S88 standard in batch and continuous process plants

with DeltaV control of Emerson

ANSI / S88 is a standard for Batch Control, often referred to as S88 or SP88. It is a design philosophy for software,
equipment and the process sequence. Part 1 was released in 1995 by ISA. ISA-88 was adopted by the IEC as IEC
61512. All the control systems that you use to drive batch can use as the basis the S88. The system suppliers teach
in your courses that you should define the whole logic of the control process within the phases, but this can lead to
considerable disadvantages depending on the application. We do not do that. Why …? Continue reading.

S88 and its states

The S88 standard describes the states which can have a phase (basic function). These can be: Idle, Running,
Complete, Stopping, Stopped, Holding, Held, Restarting, Aborting and Aborted. In order to load / unload the phases
into the controller, they must have certain states. The phases must be Idle for loading and Completed, Stopped or
Aborted for unloading. This has a direct effect on the design of recipe sequences, especially in connection with
basic functions, which have so-called "open" driving modes, like stirring or heating.

S88 structure does not have open phases (driving modes)

Figure below shows the possible transitions between the individual statuses. It is important to note that from the
states Aborted, Stopped and Complete, you can not go back to the running status via restarting or to the hero status
via holding. This is associated with open driving problems when the phase has reached the Complete state.
(Example: open driving mode: phase agitation, has reached the desired speed setpoint). In parallel, a reception
phase runs in a partial recipe, waiting for a certain amount of solvent to be presented (closed driving after
completion) At this moment an event which leads to a security position, the receive phase can be brought from
running to held. The phase agitation, which is already in the Complete state, can no longer be influenced by the
batch system.

The representation of the S88 within a phase logic module

Failure Monitor as an interface to the program code. Collateral in unit and
basic functions.
Using the Failure Monitor included in the Phase Logic Module, errors from basic functions can be brought up into
the phase and thus a reaction of the recipe can be provoked. However, this again and again with the restriction
described above. As soon as the phase reports Complete, Stopped or Aborted, it is unloaded from the controller by
the batch system and is thus no longer accessible. Therefore, the entire security level must be integrated at the unit
level and basic functions, where it is always active independently of phases (loaded or not loaded in the controller).
.

The Failure Monitor included in the Phase Logic Module

Classification of recipes
In the DeltaV system, the recipe level is separated from the control strategy in the system configuration and is
divided into operations, unit procedures (recipes) and procedures (recipes). The Phase Logic Module -> PLM
(Phase Classes) is located in the Advanced Definitions as a link between Batch System and Control Strategy. In
the PLM, only parameters and driving modes are transferred from the Batch Input Parameters -> BIP to the basic
functions and the basic functions connected via aliasing are expected to reach the phase expected by the phase
(progress condition -> FSB) Complete.

The recipes level within a configuration

Operation as the lowest recipes
Operations can be assigned to individual units or unit classes. They contain the parameters which are also found
in the basic functions. However, the operation is the GDP defined in the PLM, which are either entered directly in
the operation or by means of "Defer" to the next higher recipe level the Unit Procedures -> UP.

The assignment of an operation to a unit or unit class

Unit Procedures (Recipes)
Within a partial recipe, all operations required for a partial step of a production are then brought together. Normally
within a UP most parameters are known and can be directly formulated as a value. In order to increase the
reusability of UPs, however, individual parameters can also be uploaded to the highest level of the procedures.
Thus, recipes can be copied and reused by simply adapting these individual parameters for similar products.

In a partial recipe unified operations of a unit

Procedures (recipes)
Within the procedures, the partial recipe of the individual sub-plants is now brought together and thus the production
of a product is formulated over several units

The Recipe Procedure in which the individual units involved

in the batch process (with their sub-recipes) are connected
Continuous or batch: S88 makes it possible
In contrast to batch plants, a continuous plant will eventually be in a production step after a few preparatory steps
and start-up steps, until the operator decides to return the plant to the off-state via start-up steps. It is important that
during the production steps, either the recipe is tracked to the system state, or that parameters are ensured within
the basic functions, for example, that feeds only start running once the parameters such as pressure or temperature
are in the correct range. Thus, the inflow basic functions can not restart the feeds until the inlet conditions have
been reached after the restart of the unit.

This can also be realized by querying the state of the unit in the recipe and placing the recipe in a standby step, the
unit should fall into a safety state. In this case, for example, the inlets are interrupted in the Stanby step. When the
safety position is reset, the operator can decide whether he wants to move the unit completely or whether he wants
to go back to the dosing step. If he chooses the second option, the partial recipe goes back to the steps that are
ready for reaching the start-up release. (Heating, evacuation, etc.)

Limits associated with recipes and phases

Regarding the controller load, the following limits are set for the phases at DeltaV, which I would like to enter for the
rounding.
Controller Capacities
PLMs pro controller: non-
redundant
Unit phases simultaneously
running per unit module :
redundant and non-redundant
controller
Number of active phases per
controller
Fixed limit Maximum recommended limit
Limited by the available memory in the MD / MDPlus controller - 300
controller
MX controller - 600
10 10
Unit Phases can be specified as
"Always in Memory". This means that
these phases are loaded in any case,
even if the memory in the controller is
full
None MD / MDPlus controllers - 50
MX controller - 150
Restriction for procedures:
max. 15 units with max. 10
parallel PLMs that run on 1
controller (MX)

Number of unit modules per None MD / MDPlus controllers - 5

controller MX controller - 24