The goal of S88 is to improve the information flow between the various phases: design – definition – validation

Definition:

Reference models and terminology for batch control operations as used in industrial processes to define the relationships between the various parts and objects in the process.

The S88 standard was developed by ISA (The Instrumentation Systems and Automation Society) together with automation and production companies and in accordance with the FDA in order to simplify and improve design, definition and validation of batch control processes.

In the last years, the standard has become an international standard for Batch Control Systems. Using the S88 standard cuts down process costs while improving its productivity with a Terminology that applies to all types of process automation systems, and a set of Models that contain sufficient levels of equipment procedures to describe and manage complex Object Oriented Automation processes.

• Using S88 we create for you a common terminology for batch processing
• Using S88 we create for you a knowledge database for Re-use in all future projects
• Using S88 enables integration between production and MES (Manufacturing Executing Systems)The Market needs for S88 standard

Benefits

• Increasing efficiency in terms of production costs.
• Increasing efficiency in terms of business flexibility.
• Brand positioning and adjustment to international standards.
• Enables integration between production and MES systems

The Market needs for S88 standard

• Existing implementation has no compliance with new technologies and tools (batch engine, new DCS systems, MES systems, etc.). Currently, it is imperative to choose an implementation tool prior to the planning process to ensure its proper implementation. Using a standard enables complete separation between processes, enabling the implementation with any tool supporting the standard. Replacing standard implementation tools can be done instantly with minimum required changes.
• Plants allocate considerable resources when integrating systems from different vendors'. Systems that are based on a unified standard enable quick and simple integration, with no need to study the new systems and their features.
• Lack of common terminology between different functionaries resultsin longer validation processes and production losses.
• Inflexibility – changes to processes cause production loss. The S88 concept of dividing the systems into objects and the separation between the equipment and the process levels enable quick exchange of objects and quick process-changes with no modifications in other objects.
• Long and costly projects (planning, programming, validation). The standard enables to build an objects library for the design and implementation processes, making the objects available for re-use without any need for planning, programming, and validation.

Technical Overview

Physical model
The S88 standard divides Batch Control Systems into four physical levels:

• Control module level: typically a collection of control modules such as sensors, actuators, and associated processing equipment that, from the control point of view, is operated as a single entity. A control module can also be made up of other control modules.
• Equipment module level: consists of control modules and subordinate equipment modules. An equipment module may be part of a unit or a stand-alone equipment group within a process cell. If engineered as a stand-alone equipment group, it can be exclusively used as a resource or as a shared-use resource.
• Unit level: equipment and control modules that may be configured as part of a unit or acquired temporarily to carry out specific tasks.
• Cell level: contains all units, equipment modules, and control modules required to create batches.

Physical Model Example

Physical Tree
Describes the relationships between the various system elements, including allocating CMs to other CMs; CMs to EMs; EM or other EMs; EMs to Units; and Units to cells.

Procedural Model

The S88 standard divides the Batch Control System into four procedural levels:

Phase
The smallest element of procedural control that can accomplish a process-oriented task is a phase. A phase may be subdivided into smaller parts.

Operation
An operation is an ordered set of phases which define a major processing sequence that takes the material being processed from one state to another, usually involving a chemical or physical change.

Unit Procedure
Consists of an ordered set of operations that cause a contiguous production sequence to take place within a unit. Only one operation is presumed to be active in a unit at any time. An operation is carried to completion in a single unit. However, multiple unit procedures of one procedure may run concurrently.

Cell Procedure
The highest level in the hierarchy; defines the strategy for carrying out major processing actions such as batch creation; defined as an ordered set of unit procedures.

Recipe Example

Modularization

Creating the physical model of the facility by dividing the plant into units and EMs, and sub-dividing them into their respective EMs/CMs. This task has impact on the Recipe and at the same time takes into account the procedures that take place in the facility.
Occasionally there is a need to modify and re-modify the Physical Model to better suite the procedural needs (Recipe and Procedure development).
To design the modularization – we has to apply some criteria as follows:

• Purpose – indicates the role of the module (for all module elements).
• Independence – the ability of the module to operate on its own at the greatest extent possible.
• Use – refers to the way modules interact with other modules.
• Portability – the ability to move the module to another process or location.
• Physical Flexibility – defined modules that can be used in various sub types.
• Procedural Flexibility – the module logic definitions in order to achieve maximum flexibility in the process and its recipes.
• Isolation – the ability to minimize the effect on existing modules during process updates.

Our concept

• Protecting the product
  • Preventing human errors
  • Preventing machine failures
  • Anticipating common problems
• Separate processes from equipment
  • Creating physical objects that control the equipment
  • Creating procedural objects that run the process
• Use advanced engineering tools
  • Direct connection between design-definition-validation
  • Decreasing faults and errors
  • Shortening project life cycle
  • Faster time to market
• Create a knowledge database for Re-use in all future projects
  • Long term data management
  • Re-use of most data in future projects
  • Data exchange with external systems
• Validation automation
• Use international and proven standard (S88)

Benefits

• Proven expertise
  • Assures easy and successful implementation of the standard
• Work Flow
  • Ability to change/add processes with minimum production loss
  • Re-usable and unified knowledge base
  • Avoiding operators’ errors

• Proven expertise
  • Assures easy and successful implementation of the standard
• Work Flow
  • Ability to change/add processes with minimum production loss
  • Re-usable and unified knowledge base
  • Avoiding operators’ errors
  • Equipment monitoring prevents production loss
  • High quality documentation
• Product Quality Control
  • GAMP, full compatibility between planning and implementation
  • High standard design shortens QC
• Simple Maintenance
  • Equipment monitoring prevents faults that stop production
  • Updated documentation
  • Unified and lasting process logic structure
  • No dependency on one specific implementer
• ROI
  • New projects are based on accumulated knowledge base. As a result design- definition-validation time is significantly reduced
  • Compatibility with new technologies / tools / vendors
• Proven international standard

Standardization Process

Creation of a standard library for physical and procedural objects required for production processes, based on URS (User Requirements Specification) and on system analysis including its process properties.

Standardization Project Steps

Step 1
Creation of a company URS (User Requirements Specification) development document.
The document will include:

• Production system description
• Automation system description
• Definition and implementation tools
• Processes description
• Process equipment's
• Required flexibility.
• Operator-Process relation
• HMI application requirements
• MES application requirements
• Alarms handling requirements
• Maintenance requirements

Step 2
Creation of a company CFS (Concept Functional Specification) document:
The document will include:

• Definition and implementation methodology
• Objects (physical and procedural) naming convention
• Parameters naming convention
• Procedure state transition
• Procedure stats naming convention
• Typical logic structure
• Programming concept
• Classic equipment's stats and parameters
• Data Flow and Data exchange
• HMI Interface handling
• MES Interface handling
• Obligating rules – as the S88 standard is very flexible, it is imperative to set rules that minimize flexibility while operating in a consistent and standard objects formation
• Messages handling
• Alarms handling
• Equipment monitoring
• Process safety Handling

Step 3
Creation of DDS (Detail Design Specification) in the definition tool.
The definition will include:

• Physical model
  • CMs class library (states, parameters and FBD-Function Block Diagram logic)
  • EMs class library (stats, parameters, conditions and interlocks)
  • Units class library (stats, parameters, conditions and interlocks)
• Physical Tree
  • CMs allocation
  • EMs allocation
  • Units allocation
• Procedural model
  • Phases class library (stats, parameters, conditions, SFC logic, parameters manipulation, activations and alarms)
  • Operations class library (stats, parameters, conditions and SFC logic)
  • Unit Procedures/Recipes class library (stats, parameters, conditions, SFC logic and formulas)
•  Full or partial instantiation

Step 4 – optional
Process drawings class library, including:

• Typical Equipment blocks
• Equipment class
• Relationships between the equipment's

Step 5 – optional

• Components
• validation