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ANSI/ISA-5.06.01-2007 Functional Requirements Documentation for Control Software Applications ISBN: 978-1-934394-33-5 Copyright 2007 by ISA. All rights reserved. Not for resale. Printed in the United States of America. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic mechanical, photocopying, recording, or otherwise), without the prior written permission of the Publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709
ANSI/ISA-5.06.01-2007
Preface
This preface, as well as all footnotes and annexes, is included for information purposes and is not part of ANSI/ISA-5.06.01-2007. This document has been prepared as part of the service of ISA toward a goal of uniformity in the field of instrumentation. To be of real value, this document should not be static but should be subject to periodic review. Toward this end, the Society welcomes all comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices Board; ISA; 67 Alexander Drive; P. O. Box 12277; Research Triangle Park, NC 27709; Telephone (919) 549-8411; Fax (919) 549-8288; E-mail: standards@isa.org. The ISA Standards and Practices Department is aware of the growing need for attention to the metric system of units in general, and the International System of Units (SI) in particular, in the preparation of instrumentation standards. The Department is further aware of the benefits to USA users of ISA standards of incorporating suitable references to the SI (and the metric system) in their business and professional dealings with other countries. Toward this end, this Department will endeavor to introduce SI-acceptable metric units in all new and revised standards, recommended practices, and technical reports to the greatest extent possible. Standard for Use of the International System of Units (SI): The Modern Metric System, published by the American Society for Testing & Materials as IEEE/ASTM SI 1097, and future revisions, will be the reference guide for definitions, symbols, abbreviations, and conversion factors. It is the policy of ISA to encourage and welcome the participation of all concerned individuals and interests in the development of ISA standards, recommended practices, and technical reports. Participation in the ISA standards-making process by an individual in no way constitutes endorsement by the employer of that individual, of ISA, or of any of the standards, recommended practices, and technical reports that ISA develops. CAUTION ISA ADHERES TO THE POLICY OF THE AMERICAN NATIONAL STANDARDS INSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF AN EXISTING PATENT THAT IS REQUIRED FOR USE OF THE DOCUMENT, IT WILL REQUIRE THE OWNER OF THE PATENT TO EITHER GRANT A ROYALTY-FREE LICENSE FOR USE OF THE PATENT BY USERS COMPLYING WITH THE DOCUMENT OR A LICENSE ON REASONABLE TERMS AND CONDITIONS THAT ARE FREE FROM UNFAIR DISCRIMINATION. EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THIS DOCUMENT, THE USER IS CAUTIONED THAT IMPLEMENTATION OF THE DOCUMENT MAY REQUIRE USE OF TECHNIQUES, PROCESSES, OR MATERIALS COVERED BY PATENT RIGHTS. ISA TAKES NO POSITION ON THE EXISTENCE OR VALIDITY OF ANY PATENT RIGHTS THAT MAY BE INVOLVED IN IMPLEMENTING THE DOCUMENT. ISA IS NOT RESPONSIBLE FOR IDENTIFYING ALL PATENTS THAT MAY REQUIRE A LICENSE BEFORE IMPLEMENTATION OF THE DOCUMENT OR FOR INVESTIGATING THE VALIDITY OR SCOPE OF ANY PATENTS BROUGHT TO ITS ATTENTION. THE USER SHOULD CAREFULLY INVESTIGATE RELEVANT PATENTS BEFORE USING THE DOCUMENT FOR THE USERS INTENDED APPLICATION. HOWEVER, ISA ASKS THAT ANYONE REVIEWING THIS DOCUMENT WHO IS AWARE OF ANY PATENTS THAT MAY IMPACT IMPLEMENTATION OF THE DOCUMENT NOTIFY THE ISA STANDARDS AND PRACTICES DEPARTMENT OF THE PATENT AND ITS OWNER. ADDITIONALLY, THE USE OF THIS DOCUMENT MAY INVOLVE HAZARDOUS MATERIALS, OPERATIONS OR EQUIPMENT. THE DOCUMENT CANNOT ANTICIPATE ALL POSSIBLE APPLICATIONS OR ADDRESS ALL POSSIBLE SAFETY ISSUES ASSOCIATED WITH USE IN HAZARDOUS CONDITIONS. THE USER OF THIS DOCUMENT MUST EXERCISE SOUND
ANSI/ISA-5.06.01-2007
PROFESSIONAL JUDGMENT CONCERNING ITS USE AND APPLICABILITY UNDER THE USERS PARTICULAR CIRCUMSTANCES. THE USER MUST ALSO CONSIDER THE APPLICABILITY OF ANY GOVERNMENTAL REGULATORY LIMITATIONS AND ESTABLISHED SAFETY AND HEALTH PRACTICES BEFORE IMPLEMENTING THIS DOCUMENT. THE USER OF THIS DOCUMENT SHOULD BE AWARE THAT THIS DOCUMENT MAY BE IMPACTED BY ELECTRONIC SECURITY ISSUES. THE COMMITTEE HAS NOT YET ADDRESSED THE POTENTIAL ISSUES IN THIS VERSION. The following members of ISA5.6 contributed to the development of this standard: NAME A. Habib, Chair A. Amdur D. Beaty P. Blok R. Dwiggins J. Halajko R. Bhala S. Kolla R. Topliff R. Wood AFFILIATION Automation Consultant Consultant DLB Associates Pharma Team USA Maverick Technologies FMC, Inc. Sanofi Pasteur Bowling Green State University CH2M HILL University of Alberta
The following people served as voting members of ISA5: NAME A. Iverson, Chair T. McAvinew, Managing Director G. Barta C. Borel J. Carew A. Habib G. Ramachandran AFFILIATION Ivy Optics Jacobs Engineering Consultant Spectrum Engineering Inc. Consultant Automation Consultant Motiva Enterprises LLC
ANSI/ISA-5.06.01-2007
This standard was approved for publication by the ISA Standards and Practices Board on 17 August 2007. NAME T. McAvinew, Vice President M. Coppler E. Cosman B. Dumortier D. Dunn J. Gilsinn W. Holland E. Icayan J. Jamison R. Jones K. Lindner V. Maggioli A. McCauley, Jr. G. McFarland R. Reimer N. Sands H. Sasajima T. Schnaare J. Tatera I. Verhappen R. Webb W. Weidman J. Weiss M. Widmeyer M. Zielinski AFFILIATION Jacobs Engineering Group Ametek Inc. The Dow Chemical Company Schneider Electric Aramco Services Co. NIST Consultant ACES Inc. Jamison & Associates Ltd CDI Business Solutions Endress + Hauser Process Solutions Feltronics Corp. Chagrin Valley Controls Inc. Emerson Process Management Rockwell Automation E I du Pont Yamatake Corp. Rosemount Inc. Tatera & Associates MTL Instrument Group Consultant Parsons Energy & Chemicals Group Applied Control Solutions LLC Consultant Emerson Process Management
ANSI/ISA5.06.012007
Contents
Preface .......................................................................................................................................................... 3 1 2 3 4 4.1 Scope ................................................................................................................................................. 11 Normative References........................................................................................................................ 12 Definitions/Abbreviations.................................................................................................................... 13 Methodology ....................................................................................................................................... 14 Modular plant arrangement........................................................................................................ 14
Annex A (informative) Application Example 1: Batch Reactor ............................................................... 27 Annex B (informative) -- Application Example 2: Continuous Distillation Column ................................... 43
Figure 1 Charter upon which this standard is based.............................................................................. 12 Figure 2 Modular plant partitioning......................................................................................................... 15 Figure 3 Four components of software documentation methodology .................................................... 16 Figure 4 Example of modular plant partitioning and software documentation ....................................... 17 Figure 5 Database documentation ......................................................................................................... 18 Figure 6 Interlock matrix documentation ................................................................................................ 21 Figure 7a Normal sequence matrix ........................................................................................................ 22 Figure 7b Hold sequence matrix ............................................................................................................ 23 Figure 7c Recipe sequence matrix......................................................................................................... 23 Figure 8 Data security definition............................................................................................................. 25 Figure 9 Chemical reactor P&ID............................................................................................................. 27 Figure 10a Database I/O information ..................................................................................................... 29 Figure 10b Database HMI information ................................................................................................... 30 Figure 10c Database operating information ........................................................................................... 31 Figure 10d Control module class definition ............................................................................................ 32 Figure 11a Software interlock matrix for Unit R-101 .............................................................................. 33 Figure 11b Software interlock matrix for Equipment Module EM-1........................................................ 34
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Figure 12a Normal sequence matrix for Unit R-101............................................................................... 36 Figure 12b Hold sequence matrix for Unit R-101................................................................................... 37 Figure 12c Recipe sequence matrix for R-101....................................................................................... 38 Figure 12d Equipment module sequence matrix for EM-1 phase FILL_R101 ....................................... 39 Figure 13a Graphic elements ................................................................................................................. 40 Figure 13b Interlock status display......................................................................................................... 41 Figure 13c Sequence status display ...................................................................................................... 41 Figure 14 Continuous Distillation Column P&ID..................................................................................... 44 Figure 15a Database I/O information ..................................................................................................... 46 Figure 15b Database HMI information ................................................................................................... 47 Figure 15c Database operating information ........................................................................................... 48 Figure 16 Interlock matrix ....................................................................................................................... 49 Figure 17a Normal sequence matrix for Unit C-104 (URS format) ........................................................ 51 Figure 17b Hold sequence matrix for Unit C-104 (URS format)............................................................. 52 Figure 17c Sequence matrix for C-104 Startup phase in FRS format (continues on next page)........... 53
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Foreword
Learning and configuring today's control software packages is easier than ever before. Documentation, however, is not such an easy task. With the increased capabilities of software packages to handle more process and operator interfaces, the complexity of defining and documenting these requirements increases. This standard directly addresses this documentation issue. The ISA5.6 subcommittee was established by ISA5, Documentation of Measurement and Control Instruments and Systems, at the request of control systems engineers involved in the automation of plant operations using a wide variety of computer-based platforms. These platforms included distributed control systems, programmable logic controllers and industrialized personal computers offered by a variety of suppliers. The need for documentation to help define control software prior to hardware selection, especially for batch sequence logic, was identified due to its complexity. ISA's Standards & Practices Board subsequently expanded the scope of ISA5.6 to include the software documentation of continuous processes.
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Scope
The scope of this standard is: Covers real-time batch, discrete and continuous process automation systems. Defines regulatory, event-driven and time-driven control system actions. Encompasses both digital and analog control devices in addition to non-control actions (for example, operator messages and batch end reports). Encompasses both normal and abnormal operational requirements of systems and shows the interactions between them. Uses a set of terms that relate directly to the languages commonly used by plant operators. Excludes interactions with higher-level systems.
Within the parameters of this scope, the standard is intended to: Establish functional requirements specifications for control software documentation that covers the classes of industrial automation equipment and systems consisting of distributed control systems, programmable controllers and industrial personal computers (see Figure 1). Provide techniques for documenting control system software. The software to be generated is a function of the computer system chosen for a particular project. The documentation procedure set forth in this standard is independent of the hardware/software system that is chosen. Provide a basis for validation of run-time application software after it is developed and tested to ensure that the initial requirement specification has been met.
The documentation resulting from use of this standard: Can be used for control software definition, design, testing and validation. Is not intended to require specialized knowledge of any particular engineering or computer science discipline to develop or understand.
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Industrial Applications
Pharmaceutical
Implementation Languages
Target Systems
Database
Relay Ladder
Normative References
The following normative documents contain provisions that, through reference in this text, constitute provisions of this standard. At the time of publication the editions indicated were valid. All normative documents are subject to revision and parties to agreements based on this standard are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. Members of the IEC and ISO maintain registers of currently valid normative documents. ANSI/ISA-84.00.01-2004 Parts 1-3 (IEC 61511 Modified), Functional Safety: Safety Instrumented Systems for the Process Industry Sector. www.isa.org . ISA-88.01-1995, Batch Control Part 1: Models and Terminology. www.isa.org. ISA-5.5-1985, Graphic Symbols for Process Displays. www.isa.org. IEC 61131-3 Ed. 2.0: 2003 Programmable controllers - Part 3: Programming languages. www.iec.ch.
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Definitions/Abbreviations
3.1 analog input (AI): a modulated signal received by the control system from an external measurement device, such as a 420 mA or fieldbus signal from a pressure transmitter. 3.2 analog output (AO): a modulated signal sent by the control system to an external control device, such as an analog 420 mA or digital fieldbus signal to a flow control valve. 3.3 control module (CM): the lowest level grouping of equipment in the physical model that can carry out basic control.
NOTE This term applies to both the physical equipment and the equipment entity.
3.4 detailed design specification (DDS): a separate document that shows how a system functions and meets the requirements laid out in the Functional Requirements Specification prepared from this document. 3.5 discrete input (DI): a binary signal received by the control system from an external switch such as a 24-Vdc or fieldbus signal from a block valves closed limit switch. 3.6 discrete output (DO): a binary signal sent by the control system to an external on/off device such as a 120-Vac or digital fieldbus signal to start a pump. 3.7 equipment module (EM): a functional group of equipment that can carry out a finite number of specific minor processing activities. This may exist as part of a unit or as a common resource -- e.g., equipment shared by two or more units. 3.8 functional requirements specification (FRS): a specification listing the detailed operational requirements for a control system (i.e., what the system does, not how it does it). 3.9 operation: a major programmed processing action or set of related actions normally consisting of one or more phases. 3.10 Piping and Instrumentation Diagram (P&ID): a diagram showing the interconnection of process equipment and instrumentation used to control a process. 3.11 Process Flow Diagram (PFD): a diagram showing outlines of one or more pieces of equipment and the expected flow paths for materials and utilities. 3.12 phase: the smallest element of procedural control that can accomplish a process-oriented task. A phase may be comprised of steps.
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3.13 process cell: a logical grouping of equipment that includes the equipment required for production of one or more materials. It defines the span of a logical control of one set of process equipment within an area. 3.14 step: sequential action of control devices within a phase (shown in this standard by a number in parentheses after the status for a discrete device or setpoint for an analog device). 3.15 train: a collection of one or more units and associated lower-level equipment groupings that has the ability to be used to make a quantity of material. 3.16 unit: an equipment grouping to carry out one or more major processing activities such as reaction, crystallization and making a solution. It combines all necessary physical processing and control equipment required to perform those activities as an independent equipment grouping. It is usually centered on a major piece of processing equipment such as a mixing tank or reactor. 3.17 User Requirements Specification (URS): a specification showing the general control requirements for a unit or process cell.
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4.1
Methodology
Modular plant arrangement
The first step in applying this standard is to divide a process plant into the groupings illustrated in Figure 2. Classes of process units are grouped vertically and trains are grouped horizontally in the figure. Examples of process units include reactors, distillation columns and dryers. A train consists of one or more units necessary to complete the processing step for an intermediate or finished product. This may be as simple as a single mix tank and as complex as a refinery train consisting of multiple reactors, distillation units, dryers, etc. For flexible batch operations we may not be able to define trains other than as individual units. The boxes shown on the periphery of Figure 2 are shared resources comprising additional units and/or equipment modules.
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Discharge
Discharge
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The first three are commonly prepared using spreadsheet software. The fourth will use graphical software. Examples of each are shown in the examples that follow this description.
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Gas Waste Treatment U T I L I T I E S Train Blender # 1 2 3 4 BL-401 BL-101 BL-201 Units Reactor Centrifuge Distn Coln RX-102 RX-202 RX-302 CE-303 CE-403 CE-103 DI-104 DI-204 DI-304 DR-405 Dryer DR-105 DR-205 P A C K A G I N G
Raw Materials
S T O R A G E
S T O R A G E
Product Shipping
Discharge
The first part of the documentation is the database, which can be tabulated under various column headings as illustrated in Figure 5. This closely resembles the instrumentation index with provision to record details of Input/Output (I/O) functionality and the parameters required to support operator displays, alarms and control loops. System-dependent implementation details will be defined in the Detailed Design Specification (DDS) which follows later. Though system specific, I/O hardware and software addresses are often considered as a functional requirement because of their potential impact on process availability; as such, they may be designated in the FRS after selection of the control system.
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The five sections of the database shown in Figure 5 can be consecutive column headings across a spreadsheet. They are shown here as separate sections of the table due to space limitations. In actual use on a spreadsheet they will all follow left to right on one table. The separate sections shown here may be useful for breaking out the table for a printed copy. Leaving this as a continuous spreadsheet will make using it easier. Each row would then show the relevant information for a single instrument or control module; associated alarms may be designated using multiple entries per cell, additional columns or separate tags. This document is the cornerstone of the FRS because it forms the basis or foundation for the other documents that follow. It is applicable for both continuous and batch control but typically contains many more internal variables when applied to a batch process.
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The column names for the database (Figure 5) are suggestions only. Depending on the system, software to be used and other parameters, columns may need to be added, deleted or renamed. The planned uses for each column are: Basic Point Data CM Tag: the control module name usually corresponding to the instrument tag number shown on the P&ID, instrument index, etc. Service: the piece of equipment or module with which the instrument or loop is most closely associated. Location: the Unit or Equipment Module that includes the Control Module. P&ID: the Piping and Instrumentation Drawing showing the instrument or loop. Comments: provides additional information, if needed, for the instrument; may identify special or atypical feature requirements (not used in the examples that follow). I/O Interface Data Point Type: indicates the functionality of the item i.e., discrete vs. analog vs. digital, control vs. alarm, and input vs. output; optionally may refer to a separately specified class of control modules, equipment modules or units. Device Type: provides additional description of the item such as valve, motor starter, software / function block and may note signal conditioning such as characterization (chr) or square root extraction () to be performed within the field device. Signal Type: shows type of signal for the I/O loop. Signal Conditioning: shows any adjustments that must be made to the input signal for the desired control action--i.e., pressure or temperature linearization, square-root extraction. I/O Tags: shows all P&ID tags associated with a particular control module. I/O Address: hardware or software address information; cabinet location and software identification for troubleshooting, etc. Human/Machine Interface Data Scale: the zero and full-scale values or enumerated state descriptors for each signal. Eng Units: unit descriptor to accompany the value display. Descriptor: the full description of the instrument or loop for use on alarm and event lists, point details and other displays having sufficient space. Keywords: the abbreviated description of the instrument or loop for use on group displays and others having limited space. Data Logging & Archival: This is initially just a yes/no flag indicating if this control module should have data logging and/or archiving capability. Later, this can be expanded to show the frequency of these functions. Operating Data Alarm Type: identifies the type of each required alarm, such as bad value, high, and hihi for an analog data point or command disagree and un-commanded change for a digital loop. Alarm Setpoint: the reading values that will activate the alarms, usually just one for each value, but may specify that it will be written or activated by a recipe or sequence logic.
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Alarm Priority: the level of urgency to relay to the operator: different alarms within a loop can have different priorities. Output Direction: defines the relationship between the controller output and the final control element (direct or reverse). Controller Type: manual, automatic and supervisory. Controller Algorithm: proportional, integral, derivative and combinations desired for the control functioning. Controller Action: direct or reverse action of the controller output in response to the controlled variable-i.e., increasing or decreasing as the process value increases above the setpoint.
Note Data access rights are presented in the HMI data security section while alarm deadbands are typically noted per point only upon exception to a percentage value footnoted on the database table. A further important part of the control database definition is specifying the instance-independent functionality for each class of control modules that will be referenced in the database matrix. A typical definition is illustrated in Figure 10d as part of the first application example. The corresponding control logic can ultimately be configured through any one or more of the following control language types: Boolean, function blocks, structured text, ladder logic and others.
4.1.2
Next is the process interlock matrix illustrated in Figure 6. This contains the documentation for all of the process and safety interlocks in a particular section of the plant or project. It may be desirable to keep the safety interlock documentation separate from the process interlocks. Showing both here will help assure that all process concerns are addressed. The purpose here is to document the continuous interlock requirements within the control system regardless of whether the process is continuous or batch. Continuous timed sequences (such as for a sump pump or for baghouse blowdown valves) may be defined here or in the sequence matrix depending upon complexity and safety impact. Product-dependent trip points (such as reactor temperature limits) will normally be identified in the sequence matrix with the associated actions defined either here or in the sequence matrix. The interlock logic can be described in a simple table listing the interlock numbers taken from the P&ID (piping and instrumentation diagram) or equivalent document along with the initiating device(s) and control device(s). Examples of these include a temperature switch, proximity sensor and block valve. The P&ID presentation below graphically illustrates the different hardware and software components used to interlock the normal control function (HS-104) with a low level switch (LSLL-101) acting on the final control element (SV-104) using the software logic solver (UC-104). The company that will be operating the system defines the hazard level. Some examples of hazard levels defined by the potential for material, equipment and personnel loss are shown below. Further information can be found in Guidelines for Safe Automation of Chemical Processes (see section 2), AIChE / CCPS, 1993, www.aiche.org. Guidance for the choice of interlocks, their logic and setting the Safety Integrity Level is found in ANSI/ISA-84.00.01-2004 Parts 1-3 (IEC 61511 Modified), Functional Safety: Safety Instrumented Systems for the Process Industry Sector. www.isa.org .
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ID NUMBER
HAZARD LEVEL
OPERATING MODE
INTERLOCK PURPOSE
Sample Definitions: Hazard Level: (0) (1) (2) (3) None Low Medium High Material Loss Recoverable Batch Lost Other Batches Lost Equipment Loss Repairable Damage Replace Unit Replace Other Units Personnel Loss Medical Treatment Lost Time Accident Mult. Injury or Death
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Safety Integrity Levels--Examples: (1) One sensor, one logic solver, one actuator (2) Two sensors, two logic solvers, one actuator (3) Two sensors, two logic solvers, two actuators Operating Modes *AR = Automatic reset *R = Manual reset *V = Override (with pre-set timer) *B = Bypass (forcing, testing)
The process safety team should review this simple list before the actual software configuration is developed. These interlocks may be modified based on the results of a hazard analysis for the unit. 4.1.3 Sequence Matrix
The sequence operation of the process is then documented. This may be accomplished with the sequence matrix (see Figures 7a, 7b, and 7c). This information can also be presented using sequential function charts, relay ladder logic and other formats. Here we show the matrix as prepared on a spreadsheet. The sequence matrix has three main sections: Normal sequence matrix Hold sequence matrix Recipe sequence matrix
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RECIPE PARAMETERS
SHUTDOWN PHASE
VARIABLES CODED IN PROGRAM VARIABLES ENTERED BY OPERATOR VARIABLES ENTERED BY PRODUCTION SUPERVISOR
A Sequence matrix can be developed for either a continuous or batch process as shown in the examples to follow. It will typically be much simpler for a continuous process and may not have a recipe matrix. The sequence matrix can be used to specify the following types of control requirements: State definitions and allowed transitions for control modules (CM), equipment modules (EM), units, or classes of like CM, EM, or units whose instances have been identified in the database and/or interlock matrix (usually oriented toward low-level equipment functions requiring little product-specific knowledge; operators, interlocks or phase logic initiate all state transitions; class definitions should be reusable from project to project). Sequence definition and parameter identification for phases or classes of like phases whose instances are identified relative to a particular EM, unit or class of like EM or units referenced in the
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database (usually oriented toward minor processing functions requiring little product-specific knowledge; typically interfaces to field devices indirectly by manipulating CM and/or EM states; operators or recipe sequences initiate phase execution; class definitions for common requirements should be reusable from project to project). Definition of phase sequencing, equipment requirements/arbitration and process parameters necessary to manufacture each product or class of products (coordinates all product-specific control requirements; operator or higher-level scheduling systems initiate recipe execution) Accommodation of both normal and abnormal process conditions for each of the above including hierarchical propagation of consequential actions as needed.
Preparing the product-specific requirements necessitates a detailed knowledge of the operations to be conducted in the subject equipment. Typically, a process write-up or batch sheet and standard operating procedure will provide the necessary knowledge. Using common or generic terms for the phase names will make this document more understandable for others who use it. Sample operation names include: prepare, react, distill, extract, solvent strip, clean and shutdown. Typical phase names include: initial, fill, mix, heat, cure, settle, drain/dump and transfer. The user can employ these or other names as appropriate. These names need to be clearly understood by the plant personnel. One or more phases may require that multiple actions be completed in order to satisfy the phase requirements. These multiple actions are called steps. All of these steps are typically shown in one column of the spreadsheet. The order in which these must be satisfied is indicated with numbers in parenthesis after the listed action. Where additional distinction between the steps is necessary the column under the phase can be split to show the different steps. If an equipment module is part of the unit, this will need to be shown in the sequence matrix. If the equipment module is shared by multiple units it will require its own matrix. Otherwise, its phases can be incorporated into the matrix for that unit. Two examples are a heating/cooling system for a reactor jacket and charging manifold with valves and a pump. Using an equipment module may simplify the software programming during integration. The Normal Sequence matrix (Figure 7a) provides information for all expected usual or routine operations. As indicated, it shows the expected operation of each discrete and analog device associated with the unit. Where there are particular conditions that must be met at the start or end of a phase these should be listed. These conditions include the setpoints of analog controls that must be satisfied as given in the Recipe Sequence below. Operator messages will appear on the HMI (human-machine interface) to cue an activity by the operator. Batch report variables will be configured into reports to be prepared as hardcopy or electronic media. If manual operations are required to complete the phase, an operator message will cue the personnel and wait for the appropriate response before continuing the phase processing. Two formats for the Sequence matrix are shown in the examples. The first contains less-detailed information and will often satisfy the needs of the URS. All of the operations, phases and steps can be shown; however, little detail of their functionality is possible here. Each phase occupies a single column in the spreadsheet. This provides a good overview of the control scheme. This does not contain sufficient detail for an instrumentation engineer or system integrator. The second format provides the level of detail required by these last functions. The information for each phase is detailed over several columns. It can show the details of each control function needed for the system to function. This level of detail is necessary for the FRS and is illustrated for just one of the phases in each example. It also provides the information needed to validate the operation of a control system during start-up.
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The Hold Sequence (Figure 7b) indicates which conditions are considered to be abnormal by the system and the resulting actions in response to these conditions. If any of the abnormal conditions are met, the system will proceed to the condition shown under Hold Actions and the operator message will be displayed. When the abnormal condition no longer exists the Recovery status will be initiated if the system is in full automatic operation. The Recipe Sequence matrix (Figure 7c) may show general recipe information or have specific information for several recipes to be programmed for that unit. Each parameter needed for a recipe is shown with the permission level required by a person to enter or modify that parameter. Where there are limits on a parameter for a specific phase, this is shown in the appropriate column. This helps prevent entry of wrong values for the parameters. The allowable modes of operation for each phase include manual and automatic. Under automatic operation, a recipe will proceed without operator interaction unless a hold condition occurs or interaction is required for a particular part of a phase. 4.1.4 Human - Machine Interface (HMI)
ISA-5.5-1985, Graphic Symbols for Process Displays, provides a good starting point in defining the shapes of process equipment for the dynamic graphic displays on operator console screens. It also provides guidelines for use of color for graphic displays. Many hardware vendors have a built-in library of ISA symbols in their graphic display packages. In addition to displays that usually are supplied as standard with most systems such as controller faceplates, alarm summary displays and trend displays, custom displays may be required to facilitate the operation of a control system. Examples include the interlock and sequence status displays shown in Figures 12b and 12c. An important part of the HMI definition is setting the data security and access levels. A typical definition is shown in Figure 8. Access needs to be set for different functions in the system such as changing loop set points and changing recipes by various personnel such as operators, supervisors and engineers. For some systems, many more access levels are available. A typical example of this is multiple operator classes with permissions limited by process area(s).
PERSONNEL TYPE FUNCTION Operator Controller Tuning Controller SP Change Interlock Setting Change Alarm SP Change Recipe Selection Technician Supervisor Engineer
NO YES NO NO NO
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HS 102
UNIT R-101
I
UC 102 MIXER AG-102 TT 106
TAH TAHH
TC 106 TV 106
FILL A
ZIC 004B
UC 003
FQC 003
FILL B
ZIC 004C
FT 003
LSHH 103
STEAM
FV 003 LT 101 REACTOR R-101
FILL C
PUMP P-003
LSL HS 002
LI 101
LAH
T
HS 105 XV 105
CONDENSATE
XV 002
DRAIN
LSHH203
UC 104 HS
PUMP P-104
R-201
104
UNIT R-201
Note: XV limit switches and pump run indications are not shown here due to space limitations
ANSI/ISA5.06.012007
28
The database (Figures 10a, b and c) gives the information for each device on the P&ID in Figure 9. The digital control module classes identified in the Point Type column (Figure 10a) are functionally defined by the respective class details shown in Figure 10d. Initially, the I/O address column in Figure 10a may list only the number and type of connections as shown in Figure 10d. Later, this can be split into multiple columns as required by the system layout and details. These additional columns may show (1) the physical location of the cable connections (cabinet data); (2) the logical connections to other control software; and (3) the software address as appropriate to the control system used for the particular process system. The HMI information for scale and engineering units (Figure 10b) will come from process information and possibly equipment design limits. The keyword is necessary only if the HMI display has an insufficient number of characters for the full length descriptor. The alarm function and control loop data (Fig. 10c) will impact the Sequence Matrix inputs. Note that these three sections of Figure 10 will typically appear left to right in a spreadsheet and not as three separate items as shown in this document. This will more clearly show the relationship between the various sets of information. Obviously in this format the first three columns need not be repeated. Figure 11a illustrates the software interlock matrix for Unit R-101, which provides the following process functionality based on the P&ID: (a) If the liquid level is too low interlocks UC-102 and UC-104 will shut off the mixer and pump. (b) Interlock UC-104 will prevent the drain pump from operating if the drain valve is closed. (c) Interlock UC-003 shuts down the charging control module when the desired charge quantity has been satisfied. The Manual Reset capability for each interlock in this example is provided by de-energizing the associated Hand Switch that is normally used to manually change valve position or motor condition. In this way the Hand Switch outputs will not immediately reactivate the interlocked device when the initiating condition clears. Any additional interlocks would be set up the same way. Definitions for the hazard and safety levels are based on the example shown in Figure 6. Figure 11b illustrates the software interlock matrix for the exclusive use common Equipment Module EM-1 which provides the following functionality based on standard operating practices: (a) Reinforce the hardwired charge valve interlocks shown on the P&ID by de-energizing the associated Hand Switch when a reactor level exceeds its safe limit, thereby requiring operator intervention (Manual Reset) for charging to resume after the condition clears. (b) Additional interlocks help to assure integrity of the charge path and measurement of the charged quantity.
CM TAG XV-001
LOCATION R-101
P&ID P-101
I/O TAGS ZSC, ZSO, XS ZSC, ZSO, XS XI, XS FT, FV FC-003.PV ZSC ZSC ZSC ZIC-004A,B,C LT XI, XS LSH XI, XS ZSC, ZSO, XS TT, TV
XV-002 HS-003 FC-003 FQ-003 ZIC-004A ZIC-004B ZIC-004C HS-004 LI-101 HS-102 LAHH-103 HS-104 XV-105 Copyright 2007 ISA. All rights reserved.
R-102 P-003 P-003 P-003 P-003 P-003 P-003 P-003 R-101 AG-102 R-101 P-104 R-101
P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101
VLV-FC MOTOR LOOP ACCUM VLV-1 VLV-1 VLV-1 HS-004 AI MOTOR ALARM-1 MOTOR VLV-FC
BALL VALVE PUMP CORIOLIS / FT GLOBE VALVE BALL VALVE BALL VALVE BALL VALVE RADAR AGITATOR CONDUCTIVITY PUMP PLUG VALVE PT RTD / TT(chr) GLOBE VALVE
24 VDC 120 VAC 4-20 MA software 24 VDC 24 VDC 24 VDC software 4-20 MA 120 VAC 24 VDC 120 VAC 24 VDC
29
ANSI/ISA5.06.012007
TC-106
R-101
P-101
LOOP
4-20 MA
AI (1), AO (1)
* I/O counts to be replaced by addresses upon system selection and I/O assignment ** Functionality defined by Control Module class definition matrix (Fig. 10d)
ANSI/ISA5.06.012007
CM TAG LOCATION XV-001 XV-002 HS-003 FC-003 FQ-003 ZIC-004A ZIC-004B ZIC-004C HS-004 LI-101 HS-102 LAHH-103 HS-104 XV-105 TC-106 Copyright 2007 ISA. All rights reserved. R-101 R-102 P-003 P-003 P-003 P-003 P-003 P-003 P-003 R-101 AG-102 R-101 P-104 R-101 R-101 P&ID
SCALE LOW P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 P-101 70 250 0 100 0 0 1000 30000 HIGH
ENG. DESCRIPTOR UNITS REACTOR INLET VALVE REACTOR INLET VALVE FILL PUMP MOTOR LB/MIN LBS FEED FLOW CONTROLLER FEED TOTALIZING SWITCH FEED MANIFOLD VALVE A FEED MANIFOLD VALVE B FEED MANIFOLD VALVE C FILL SOURCE SELECTOR % REACTOR LEVEL INDICATOR REACTOR AGITATOR REACTOR HIHI LEVEL ALARM DRAIN PUMP MOTOR REACTOR OUTLET VALVE DEGREE C TEMERATURE CONTROLLER INLET VALVE INLET VALVE FILL PUMP FEED CONT. FEED TOTAL FEED VLV A FEED VLV B FEED VLV C FILL SOURCE RX LEVEL AGITATOR RX HIHI LVL DRAIN PUMP OUTLET VALVE TEMP. CONT. KEYWORD
30
ALARM FUNCTIONS
TYPE SP 10 SEC 10 SEC 3 SEC PRIORITY MED MED MED
OUTPUT DIRECTION
DIRECT DIRECT DIRECT DIRECT
CONTROLLERS
TYPE . ALGORITHM . ACTION .
XV-001 XV-002 HS-003 FC-003 FQ-003 ZIC-004A Copyright 2007 ISA. All rights reserved. ZIC-004B ZIC-004C HS-004
P-101
P-101
P-101 P-101 P-101 P-101 P-101 P-101 P-101
M/A
P,I,D
REVERSE
RECIPE ** ** **
31
LI-101
R-101
P-101
. . . . M/A
. . . . P,I,D
. .
ANSI/ISA5.06.012007
. . REVERSE
* Enabled/disabled by HS-004 according to commanded position ** Set by HS-004 according to commanded position
CLASS FEATURES INPUT STATE I/O STATE NAMES VLV-FC ALARM TYPE TRIP LOGIC I/O STATE NAMES MOTOR ALARM TYPE TRIP LOGIC I/O ALARM-1 STATE NAMES ALARM TYPE I/O VLV-1 STATE NAMES ALARM TYPE I/O Copyright 2007 ISA. All rights reserved.
ANSI/ISA5.06.012007
ZIC ZSO XS OPEN OFF ON OPEN ON CLOSED ON OFF CLOSED OFF MOVING OFF OFF INVALID ON ON FB_ERR ALARM IF INPUT STATE DOES NOT TRACK OUTPUT STATE WITHIN 10 SECONDS ** INTERLOCK FORCE CLOSED FB_ERR COMMAND CLOSED XI XS RUN ON RUN ON STOP OFF STOP OFF FB_ERR ALARM IF INPUT STATE DOES NOT TRACK OUTPUT STATE WITHIN 3 SECONDS ** INTERLOCK FORCE STOP FB_ERR COMMAND STOP LSHH LAHH OFF NORMAL ON STATE ALARM IF LSHH = OFF ZIC OPEN OFF CLOSED ON STATE ALARM IF ZSC = OFF ZIC-004A ZIC-004B ZIC-004C OPEN_A OFF ON ON OPEN_B ON OFF ON OPEN_C ON ON OFF CLOSED ON ON ON MISALIGNED ANY OTHER COMBINATION ENABLE ZIC-004A/B/C ALARMS WHEN HS-003 OUTPUT (DESIRED) STATE IS NOT CLOSED; SET ALARM STATES OF ZIC-004A/B/C ACCORDING TO HS-004 OUTPUT AS FOLLOWS: ZIC ON ZIC OFF ZIC OFF OPEN_A ZIC OFF ZIC ON ZIC OFF OPEN_B ZIC OFF ZIC OFF ZIC ON OPEN_C ZIC ON ZIC ON ZIC ON CLOSED
32
INITIATING DEVICES (FAULT) ID NUMBER SETPOINTS {HS-004 CMD = CLOSED *} UC-003 OR {HS-004 INPUT = MISALIGNED *} OR {FQ-003 > RECIPE SP (FQSH-003 ON)} LI-101 < 10% (LAL-101 ON) {XV-101 CLOSED (ZIC-101 ON)} OR UC-104 {P-104 RUNNING (XS-104 FB ON) FOR 60 SEC WHILE LI-101 < 3% (LALL-101 ON)}
HAZARD LEVEL
LOW
MANUAL RESET
PREVENT PUMP RUNNING WHEN FEED SOURCE NOT SELECTED, MISALIGNED, OR CHARGE COMPLETE
UC-102
LOW
MANUAL RESET
PROTECT AGITATOR
33
LOW
MANUAL RESET
ANSI/ISA5.06.012007
ANSI/ISA5.06.012007
ANSI SETPOINTS Copyright 2007 ISA. All rights reserved. LOGIC ID NUMBER {LAHH-103 IN ALARM (ALSO HARDWIRED***)} OR * {R01.BATCHID <> EM1.BATCHID **} OR {XV-002 OPEN (ZSC-002 OFF)} OR {HS-004 MISALIGNED (INPUT STATE)} {LAHH-203**** IN ALARM (ALSO HARDWIRED***)} OR * {R02.BATCHID <> EM1.BATCHID **} OR {XV-002 OPEN (ZSC-002 OFF)} OR {HS-004 MISALIGNED (INPUT STATE)} {XV-001 FB_ERR OR XV-002 FB_ERR (ALARM STATES)} OR * {XV-001 CLOSED AND XV-002 CLOSED (COMMAND STATES)} OR {HS-004 CLOSED (INPUT STATE)} * P-003 RUNNING (XI-003 ON) START FQC-003 INTEGRATION (FQ-003 ACCUMULATOR) STOP P-003 (HS-003 OFF) CLOSE XV-002 (HS-002 OFF) CLOSE XV-001 (HS-001 OFF)
OPERATING MODE
INTERLOCK PURPOSE
PREVENT R-101 FROM OVERFLOWING, MANUAL RESET CONFIRM PROCESS OWNER, INTEGRITY OF CHARGE MEASUREMENT, AND PREVENT CHARGING WRONG MATERIAL PREVENT REACTOR FROM OVERFLOWING, MANUAL RESET CONFIRM PROCESS OWNER, INTEGRITY OF CHARGE MEASUREMENT, AND PREVENT CHARGING WRONG MATERIAL INTEGRITY OF CHARGE PATH, MANUAL RESET PREVENT PUMP RUNNING WITH DISCHARGE BLOCKED, AND PREVENT PUMP RUNNING WITH INLET BLOCKED
34
MANUAL RESET
* Not shown on P&ID ** BATCHIDs allocated by recipe after confirming EM or unit availability *** SIL satisfied by hardwired protection; independent software layer provided for proper HS operation. **** LAHH-203 specified separately in R-201 database matrix
35
ANSI/ISA5.06.012007
The Sequence Matrix (Figures 12a, b, c) for this relatively simple example can quickly become very involved because of the number of potential interactions among the control entities. To avoid overwhelming complexity, it is imperative to efficiently modularize the sequencing requirements by separating low-level and highly reusable equipment-centric sequences from high-level product-centric requirements. For notational simplicity, the abbreviations OP, SP, and PV are used to denote the output, setpoint, and measured value, respectively, for each loop. The Fill and Dump phases in Figure 12a show three steps with their sequence of operation to complete the phase. For the Fill phase, the agitator must be stopped, then the outlet valve must be closed; finally, the fill module will operate to permit entry of material. The fill module will not be instructed to operate by the control system until both of the other steps have been completed. Interruption of a particular phase can result from multiple causes as shown in Figure 12b. Each cause will result in an appropriate alarm message at the operator console. Recovery from this interruption will occur as shown if the control system is in auto mode. Otherwise, operator intervention will be required to resume operations. The Recipe Matrix may have very specific values for each recipe parameter or have a range as shown in Figure 12c. If ranges are included, the security level required to enter or change a particular value must be shown in the Parameter Entered By column. The recipe to be used for each batch is selected from the options in Figure 12c. The batch sequence matrix must also contain logic to request allocation of equipment module EM-1 to the batch and, upon acceptance by EM-1, to set its parameters and initiate its phase logic. EM-1 continuously compares its batch assignment with those downstream of XV-001 and XV-002, to determine which one (if either) to enable and which to force closed. The recipe-controlled HS-004 setpoint determines the proper ZIC-004A/B/C permissives to operate the feed pump and alarms if any valve is opened erroneously. Figures 12a, b, c define the procedural control requirements for Unit R-101 at a suitable level of detail for a User Requirement Specification (URS). The full level of phase specification detail required for a Functional Requirement Specification (FRS) is illustrated in Figure 12d for the exclusive use common Equipment Modules FILL_R101 phase. The top section shows the final setpoints and initial values for the control modules plus other reference values used during this phase. The bottom section of Figure 12d shows the detailed actions and end conditions for each of the steps referred to above. The text comment gives a good description of the purpose for each step. The step sequence diagram may be included if necessary to illustrate parallel execution paths. The FRS information for R-101 would include a similar level of detail. It is generally easier to keep all the information clear by stacking the normal, hold, and recipe matrix elements on top of one another in a spreadsheet. This is shown on the matrix for the equipment module (Figure 12d). In certain instances, there may be more than one condition, which would cause a phase to end or a Hold Condition to occur. To clearly show this, split the column under the particular phase and enter both conditions.
ANSI/ISA5.06.012007
OPERATIONS PHASES PHASE REF. NO. CM TAG XV-105 DISCRETE HS-102 CONTROL HS-104 DRAIN PUMP AGITATOR DESCRIPTION OUTLET VALVE
CLEAN
SHUT DOWN
(6)
(7)
OPEN STOP
(2) (1)
CLOSE (2) / OPEN (4) RUN (2) STOP (1) / RUN (4)
Copyright 2007 ISA. All rights reserved. Copyright 2007 ISA. All rights reserved.
RUN (3)
N O
MODULES
ANALOG
TC-106
BATCH TEMP.
SP = 95C
SP= 20C
R M
CONTROL MODULES
FQ-003
FILL AMOUNT
RUN (3);
36
A L
ACQUIRED EQUIPMENT MODULE EM1.BATCHID = R101.BATCHID; EM1.FILL_R101 N/A N/A N/A N/A EM1.BATCHID = R101.BATCHID; N/A
S E Q U E N C E
ALLOWABLE PHASE TRANSITIONS 2 PHASES & PARAMETERS
EM1.RM_SRC = XV-002;
EM1.RM_SRC = XV-002;
EM1.FQ_TOT.TAR = R101.RP3.TAR PV OF TC-106 WAIT TIME=RP2 = RP1 (SEE HOURS (SEE RECIPE RECIPE MATRIX) MATRIX) 4 5&3 ENTER PHASE DURATION TIME TEMP.AT END OF PHASE PHASE DURATION
EM1.FQ_TOT.TAR = 600 L
IF LI-101 < 1% PV OF FQ-003= RP3 AND OPERATOR (SEE RECIPE START BATCH MATRIX)
LI-101=<1%
1 &3
OPERATOR MESSAGES
PHASE DURATION
PHASE DURATION
OPERATIONS PHASES PHASE REF. NO. CM TAG XV-001 DISCRETE H O L I D N ANALOG CONTROL MODULES ACQUIRED EQUIPMENT MODULES EM-1 I C CONTROL HS-102 MODULES HS-104 TC-106 FQ-003 LI-101 XV-105
OPEN STOP
OPEN
N O
Copyright 2007 ISA. All rights reserved. Copyright 2007 ISA. All rights reserved.
T D I I
IF >140 C
37
A T S E Q U E N T I
IF > 5%
I O N N\ G S
FILL_R101.HOLD
FILL_R101.HOLD
ELAPSED TIME DO NOT PROCEED TO FILLING PHASE EMPTY REACTOR RESTART PHASE
IF >30 min
IF >30 min
ANSI/ISA5.06.012007
CLOSE XV-105
CHECK XV-105
RECOVERY
RESUME PHASE
RESUME PHASE
ANSI/ISA5.06.012007
R E C I P E
RECIPE #
PRAMETER ENTERED BY PROGRAM OPERATOR SUPERVISOR PROGRAM OPERATOR SUPERVISOR PROGRAM OPERATOR
INITIAL (1)
HEAT (3)
CURE (4)
DUMP (5)
SHUT-DOWN (6)
1 HR < Y < 2 HR 50C< X <90C 600 L 2 HR < Y < 3 HR 60C < X <100C 1500 L 3 HR < Y < 5 HR
B M A T R I X C
CURE PHASE TIME (RP2) TC-106 (RP1) FQ-003 (RP3) CURE PHASE TIME (RP2)
38
TC-106 (RP1)
SUPERVISOR
39
PHASE PARAM. SCOPE TYPE / RANGE TEXT HS004_ENUM 1000-5000 REPORT * TIME/DATE TEXT 0-100 0-150 0-500 0-50 TEXT DEVICE XV-002 FQ-003 HS-004 OPERATOR MESSAGE XV-001 FQ-003 FC-003 HS-003 FC-003 OPERATOR MESSAGE FIC-003 OPERATOR MESSAGE HS-003 FC-003 XV-001 HS-004 FQ-003 OPERATOR MESSAGE DEVICE XV-002 HS-004 INITIATING CONDITIONS HOLD SEQUENCE XV-001 HS-003 STEP# H1 HMI DEVICE HS-003 FC-003 XV-001 XV-002 HS-004 FQ-003 OPERATOR MESSAGE EM1.FILL_ R101 IDENTIFIER EM1.BATCHID EM1.RM_SRC EM1.FQ_TOT START & END TIMES OPER_ID EM1.VLV_POS EM1.FLOW_SP EM1.PRESET EM1.TRICKLE EM1.MSG_TEXT ACTIONS CLOSED RESET IF HS-001 OFF EM1.RM_SRC "PREPARE FEED SOURCE RM_SRC AND ALIGN MANUAL VALVES" OPEN SP=FQ_TOT.TAR; START MANUAL; OUTPUT = VLV_POS RUN AUTO; SP = FLOW_SP IF STEP TIME>60 MINS: "CHARGE TIME EXCEEDED: CHECK FLOW" AUTO; SP = TRICKLE IF STEP TIME>5 MINS: "CHARGE TIME EXCEEDED: CHECK FLOW"
ANSI/ISA5.06.012007
PARAMETERS
RECIPE-WRITTEN
FQ-003.TOTAL IN STEP 8 RECORDED AT PHASE START & END RECORDED IN STEP 8 50 120 200 30 "" END CONDITION ZSC-002 ON HS-004.INPUT STATE = COMMANDED STATE ZSC-001 OFF XI-003 ON FOR 15 SEC FQ-003.TOTAL > FQ-003.SP - PRESET FQ-003.TOTAL > FQ-003.SP
INTERNAL
STEP# 1
NORMAL SEQUENCE
3 4 5
H2
STOP WAIT 10 SEC OUTPUT = 0 CLOSED CLOSED OPER_ID RECORDED WITH STOP; FQ_TOT.ACT = TOTAL MESSAGE CONFIRMATION "CONFIRM CHARGE PROPERLY COMPLETED" CONDITION (ACTIVE STEPS) MSG_TEXT VALUE FB_ERR AND HS-002 OFF (1-6) "CHECK XV-002 AND" "CHECK RM MANIFOLD MISALIGNED OR CLOSED (3-6) AND" FB_ERR (3) "CHECK XV-001 AND" HS-001 OFF (4-6) "CHECK XV-001 AND" FB_ERR (4) "CHECK HS-003 AND" XI-003 OFF (5-6) "CHECK HS-003 AND" OPERATOR INITIATED (1-6) "OPERATOR INITIATED -" ACTIONS END CONDITION STOP WAIT 10 SEC MANUAL; OUTPUT = 0 CLOSED CLOSED OPERATOR CONFIRMS CLOSED MESSAGE STOP "HOLDING FILL: "; MSG_TEXT; " CONFIRM WHEN OK TO RESUME"
Figure 12d Equipment module sequence matrix for EM-1 phase FILL_R101
ANSI/ISA5.06.012007
40
The graphical elements shown in Figure 13a are typical of those available from ISA-5.5-1985, Graphic Symbols for Process Displays. These can generally be added to a display and configured as required to be active elements. The two status displays (Figures 13b & 13c) will quickly show the operator the current condition of each interlock and the progress through a recipe. These are also valuable for troubleshooting when it becomes necessary.
Control Valve
Interlock/ Bypass
M /A
Manual / Auto
Gree n Red Close Y ellow Trav el Blinking Y ellow Failure
I/B
C/O
Open
XV-501 Motor
Interlock/ Bypass
I/B M
M/A
Manual / Auto
Gree n Red Stop
S/R
Run
XM -601
41
ANSI/ISA5.06.012007
I#
Initiating Devices
1 3 4 5 6 7
Common Alarm
Operator Message
Operation: Reaction Phases:
Initial Fill Heat Cure Dump Shutdown Parameter
Catalyst Volume
Modes of operation
Automatic Manual
Target
500 Gal.
Recipe # A
Phase Progress
Common Alarm
ANSI/ISA5.06.012007
42
Most systems available today have these and many other standard elements built in and ready to use after minimal configuration. Special elements can also be created as needed using CAD software. This should seldom be needed given the large library of control face plates, alarm lists, interlock annunciations, etc.
43
ANSI/ISA5.06.012007
TO UC-104
TI 106
TT 106
PT 106
PC 106
PAH PAL
PV 106
HS 109
ANSI/ISA5.06.012007
CONDENSER H-106
TC 107 TT 107
UC 110
LV 107
44
LAH
LI 101
LAL 101
LT 101 LT 104
UC 102
STEAM CONDENSATE
LV 104
45
ANSI/ISA5.06.012007
The database (Figures 15a, b, c) gives the information for all devices in the P&ID (Figure 14). The digital control module classes identified in the Point Type column (Figure 15a) are functionally defined by the respective class details shown in Figure 10d (see previous example). I/O address information (Figure 15a) initially will show only the types and number of connections from this control module to the system. When the actual plant layout is known, these can be replaced by columns showing the cabinet and cable connections, software logical connections, and/or software address for the particular process system. This requires some knowledge of the new or existing layouts. The HMI information for scale and engineering units (Figure 15b) will come from process information and possibly equipment design limits. The keyword is necessary only if the HMI display has an insufficient number of characters for the full length descriptor. The alarm function and control loop data (Figure 15c) will impact the Sequence Matrix inputs. This is set up and prepared using the same methodology as for the batch example above. Figure 16 illustrates the software interlock matrix for Unit C-104, which provides the following process functionality based on the P&ID: (a) Interlock UC-102 turns off the column feed pump (P-102) when the feed tank (T-101) level drops below 2500 liters. (Turning off this pump will eventually activate UC-104 and UC-111, shutting down the column steam supply and bottoms pump.) (b) Interlock UC-104 closes the reboiler steam valve (TV-104) if the column level drops below the 5% value or if the condenser cooling water flow slows (FAL-106). (c) Interlock UC-110 turns off the reflux pump (P-110) when the reflux drum level (LIC-107) reaches 10%. (d) Interlock UC-111 turns off the bottoms pump (P-111) if the column level drops below the 5% value. The Manual Reset capability for each interlock in this example is provided by de-energizing the associated Hand Switch that is normally used to manually change valve position or motor condition. In this way, the Hand Switch outputs will not immediately reactivate the interlocked device when the initiating condition clears. Any additional interlocks, including those to meet operational requirements and standard operating practice, would be set up the same way. Definitions for the hazard and safety levels are based on the example shown in Figure 6.
ANSI/ISA5.06.012007
CM TAG FC-101 LI-101 HS-102 LC-104 TC-104 FAL-106 Copyright 2007 ISA. All rights reserved. PC-106 TI-106 FC-107 LC-107 TC-107 HS-109 HS-110
LOCATION T-101 T-101 P-103 C-104 C-104 H-106 C-104 C-104 T-107 T-107 H-106 P-109 P-110
P&ID P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104
POINT TYPE ** LOOP AI MOTOR LOOP LOOP ALARM-1 LOOP AI LOOP LOOP LOOP MOTOR MOTOR
DEVICE TYPE ORIFICE / PDT(); GLOBE VALVE PDT PUMP PDT; GLOBE VALVE PT RTD / TT(chr); GLOBE VALVE FSL PT(abs); GLOBE VALVE PT RTD / TT(chr) PDT; GLOBE VALVE PDT; GLOBE VALVE PT RTD / TT(char); GLOBE VALVE PUMP PUMP
SIGNAL TYPE 4-20 MA 4-20 MA 120 VAC FIELDBUS FIELDBUS 24 VDC FIELDBUS 4-20 MA 4-20 MA 4-20 MA 4-20 MA 120 VAC 120 VAC
I/O TAGS FT, FV LT XI, XS LT,LV TT, TV FSL PT, PV TT FT, FV LT, LV TT, TV XI, XS XI, XS
I/O ADDRESSES * AI (1), AO (1) AI (1) DI (1), DO (1) AI (1), AO (1) AI (1), AO (1) DI (1) AI (1), AO (1) AI (1) AI (1), AO (1) AI (1), AO (1) AI (1), AO (1) DI (1), DO (1) DI (1), DO (1)
46
HS-111
P-111
P-104
MOTOR
PUMP
120 VAC
XI, XS
DI (1), DO (1)
* I/O counts to be replaced by addresses upon system selection and I/O assignment ** Functionality defined by Control Module class definition matrix (Fig. 10d)
CM TAG LOCATION FC-101 LI-101 HS-102 LC-104 TC-104 FAL-106 PC-106 TI-106 FC-107 LC-107 TC-107 HS-109 HS-110 HS-111 Copyright 2007 ISA. All rights reserved. T-101 T-101 P-103 C-104 C-104 H-106 C-104 C-104 T-107 T-107 H-106 P-109 P-110 P-111 P&ID
SCALE LOW P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 P-104 0 0 0 0 0 800 250 200 100 250 0 0 100 250 10 0 HIGH 100 50000
ENG. DESCRIPTOR UNITS LPM LITER COLUMN FEED RATE FEED TANK LEVEL FEED PUMP % Deg. C COLUMN BOTTOM LEVEL BOTTOMS TEMPERATURE CONTROL CONDENSER LOW WATER FLOW mmHg abs Deg. C LPM % Deg. C COLUMN OVERHEAD PRESS COLUMN OVERHEAD TEMP REFLUX FLOW RATE REFLUX DRUM LEVEL CONDENSATE TEMP COLUMN VACUUM PUMP REFLUX PUMP COLUMN BOTTOMS PUMP FEED FLO FEED LVL FEED PMP BOTM LVL BOTM TMP CWR FSL OVHD PRS OVHD TMP RFLX FLO KEYWORD
47
RFLX LVL COND TMP VACM PMP REFL PMP BOTM PMP
ANSI/ISA5.06.012007
ANSI/ISA5.06.012007
ALARM FUNCTIONS TYPE SP 15 40000 2500 3 SEC 10 135 115 PRIORITY HIGH HIGH MED MED MED MED MED HIGH 120 80 MED MED
FC-101 LI-101 HS-102 LC-104 TC-104 FAL-106 PC-106 TI-106 FC-107 LC-107 TC-107 HS-109 HS-110 HS-111
T-101 T-101 P-103 C-104 C-104 H-106 C-104 C-104 T-107 T-107 H-106 P-109 P-110 P-111
P104 P104 P104 P104 P104 P104 P104 P104 P104 P104 P104 P104 P104 P104
FAL LAH LAL FB_ERR LAL TAH TAL STATE PAH PAL
DIRECT
M/A
P,I,D
DIRECT
48
DIRECT LAL 10 MED DIRECT REVERSE FB_ERR FB_ERR FB_ERR 3 SEC 3 SEC 3 SEC MED MED MED DIRECT DIRECT DIRECT
ID NUMBER
HAZARD LEVEL
OPERATING MODE
INTERLOCK PURPOSE
SETPOINTS LI-101 < 2500 L (LAL-101 ON) {FAL-106 IN ALARM (ALSO HARDWIRED)} OR {LC-104 < 5% (LAL-104 ON)} LC-107 < 10% (LAL-107 ON) LC-104 < 5% (LAL-104 ON)
UC-102
LOW
MANUAL RESET
MEDIUM
MANUAL RESET
UC-110
LOW
MANUAL RESET
49
UC-111
LOW
MANUAL RESET
ANSI/ISA5.06.012007
50
A continuous process will normally have fewer phases than for batch, if any at all. The sequence matrix for this example is shown in User Requirement Specification (URS) format in Figures 17a and 17b. The sequence of phase commands to control modules is identified by the adjacent numbering. Unless otherwise noted, each step remains active until the corresponding feedback signal confirms the specified action(s). If no sequence numbering exists, the phase comprises a single step in which all specified actions must be confirmed before the system can move to the next phase. All steps must be completed and the End Of Phase Conditions satisfied before transitioning to a subsequent phase. For the Drain phase (4), all of the actions with (1) following them are executed as soon as the control system moves to this phase. The other actions then follow in order, pending confirmation of each. The steps for the Startup phase (2) become very complex for this system. There are actually three parallel paths occurring here. This is best shown in the step sequence diagram at the bottom of Figure 17c. The number sequence shown here can often only be developed after something similar to the step sequence diagram is developed. Path A sets up the reboiler and bottoms pump; path B starts up the overhead system; while path C sets up the feed system. These can proceed independently until all three systems are operating. Only after all three pathways are fully satisfied will the system transition to the Distill phase. The full level of phase specification detail required for a Functional Requirement Specification (FRS) is illustrated for the Startup phase in Figure 17c. The top section shows the final setpoints and initial values for the control modules plus other reference values used during this phase. The step sequence diagram shows the parallel paths used to begin operations for each part of this unit. The bottom section of Figure 17c shows the detailed actions and end conditions for each of the steps referred to above. The text comment gives a good description of the purpose for each step. The detailed information for the other phases would have a similar appearance. Other formats can also be used to show this information, including sequential function charts, ladder diagrams, and text narratives. No recipe matrix is included here, as the operating values for a single set of conditions can be entered directly into the Normal Sequence Matrix. Once up and running, this process will typically remain in the Distill phase for an extended period of time. The Preparation and End phases are very similar for the batch and continuous processes.
KEYWORD
FEED PMP VACM PMP REFL PMP BOTM PMP STOPPED STOPPED STOPPED STOPPED RUN RUN RUN RUN STOP (1) STOP (1) STOP (3A) STOP (1); RUN (3B); STOP (5) STOP STOP STOP STOP STOP STOP STOP STOP
FC-101
FEED FLO
OP = 0 (1) OP = 0 (1); WAIT UNTIL PV < 10 (4) OP = 0 (1) OP = 0 (5) OP = 0 (1) OP = 0 (1) OP = 100 (1); WAIT UNTIL PV < 10 (2A); OP = 0 (3A)
OP = 0
LC-104
BOTM LVL
OP = 0
OP = 0 OP = 0 OP = 0 OP = 0
51
FC-107
RFLX FLO
OP = 0
ANSI/ISA5.06.012007
2, 5
1, 2
READY TO START
Figure 17a Normal sequence matrix for Unit C-104 (URS format)
OPERATIONS PHASES
PREPARATION
RUN
END CLEAN
ANSI/ISA5.06.012007
START-UP (2)
DISTILL (3)
DRAIN (4)
SHUTDOWN (4)
(5)
HS-102 DISCRETE I C MODULES HS-109 HS-110 HS-111 LI-101 FC-101 LC-104 ANALOG MODULES TC-104 TC-107 PC-106 LC-107 FC-107 ELAPSED TIME HOLD ACTIONS
FEED PMP VACM PMP REFL PMP BOTM PMP FEED LVL FEED FLO BOTM LVL BOTM TMP COND TMP OVHD PRS RFLX LVL RFLX FLO
STOP STOP STOP STOP IF PV < 15K IF PV < 20 IF PV < 5 120 > PV > 150 20 > PV > 40 IF PV > 1 IF PV > 2000
N O I N
T D I
Copyright 2007 ISA. All rights reserved.
A T T I I O
52
N N G S
75 > PV > 95
IF PV < 125
25 > PV > 45
IF PV > 0
OPERATOR MESSAGES
RECOVERY
Figure 17b Hold sequence matrix for Unit C-104 (URS format)
C104.STARTUP TYPE / RANGE 0-250 0-400 0-250 0-100 0-200 0-100 10-100 0-100 0-100 0-100 0-100 0-150 0-120 0-120 0-100 0-100 0-100 0-100 0-100 0-100 0-250 0-250 0-100 0-100 10-100 10-100 IDENTIFIER .CW_SP .PC_SP .BTM_T_SP .BTM_L_SP .RFLX_SP .OHD_L_SP .FEED_SP .CW_INIT .BTM_L_INIT .RFLX_INIT .FEED_INIT .PIC_HI .BTM_T_TIMSP .BTM_L_TIMSP .BTM_L_LOREF .BTM_L_LOPB .BTM_L_HIREF .BTM_L_HIPB .BTM_L_HIHI .BTM_L_DEV .OVHD_T_INIT .OVHD_T_NORM .OVHD_L_LOREF .OVHD_L_LOPB .FEED_LO .FEED_SP_MIN CORRESPONDING ACTUAL VALUE 40 85 125 50 150 50 75 100 20 20 30 95 60 30 20 10 80 20 90 5 70 50 20 10 15 30 DESCRIPTION
53 ANSI/ISA5.06.012007
Figure 17c Sequence matrix for C-104 Startup phase in FRS format (continues on next page)
PHASE STEP# 1 2
C104.STARTUP
DEVICE ACTIONS END CONDITION COMMENT TC-107 Manual; Output = .CW_INIT FAL-106 not in alarm Start cooling water and confirm flow HS-109 Run Start vacuum system, place controller into auto, and HS-109 On and PC-106 < .PC_SP + 20 wait for pressure drop PC-106 Auto; SP = .PC_SP Execute startup sequences in parallel for reboiler (3A-6A), overhead (3B-7B), and feed (3C-5C); phase ends after completion of all 3 paths. Manual; continuously calc. Output = 100 * min TC-104 ((LC104 - .BTM_L_LOREF) / .OVHD_L_LOPB, 1) Set steam rate based on bottoms level until the final OPERATOR TC-104 > .BTM_T_SP "OPEN REBOILER STEAM BLOCK VALVE" temperature SP is reached MESSAGE OPERATOR IF STEP_TIME > .BTM_T_TIMSP MINS: "HEATUP MESSAGE TIME EXCEEDED: CHECK REBOILER" TC-104 Auto; SP = .BTM_T_SP Set steam rate on temperature control and wait until LC-104 > .OHD_L_SP OPERATOR IF STEP_TIME > .BTM_L_TIMSP MINS: "BOTTOM the final level SP is reached MESSAGE CHARGE TIME EXCEEDED: CHECK FEED" HS-111 Run HS-111 On Start bottoms pump LC-104 Manual; Output = .BTM_L_INIT LC-104 Auto; SP = .BTM_L_SP abs(LC104-SP) < .BTM_L_DEV Set bottoms takeoff on level control Wait until reflux pump is on or overhead n/a n/a TI-106 > .OVHD_T_INIT or HS-110 On temperature indicates significant boilup Set cooling water on condensate temperature LC-107 > .OVHD_L_LOREF + .OVHD_L_LOPB TC-107 Auto; SP = .CW_SP control and wait for minimum drum level to run * .RFLX_INIT / .RFLX_SP pump HS-110 Run HS-110 On and FC-107 > .FEED_LO Start reflux pump, open valve, and confirm flow FC-107 Manual; Output = .RFLX_INIT Auto; continuously calc. SP = .RFLX_SP * min TI-106 < .OVHD_T_NORM and Set reflux rate based on drum level until its final flow FC-107 ((LIC107 - .OVHD_L_LOREF) / .OVHD_L_LOPB, 1) FC-107.SP = .RFLX_SP SP is reached Set overhead takeoff on level control and wait for it LC-107 Auto; SP = .OHD_L_SP abs(LC107-SP) < .BTM_L_DEV to approach SP (HS-110 On and LC-104 < .BTM_L_HIREF Wait until (a) reflux pump is on and reboiler level not n/a n/a .BTM_L_HIPB * .FEED_SP_MIN / .FEED_SP) high or (b) reboiler level below SP or (c) feed pump or LC-104 < .BTM_L_SP or HS-102 On is on HS-102 Run HS-102 On and FC-101 > .FEED_LO Start feed, open valve, and confirm flow FC-101 Manual; Output = .FEED_INIT Cond5C.1: HS-110 On and HS-111 On and Set feed rate on bottoms level control until (a) the Auto; continuously calc. SP = max (.FEED_SP_MIN, FC-101.SP = .FEED_SP overhead and bottoms pumps are on and the feed .FEED_SP * min ((.BTM_L_HIREF - LC104) / FC-101 rate is at its final SP (ending the feed sequence) or .BTM_L_HIPB, 1)) Cond5C.2: LC-104 > .BTM_L_HIHI or HS-102 (b) the feed pump stopped or bottoms level is too Off high (triggering step 6C) HS-102 Stop LC-104 < .BTM_L_LOREF - .BTM_L_LOPB * Stop the feed and wait for the bottoms level to drop FC-101 Manual; Output = 0 .FEED_SP_MIN / .FEED_SP sufficiently to resume at step 4C OPERATOR "FEED PAUSED ON HIGH BOTTOMS LEVEL" MESSAGE DEVICE CONDITION (ACTIVE STEPS) MSG_TEXT VALUE None defined
ANSI/ISA5.06.012007
3A
54
5C
HOLD SEQUENCE
Figure 17c Sequence matrix for C-104 Startup phase in FRS format (continued from previous page)
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ANSI/ISA5.06.012007
Guidelines for specification of graphical elements, illustrated for the batch reactor example (Figures 13a, b, c), apply equally to the continuous distillation column and are not repeated in this example.
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