles. Think conveyors, robots, nuts, bolts, and torque wrenches when considering discrete processes. Continuous processes involve the continu

37、ous flow of material through various processing equipment. Once a continuous process is operating in a steady state, the goal is to produce a consistent product no matter how long the operation may run. The production of gasoline is often thought of as a prime example of a continuous process. Once s

38、tarted, refineries do not want to shut down. When looking at a continuous process, youll see pumps, valves, instrumentation, and larger processing equipment (such as a cracking tower). According to the 588 standard, a batch process is defined as follows: “a process that leads to the production of fi

39、nite quantities of material by subjecting quantities of input materials to an ordered set of processing activities over a finite period of time using one or more pieces of equipment.“ So, instead of a continuous flow that can go on for days or weeks, batch processing involves limited quantities of m

40、aterial called-are you ready for this?-batches. By the nature of the process, batch manufacturing is discontinuous. That is, you start with some raw material, do something with it, send it on its way, and start all over again with some new raw materiaL Batch manufacturing is also not discrete. There

41、 are no things that you can easily separate or identify. Sure, you can place a portion of a batch into some specific container, like a bottle of soy sauce, but that doesnt make the process discrete. If 2 Applying 888 you combine a whole bunch of uniquely stamped gas caps in a box and mix them up, yo

42、u can still identify each one individually. You can individually mark bottles of soy sauce, but the sauce inside the bottle is still part of the same batch and cannot be distinguished from one bottle to the next. The distinguishing factor of a product like soy sauce is the batch or lot from which it

43、 was bottled. Thats why youll see some type of batch or lot identifier printed on the cap or labeL Weve dealt with batch processes throughout our lives. Our mothers made brownies in batches. We wash clothes in batches. (The clothing in the washing machine may be uniquely distinguishable, but washing

44、 is a batch process nonetheless.) The word batch is a noun, but it is also a verb. To “batch“ is to apply a batch process. Producing a product consistently is always a top priority. Once a process is repeatable, you can then work on issues like reducing cost, waste, or both. Consistently producing p

45、roducts with batch manufacturing is especially tricky. Unlike continuous processes, which may run for a long time, brand-new batches are created often. And unlike both discrete and continuous processes, it may not be possible to determine if the batch is being made correctly while it is being made.

46、You may have to wait until the batch is complete before checking. If its a bad batch, you can try to correct it (which costs time and money) or trash it (which really costs time and money). The point is to make a batch right the first time. So, the control of the batch process (or as we automation e

47、ngineers like to call it, batch control) is a very important aspect of batch manufacturing. Wow, what a lead-in to S88! WHAT REALLY Is 588? First of all, for the purposes of our book, heres the golden rule regarding S88 and SP88, which also applies to all ISA standards and committees: 588 is the sta

48、ndard (5 stands for “Standard“). 5P88 is the committee that wrote it (5P stands for “Standards 588.00.02, Batch Control Part 2: Data Structures and Guidelines for Languages had not yet been officially released by I5A or AN5I when we wrote this book. However, to gain valuable insight into 588.00.02,

49、we activated the “mole“ that we planted in the committee many years ago. Our source gave us important and accurate advance information about 588.00.02 that we have included in this book. Most of that information will be focused on data structures, which are discussed in Chapter 9. The portion of 588.00.02 that deals with language guidelines seems to be leaning more toward a vendor focus and is not quite as important to the user. We made a difficult decision not to include language guidelines in this book; however, we can always write another book. We will often sho