Document 6507512
Transcription
Document 6507512
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 1 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) Hogeschool Antwerpen 2 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 Hogeschool Antwerpen 3 1 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 Hogeschool Antwerpen 4 Industrial science and technology S88 and automation • Structure for all levels of automation • Full-automatic systems • Full-manual systems • Semi-automatic systems Hogeschool Antwerpen 5 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) Hogeschool Antwerpen 6 2 Industrial science and technology Preparation Product variants Process experts PLC programmers Meeting Interface ≈ Control recipe Recipe structure Procedures, Operations, Phases Hogeschool Antwerpen 7 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 Hogeschool Antwerpen 8 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 Hogeschool Antwerpen 9 3 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’. Hogeschool Antwerpen 10 Industrial science and technology Types of ‘trains’ 1. Single-path 2. Multiple-path 3. Network-path Hogeschool Antwerpen 11 Industrial science and technology 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 Hogeschool Antwerpen 12 4 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 Hogeschool Antwerpen 13 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 Hogeschool Antwerpen 14 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. Hogeschool Antwerpen 15 5 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 Hogeschool Antwerpen 16 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. Hogeschool Antwerpen 17 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. Hogeschool Antwerpen 18 6 Industrial science and technology Design physical model • Highest level’s are often easy: • Company = enterprise • Establishment = site • Area = production plant Hogeschool Antwerpen 19 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 Hogeschool Antwerpen 20 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 Hogeschool Antwerpen 21 7 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 Hogeschool Antwerpen 22 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. Hogeschool Antwerpen 23 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 Hogeschool Antwerpen 24 8 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 Hogeschool Antwerpen 25 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 Hogeschool Antwerpen 26 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. Hogeschool Antwerpen 27 9 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 Hogeschool Antwerpen 28 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 Hogeschool Antwerpen 29 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 Hogeschool Antwerpen 30 10 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 Hogeschool Antwerpen 31 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. Hogeschool Antwerpen 32 Equipment Control Recipe Procedure Equipment Procedure Recipe Unit Procedure Equipment Unit Procedure Recipe Operation Equipment Operation Recipe Phase Equipment Phase Hogeschool Antwerpen Mechanics Control Recipe Procedure Flexibility Industrial science and technology Linking recipe to equipment 33 11 Industrial science and technology 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 Hogeschool Antwerpen 34 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 Hogeschool Antwerpen 35 Industrial science and technology States Hogeschool Antwerpen 36 12 Industrial science and technology State matrix Hogeschool Antwerpen 37 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 Hogeschool Antwerpen 38 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 Hogeschool Antwerpen 39 13 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) Hogeschool Antwerpen 40 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 Hogeschool Antwerpen 41 Industrial science and technology Questions? • Dirk van der Linden • Scientific researcher automation • Hogeschool Antwerpen (Belgium) • Industrial Science and Techology • [email protected] Hogeschool Antwerpen 42 14