Practical Batch Management & Control (Including S88) for Industry

WORKSHOP OBJECTIVES

At the end of this workshop participants will be able to:

  •  Acquire a basic knowledge of standards and techniques in the automation of batch processes
  •  Design a batch manufacturing control system for new or upgrade projects using principles supported by the ISA S88 standard
  • Obtain guidance in the integration of batch control systems with manufacturing information systems
  • Design and specify instrumentation and batch controls in modules leading to complete unit operations
  • Carry out the detailed design of batch control operations including the sequencing and interlocking functions
  • Develop batch operations into complete recipe based production systems
  • Be aware of and be able to evaluate the choices in the range of batch control system products
  • Avoid the pitfalls of not having the batch control system package match your requirements.

WHAT IS INCLUDED?

  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month

WHO SHOULD ATTEND?

  • Chemical engineers
  • Design engineers
  • Electrical engineers
  • Electrical technicians
  • Electricians
  • Engineers and technicians in process or control/instrument fields who are involved in batch process control projects
  • Field technicians
  • Instrumentation and design engineers
  • Plant operators
  • Process engineers
  • Production supervisors or managers interested in developing improved batch management techniques through the use of automation systems
  • Project engineers
  • System integrators seeking to provide a design service to clients
  • Those in businesses that have automated batch manufacturing as a part of their production activity

CONTENT SUMMARY

WORKSHOP OUTLINE AND OBJECTIVES

  • Identification of batch processes, characteristics and examples
  • Background to the demand for integrated batch systems
  • Overview of batch systems engineering
  • Introduction to standards: ISA S88, IEC 849/BS 7716

IDENTIFY AND DEFINE PHYSICAL MODELS

  • We begin with a hypothetical but typical process in batch manufacturing
  • Presentation of a typical P&ID with several units linked to supply systems
  • Show how this is structured into elements, equipment modules, units, cells and trains using the physical models technique in S88
  • Show how well structured batch plants can save on equipment costs

IDENTIFY AND DEFINE PROCESS MODELS, ACTIONS, OPERATIONS, STAGES

  • Relationship between physical and process models
  • A unit operation example based on the typical P&ID shown in the first practical session

IDENTIFY AND DEFINE PROCEDURAL MODELS

  • Sequence steps, phases, operations, unit procedures
  • Introduction to co-ordination control

THE CONCEPTS OF EQUIPMENT ENTITIES

  • The relationship between procedural control, physical model and procedural model
  • Explanation of basic control, procedural control and co-ordination control
  • This concept illustrated by using the example process
  • Show how batch control is built up around the common, functional entities of control modules, equipment modules and units

INTRODUCTION TO RECIPES

  • The use of recipes to define all requirements for batch manufacture of a given product
  • The concepts of master and control recipes
  • Using and creating recipes
  • How to hide the complexities of unit operations and create flexibility for the production team

BATCH MANUFACTURING BASICS

  • Batch numbering, tracking and reporting
  • Batch planning and scheduling

BATCH AND SEQUENCE PROGRAMMING FUNDAMENTALS

  • Practical techniques for batch control elements
  • Implementation of valve elements, motor controls, interlocks, permits etc.
  • Interactions with continuous process sections

PRACTICAL TECHNIQUES IN SEQUENCE CONTROL DESIGN

  • How to capture the need, design the operation and document it for programming into PLC/DCS
  • Practical methods for functional specifications; flowcharts and structured text
  • Defining equipment and process states using transition diagrams
  • Dealing with sequencing problems such as alarms, holds, aborts and restarts

INTERFACING TO THE OPERATOR AND THE SUPERVISOR

  • Display screens for recipes, monitoring of sequence operations, trouble shooting, maintenance
  • Illustrations using currently available software packages

BATCH MANAGEMENT ISSUES

  • Introduction to batch control activities and activity models as described in ISA S88
  • Practical problems in batch management
  • Ownership issues and conflict
  • Using command structures to resolve problems

PRACTICAL BATCH CONTROL TECHNOLOGIES

  • Overview of DCS/PLC architectures
  • Examples of current products
  • Integration of batch control systems to production management and ERP systems
  • ERP requirements as inputs to batch production
  • Sending process quality and production reports back to ERP

PRACTICAL SOFTWARE PROJECT PLANNING AND IMPLEMENTATION

  • What to look for in batch software packages
  • Batch control software products
  • Overview of S88 compliant packages
  • Examples and demonstrations of key features from existing vendor packages

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