AMERICAN NATIONAL STANDARD

ANSI/ISA-5.06.01-2007
Functional Requirements Documentation
for Control Software Applications
Approved 29 October 2007

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
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P.O. Box 12277
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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:
[email protected].
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.
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INSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF AN EXISTING PATENT THAT IS
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EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THIS DOCUMENT, THE USER IS
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HAZARDOUS CONDITIONS. THE USER OF THIS DOCUMENT MUST EXERCISE SOUND

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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

AFFILIATION

A. Habib, Chair
A. Amdur
D. Beaty
P. Blok
R. Dwiggins
J. Halajko
R. Bhala
S. Kolla
R. Topliff
R. Wood

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

AFFILIATION

A. Iverson, Chair
T. McAvinew, Managing Director
G. Barta
C. Borel
J. Carew
A. Habib
G. Ramachandran

Ivy Optics
Jacobs Engineering
Consultant
Spectrum Engineering Inc.
Consultant
Automation Consultant
Motiva Enterprises LLC

Copyright 2007 ISA. All rights reserved.

ANSI/ISA-5.06.01-2007

This standard was approved for publication by the ISA Standards and Practices Board on 17 August
2007.
NAME

AFFILIATION

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

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

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ANSI/ISA5.06.012007

Contents
Preface .......................................................................................................................................................... 3
1

Scope ................................................................................................................................................. 11

Normative References........................................................................................................................ 12

Definitions/Abbreviations.................................................................................................................... 13

Methodology ....................................................................................................................................... 14
4.1

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

Copyright 2007 ISA. All rights reserved.

ANSI/ISA5.06.012007

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

Copyright 2007 ISA. All rights reserved.

ANSI/ISA5.06.012007

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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 11

ANSI/ISA5.06.012007

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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ANSI/ISA5.06.012007

12

Industrial
Applications

ISAISA-5.06.01
User
Users Software
Requirements

Implementation
Languages

Pharmaceutical
Database

Power
Interlock Logic

Chemical

Sequential
Function
Chart
Vendor
Languages

Target
Systems

Distributed
Control Systems

Programmable
Logic Controllers

Sequence Logic

Food

Proprietary
Languages

Automotive

HumanHuman- Machine
Interface

Many others

Industrial PC
PCs

Relay Ladder

Figure 1 Charter upon which this standard is based.

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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 13

ANSI/ISA5.06.012007

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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ANSI/ISA5.06.012007

14

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.

4
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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ANSI/ISA5.06.012007

Discharge

Gas Waste Treatment

Units
Raw
Materials

S
T
O
R
A
G
E

U
T
I
L
I
T
I
E
S

Train #

P
A
C
K
A
G
I
N
G

S
T
O
R
A
G
E

Product
Shipping

Liquid & Solid Waste Treatment

Discharge

Figure 2 Modular plant partitioning

This approach has benefits when configuring both the hardware and the software of a control system.
Maximizing the separation of control hardware between trains will minimize the production impact of a
hardware failure, while maximizing similarity within each class of process units will minimize
implementation costs and human errors in both design and operation. The latter is accomplished by
employing reusable design features wherever possible by means of standard class definitions (for units,
equipment modules, control modules, etc.) that can be completed and validated for one instance, then
copied or instantiated and quickly validated for the remaining members of each class.
Depending on the needs of the design team, the initial design may utilize a User Requirements
Specification (URS). This outlines the process control needs for the process cell being designed. A
standard Piping and Instrumentation Drawing (P&ID) and instrument index may provide all of the
necessary information. Alternatively, more detail as shown on the matrices below may be desired at this
stage. The URS is often adequate for review by plant operations, maintenance and process engineering
personnel.
After the design basis of the process cell is settled, the basic documentation such as process flow
diagram, P&ID, instrument index and preliminary equipment design can be completed. If adequate, as
noted above, these will comprise the URS.
The next step is to develop four basic elements of the Functional Requirements Specification (FRS) that
describe the instances and detailed requirements for each class of objects so defined (see Figure 3). The
Functional Requirements Specification (FRS) is much more detailed and is utilized by instrumentation
and system integration personnel as well as during process safety reviews. The four elements of the FRS
are:

Database (instrument tag table)

Interlock matrix (interlock logic)

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ANSI/ISA5.06.012007

16

Sequence matrix (sequence logic)

Human Machine Interface (HMI)

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.

D atabase
Interloc
In terloc k M atrix

Sequen
ce M atrix
S equ ence
H um
u m an - M achine
ach ine In terface
Figure 3 Four components of software documentation methodology
Developing these FRS elements assumes that the equipment and processing requirements are well
defined. The necessary information can normally be found on various drawings (such as PFDs, P&IDs,
and equipment drawings), equipment specifications and data sheets, and other sources. Classes of
control objects to supply the required functionality can be developed as needed or drawn from an existing
archive.
Figure 4 illustrates the connection between typical units and modules of a partitioned modular plant and
the four basic FRS elements. As shown, a single FRS can describe an entire facility or a select subset as
required by the project scope. Likewise, certain aspects such as the Sequence matrix may be omitted
from the FRS if they are to be deferred to a separate project or provided by a different supplier.

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ANSI/ISA5.06.012007

Database
Interlock Matrix
Sequence Matrix
Human-Machine Interface
Discharge

Gas Waste Treatment

Raw
Materials

S
T
O
R
A
G
E

U
T
I
L
I
T
I
E
S

Train
Blender
#

Units
Reactor Centrifuge Distn Coln

BL-101

RX-102

BL-201

RX-202
RX-302

3
4

BL-401

CE-103

CE-303

Dryer

DI-104

DR-105

DI-204

DR-205

DI-304

CE-403

P
A
C
K
A
G
I
N
G

S
T
O
R
A
G
E

Product
Shipping

DR-405

Liquid & Solid Waste Treatment

Discharge

Figure 4 Example of modular plant partitioning and software documentation

4.1.1

Database

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.

Copyright 2007 ISA. All rights reserved.

ANSI/ISA5.06.012007

18

Figure 5 Database documentation

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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ANSI/ISA5.06.012007

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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ANSI/ISA5.06.012007

20

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

Process Interlock Matrix

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 .

Copyright 2007 ISA. All rights reserved.

 21

ID
NUMBER

INITIATING
DEVICE (FAULT)

CONTROL DEVICE
(ACTION)

SET POINTS

LOGIC

HAZARD
LEVEL

ANSI/ISA5.06.012007

SAFETY
INTEGRITY
LEVEL

OPERATING
MODE

Figure 6 Interlock matrix documentation

Sample Definitions:
Hazard Level:

Material Loss

Equipment Loss

Personnel Loss

(0)
(1)
(2)
(3)

Recoverable
Batch Lost
Other Batches Lost

Repairable Damage
Replace Unit
Replace Other Units

Medical Treatment
Lost Time Accident
Mult. Injury or Death

None
Low
Medium
High

Copyright 2007 ISA. All rights reserved.

INTERLOCK
PURPOSE

ANSI/ISA5.06.012007

22

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

Figure 7a Normal sequence matrix

Copyright 2007 ISA. All rights reserved.

 23

ANSI/ISA5.06.012007

Figure 7b Hold sequence matrix

RECIPE

INITIAL

PARAMETERS

PHASE

OPERATIONS
PHASE

PHASE

PHASE

PHASE

SHUTPHASE

DOWN

CHANGE CONTROL
DESCRIPTION DATE

PHASE
VARIABLES CODED IN PROGRAM
VARIABLES ENTERED BY OPERATOR
VARIABLES ENTERED BY PRODUCTION SUPERVISOR

Figure 7c Recipe sequence matrix

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

Copyright 2007 ISA. All rights reserved.

BY

ANSI/ISA5.06.012007

24

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.

Copyright 2007 ISA. All rights reserved.

 25

ANSI/ISA5.06.012007

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

Technician

Supervisor

Engineer

Controller Tuning

NO

YES

NO

YES

Controller SP Change

YES

YES

YES

YES

Interlock Setting Change

NO

YES

NO

YES

Alarm SP Change

NO

YES

YES

YES

Recipe Selection

NO

NO

YES

YES

Figure 8 Data security definition

Copyright 2007 ISA. All rights reserved.

This page intentionally left blank.

 27

ANSI/ISA5.06.012007

Annex A (informative) Application Example 1: Batch Reactor

The following chemical reactor example illustrates the application of the methodology to a simple batch
process. As the P&ID shows (Figure 9), this reactor will fill multiple materials, heat, mix, and drain
material.

HS

SHARED EQUIPMENT MODULE EM -1

UNIT R-101

102
HS
HS

001

I
UC

004

102

HS
ZIC

MIXER
AG-102

003

004A

FILL A
ZIC

UC

FQC

003

003

XV
001

LAHH

106
TV
106

LSHH
103

FT
003

FILL B

TT
106

103

004B

TAH
TAHH

TC

STEAM

ZIC
004C

FILL C

FV
003

PUMP
P-003

HS
002

LT
101

XV
002

LSL

LI

101

101

LSLL

REACTOR
R-101

LAH

HS

CONDENSATE

XV
105

105

DRAIN

101

LSHH203

PUMP
P-104

UC
104
HS

R-201

104

UNIT R-201

Note: XV limit switches and pump run indications

are not shown here due to space limitations

REACTOR R-1
P&ID
DRAWING # P-101

Figure 9 Chemical reactor P&ID

The raw material charging manifold and pump are treated as a shared equipment module (EM-1)
because this feed system serves more than one reactor. Accordingly, the phase logic for EM-1 is defined
in a separate, small sequence matrix whose operation is triggered by the batch recipe. The HS-004
setpoint, which is also recipe-controlled, determines the proper position switch (ZIC-004A/B/C) alignment
and selectively enables the valve position alarms. All valves and other instruments for R-201 and EM-1
are included in the full database matrix.

Copyright 2007 ISA. All rights reserved.

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.

Copyright 2007 ISA. All rights reserved.

CM TAG

LOCATION

P&ID

POINT TYPE **

DEVICE TYPE

SIGNAL TYPE

R-101

P-101

VLV-FC

BALL VALVE

24 VDC

XV-002

R-102

P-101

VLV-FC

BALL VALVE

24 VDC

HS-003

P-003

P-101

MOTOR

PUMP

120 VAC

XI, XS

DI (1), DO (1)

FC-003

P-003

P-101

LOOP

4-20 MA

FT, FV

AI (1), AO (1)

FQ-003

P-003

P-101

ACCUM

software

FC-003.PV

ZIC-004A

P-003

P-101

VLV-1

BALL VALVE

24 VDC

ZSC

DI (1)

ZIC-004B

P-003

P-101

VLV-1

BALL VALVE

24 VDC

ZSC

DI (1)

ZIC-004C

P-003

P-101

VLV-1

BALL VALVE

24 VDC

ZSC

DI (1)

HS-004

P-003

P-101

HS-004

software

ZIC-004A,B,C

LI-101

R-101

P-101

AI

RADAR

4-20 MA

LT

AI (1)

HS-102

AG-102

P-101

MOTOR

AGITATOR

120 VAC

XI, XS

DI (1), DO (1)

LAHH-103

R-101

P-101

ALARM-1

CONDUCTIVITY

24 VDC

LSH

DI (1)

HS-104

P-104

P-101

MOTOR

PUMP

120 VAC

XI, XS

DI (1), DO (1)

XV-105

R-101

P-101

VLV-FC

PLUG VALVE

24 VDC

TC-106

R-101

P-101

LOOP

XV-001

CORIOLIS / FT
GLOBE VALVE

XS
ZSC, ZSO,
XS

ZSC, ZSO,

4-20 MA

* 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)

Figure 10a Database I/O information

XS
TT, TV

DI (2), DO (1)

DI (2), DO (1)

DI (2), DO (1)

AI (1), AO (1)

ANSI/ISA5.06.012007

GLOBE VALVE

ZSC, ZSO,

I/O ADDRESSES *

29

Copyright 2007 ISA. All rights reserved.

PT RTD / TT(chr)

I/O TAGS

SCALE
LOCATION

ENG.

P&ID
LOW

HIGH

DESCRIPTOR

KEYWORD

UNITS

R-101

P-101

REACTOR INLET VALVE

INLET VALVE

XV-002

R-102

P-101

REACTOR INLET VALVE

INLET VALVE

HS-003

P-003

P-101

FILL PUMP MOTOR

FILL PUMP

FC-003

P-003

P-101

1000

LB/MIN

FEED FLOW CONTROLLER

FEED CONT.

FQ-003

P-003

P-101

30000

LBS

FEED TOTALIZING SWITCH

FEED TOTAL

ZIC-004A

P-003

P-101

FEED MANIFOLD VALVE A

FEED VLV A

ZIC-004B

P-003

P-101

FEED MANIFOLD VALVE B

FEED VLV B

ZIC-004C

P-003

P-101

FEED MANIFOLD VALVE C

FEED VLV C

HS-004

P-003

P-101

FILL SOURCE SELECTOR

FILL SOURCE

LI-101

R-101

P-101

REACTOR LEVEL INDICATOR

RX LEVEL

HS-102

AG-102

P-101

REACTOR AGITATOR

AGITATOR

LAHH-103

R-101

P-101

REACTOR HIHI LEVEL ALARM

RX HIHI LVL

HS-104

P-104

P-101

DRAIN PUMP MOTOR

DRAIN PUMP

XV-105

R-101

P-101

REACTOR OUTLET VALVE

OUTLET VALVE

TC-106

R-101

P-101

TEMERATURE CONTROLLER

TEMP. CONT.

70

100

250

DEGREE C

Figure 10b Database HMI information

30

Copyright 2007 ISA. All rights reserved.

XV-001

ANSI/ISA5.06.012007

CM TAG

CM TAG

ALARM FUNCTIONS
LOCATION

P&ID
TYPE

SP

PRIORITY

OUTPUT
DIRECTION

CONTROLLERS
TYPE

ALGORITHM

ACTION

DIRECT

M/A

P,I,D

REVERSE

R-101

P-101

FB_ERR

10 SEC

MED

DIRECT

XV-002

R-201

P-101

FB_ERR

10 SEC

MED

DIRECT

HS-003

P-003

P-101

FB_ERR

3 SEC

MED

DIRECT

FC-003

P-003

P-101

FQ-003

P-003

P-101

FQSH

RECIPE

LOG ONLY

ZIC-004A

P-003

P-101

STATE *

**

MED

ZIC-004B

P-003

P-101

STATE *

**

MED

ZIC-004C

P-003

P-101

STATE *

**

MED

HS-004

P-003

P-101

LI-101

R-101

P-101

LAH
LSL
LSLL

85%
10%
3%

MED
LOG ONLY
LOG ONLY

HS-102

AG-102

P-101

FB_ERR

3 SEC

MED

DIRECT

LAHH-103

R-101

P-101

STATE

HIGH

HS-104

P-104

P-101

FB_ERR

3 SEC

MED

DIRECT

XV-105

R-101

P-101

FB_ERR

10 SEC

MED

DIRECT

TC-106

R-101

P-101

TAHH
TAH

200 C
RECIPE

HIGH
MED

DIRECT

M/A

P,I,D

REVERSE

31

Copyright 2007 ISA. All rights reserved.

XV-001

** Set by HS-004 according to commanded position

Figure 10c Database operating information

ANSI/ISA5.06.012007

* Enabled/disabled by HS-004 according to commanded position

CLASS

INPUTS

CORRESPONDING OUTPUTS

FEATURES
INPUT STATE

STATE NAMES
VLV-FC
ALARM TYPE
TRIP LOGIC
I/O
STATE NAMES
MOTOR

ALARM TYPE
TRIP LOGIC

STATE NAMES
ALARM TYPE
I/O

VLV-1

STATE NAMES
ALARM TYPE
I/O

STATE NAMES
HS-004
LOGIC FOR
ENABLING
EXTERNAL
ALARMS

INPUT 2

INPUT 3

COMMANDED STATE

OUTPUT 1

* Identified as Point Type in Figure 10a

** Actual timing individually adjustable for each instance

Figure 10d Control module class definition

OUTPUT 2

32

Copyright 2007 ISA. All rights reserved.

I/O
ALARM-1

INPUT 1

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

ANSI/ISA5.06.012007

I/O

INITIATING DEVICES (FAULT)

ID NUMBER
SETPOINTS

CONTROL DEVICES
(ACTION)

INTERLOCK PURPOSE

HAZARD
LEVEL

SAFETY
INTEGRITY
LEVEL

OPERATING MODE

LOW

MANUAL RESET

PREVENT PUMP RUNNING

WHEN FEED SOURCE NOT
SELECTED, MISALIGNED, OR
CHARGE COMPLETE

LOW

MANUAL RESET

PROTECT AGITATOR

LOW

MANUAL RESET

PREVENT PUMP RUNNING

WHEN VALVE CLOSED OR

LOGIC

{HS-004 CMD = CLOSED *}

UC-003

OR {HS-004 INPUT = MISALIGNED *} OR

STOP P-003

{FQ-003 > RECIPE SP

(XS-003 OFF)

(FQSH-003 ON)}
LI-101 < 10%

STOP AG-102

(LAL-101 ON)

(XS-102 OFF)

{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)}

STOP P-104
(XS-104 OFF)

33

REACTOR EMPTY

* Not shown on P&ID

Figure 11a Software interlock matrix for Unit R-101

ANSI/ISA5.06.012007

Copyright 2007 ISA. All rights reserved.

UC-102

CONTROL DEVICES
(ACTION)

ANSI

OPERATING
MODE
SETPOINTS

INTERLOCK PURPOSE

ANSI/ISA5.06.012007

INITIATING DEVICES (FAULT)

LOGIC

{LAHH-103 IN ALARM
(ALSO HARDWIRED***)} OR
*

{R01.BATCHID <> EM1.BATCHID **} OR

{XV-002 OPEN (ZSC-002 OFF)} OR

CLOSE XV-001
(HS-001 OFF)

MANUAL
RESET

PREVENT CHARGING WRONG MATERIAL

{LAHH-203**** IN ALARM

PREVENT REACTOR FROM OVERFLOWING,

{R02.BATCHID <> EM1.BATCHID **} OR

{XV-002 OPEN (ZSC-002 OFF)} OR

CLOSE XV-002
(HS-002 OFF)

MANUAL
RESET

INTEGRITY OF CHARGE MEASUREMENT,

AND

{XV-001 FB_ERR OR XV-002 FB_ERR

INTEGRITY OF CHARGE PATH,

(ALARM STATES)} OR

PREVENT PUMP RUNNING WITH

DISCHARGE BLOCKED, AND

{XV-001 CLOSED AND XV-002 CLOSED (COMMAND

STATES)} OR

STOP P-003
(HS-003 OFF)

MANUAL
RESET

{HS-004 CLOSED (INPUT STATE)}

*

CONFIRM PROCESS OWNER,

PREVENT CHARGING WRONG MATERIAL

{HS-004 MISALIGNED (INPUT STATE)}

CONFIRM PROCESS OWNER,

INTEGRITY OF CHARGE MEASUREMENT,
AND

{HS-004 MISALIGNED (INPUT STATE)}

(ALSO HARDWIRED***)} OR
*

PREVENT R-101 FROM OVERFLOWING,

P-003 RUNNING (XI-003 ON)

START FQC-003
INTEGRATION (FQ-003
ACCUMULATOR)

MANUAL
RESET

PREVENT PUMP RUNNING WITH INLET

BLOCKED

INTEGRITY OF CHARGE MEASUREMENT

* 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

Figure 11b Software interlock matrix for Equipment Module EM-1

34

Copyright 2007 ISA. All rights reserved.

ID NUMBER

 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.

Copyright 2007 ISA. All rights reserved.

PHASES
PHASE REF. NO.

PREPARATION

REACTION

TRANSFER

INITIAL

FILL

HEAT

CURE

DUMP

(1)

(2)

(3)

(4)

(5)

CLEAN

SHUT
DOWN

(6)

(7)

CM TAG

DESCRIPTION

XV-105

OUTLET VALVE

CLOSED

CLOSE (2)

CLOSE

CLOSE

OPEN

(2)

CLOSE (2) / OPEN (4)

CLOSE

HS-102

AGITATOR

STOPPED

STOP (1)

RUN

RUN

STOP

(1)

RUN (2)

STOP

HS-104

DRAIN PUMP

STOPPED

STOP (1)

STOP

STOP

STOP (1) / RUN (4)

STOP

TC-106

BATCH TEMP.

SP = 95C

SP= 20C

FQ-003

FILL AMOUNT

DISCRETE

ANSI/ISA5.06.012007

OPERATIONS

N
O

ANALOG

RUN (3)

MODULES

CONTROL
MODULES

RAMP SP: AT 2
DEG/MIN
RESET TOTAL=0

M
RUN (3);

RUN (3);

EM1.BATCHID =

EM1.BATCHID =

R101.BATCHID;

R101.BATCHID;

36

Copyright 2007 ISA. All rights reserved.

Copyright 2007 ISA. All rights reserved.

CONTROL

A
L
ACQUIRED
EQUIPMENT
MODULE

EM1.FILL_R101

N/A

S
E

PHASES &
PARAMETERS

Q
U
E

END OF PHASE CONDITIONS

EM1.RM_SRC =

OPERATOR MESSAGES

START NEW
BATCH ??

BATCH REPORT VARIABLES

N/A

EM1.RM_SRC =
XV-002;

EM1.FQ_TOT.TAR =

EM1.FQ_TOT.TAR =

R101.RP3.TAR

600 L

IF LI-101 < 1% PV OF FQ-003= RP3

AND OPERATOR
(SEE RECIPE
START BATCH
MATRIX)

ALLOWABLE PHASE TRANSITIONS

N/A

XV-002;

N
C

N/A

1 &3

PHASE DURATION

PV OF TC-106 WAIT TIME=RP2

= RP1 (SEE
HOURS (SEE
RECIPE
RECIPE
MATRIX)
MATRIX)
4

5&3

ENTER SP. OF
TC-106

ENTER PHASE
DURATION
TIME

PHASE
DURATION

TEMP.AT END
OF PHASE

LI-101=<1%

PV OF FQ-003= 500 AND

TIC = 95C FOR1 HOUR

PHASE
DURATION

Figure 12a Normal sequence matrix for Unit R-101

N/A

OPERATIONS
PHASES
PHASE REF. NO.

PREPARATION

REACTION

END

SHUT

INITIAL

FILL

HEAT

CURE

DUMP

CLEAN

DOWN

(1)

(2)

(3)

(4)

(5)

(6)

(7)

CM TAG
XV-001
DISCRETE
H
O

XV-105
I

N O

HS-102

ANALOG

TC-106

A T

CONTROL

FQ-003

MODULES

LI-101

I O

U
E

IF >140 C

IF >140 C

HS-104

T D

STOP

N N\

ACQUIRED

G S

EQUIPMENT
MODULES

IF > RP3
> 1%

EM-1

IF > 5%

FILL_R101.HOLD

IF >30 min

ELAPSED TIME

FILL_R101.HOLD

IF >2 hr

CLOSE XV-001

OPERATOR MESSAGES

EMPTY
REACTOR

CHECK XV-105

CHECK AG102

RECOVERY

RESTART
PHASE

RESUME PHASE

GO TO SHUTDOWN

HOLD ACTIONS
C
E

IF >30 min

SET TC-106

SET TC-106

= 60C

= 60C

CLOSE XV-105

RESTART
PHASE

Figure 12b Hold sequence matrix for Unit R-101

RESUME
PHASE

ANSI/ISA5.06.012007

DO NOT
PROCEED TO
FILLING
PHASE

37

Copyright 2007 ISA. All rights reserved.

Copyright 2007 ISA. All rights reserved.

OPEN

MODULES

L
I

OPEN

CONTROL

RECIPE

RECIPE

PRAMETER

INITIAL

FILL

HEAT

CURE

DUMP

SHUT-DOWN

PARAMETERS(RP)

ENTERED BY

(1)

(2)

(3)

(4)

(5)

(6)

FQ-003 (RP3)

PROGRAM

CURE PHASE TIME (RP2)

OPERATOR

TC-106 (RP1)

SUPERVISOR

FQ-003 (RP3)

PROGRAM

CURE PHASE TIME (RP2)

OPERATOR

TC-106 (RP1)

SUPERVISOR

FQ-003 (RP3)

PROGRAM

CURE PHASE TIME (RP2)

OPERATOR

TC-106 (RP1)

SUPERVISOR

C
I

B
M

T
R
I

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

C
70C < X < 110C

Figure 12c Recipe sequence matrix for R-101

38

Copyright 2007 ISA. All rights reserved.

1000 L

ANSI/ISA5.06.012007

 39
PHASE

PARAMETERS

PARAM. SCOPE

RECIPE-WRITTEN

REPORT *

INTERNAL

STEP#
1

NORMAL SEQUENCE

3
4
5

EM1.FILL_ R101
TYPE /
RANGE
TEXT
HS004_ENUM

EM1.BATCHID
EM1.RM_SRC

1000-5000

EM1.FQ_TOT

TIME/DATE

START & END TIMES

TEXT
0-100
0-150
0-500
0-50
TEXT
DEVICE
XV-002
FQ-003
HS-004

XV-001
FQ-003
FC-003
HS-003
FC-003
OPERATOR
MESSAGE
FIC-003

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

OPERATOR
MESSAGE

IF STEP TIME>5 MINS: "CHARGE

TIME EXCEEDED: CHECK FLOW"

HS-003
FC-003
XV-001
HS-004
FQ-003
OPERATOR
MESSAGE
DEVICE
XV-002

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"

OPERATOR
MESSAGE

HS-004

HOLD SEQUENCE

INITIATING
CONDITIONS

XV-001
HS-003

STEP#
H1

H2

ANSI/ISA5.06.012007

HMI
DEVICE
HS-003
FC-003
XV-001
XV-002
HS-004
FQ-003
OPERATOR
MESSAGE

IDENTIFIER

CORRESPONDING
ACTUAL VALUE

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

* BESIDES ACTUAL VALUES CORRESPONDING TO EACH RECIPE-WRITTEN VARIABLE

Figure 12d Equipment module sequence matrix for EM-1 phase FILL_R101

Copyright 2007 ISA. All rights reserved.

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

I/B

Manual / Auto

C/O

XV-501

Gree n

Red

Y ellow

Open

Close

Trav el

Blinking
Y ellow
Failure

Show only on failure

Motor
Interlock/
Bypass

M/A

I/B
M

Manual / Auto

S/R

Gree n

Red

Run

Stop

XM -601

Figure 13a Graphic elements

Copyright 2007 ISA. All rights reserved.

Blinking
Y ellow
Failure

 41

I#

Initiating Devices

Low Rx level ( <15 %)

Outlet
Agitator
pump
Ag-1
XM-1
AR

ANSI/ISA5.06.012007

Steam
Valve
TV-1

AR
R

2 High Rx Temp.( > 200C)

3
4
5
6
7
AR = AUTOMATIC RESET
R= MANUAL RESET

Common Alarm

Figure 13b Interlock status display

Operator Message
Operation: Reaction
Phases:

Modes of operation
Automatic

Initial
Fill
Heat
Cure
Dump
Shutdown

Manual

Start Sequence
Stop Sequence

Parameter

Actual

Target

Catalyst Volume

450 Gal.

500 Gal.

Recipe # A

Start Phase
Stop Phase

Phase Progress
Common Alarm

Figure 13c Sequence status display

Copyright 2007 ISA. All rights reserved.

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.

Copyright 2007 ISA. All rights reserved.

 43

ANSI/ISA5.06.012007

Annex B (informative) Application Example 2: Continuous Distillation Column

The following distillation example illustrates the application of the methodology to a continuous process.
The P&ID for this example is shown in Figure 14. The distillation column feed comes from Tank T-101
through an economizer. The reflux is on flow control and the reflux drum level controls the distillate flow.
The distillation column pressure is controlled by a vacuum pump. Obviously, many other control schemes
are possible and necessary for specific processes. This scheme was chosen only to provide information
for this example. Only basic interlocks are shown here. Additional instrumentation and interlocks would be
necessary to provide the level of personnel and process safety required by most processes today.

Copyright 2007 ISA. All rights reserved.

TT
106

TI
106

FAL
106
FSL
106

PT
106

PV
106

PC
106
PAH
PAL

TV
107

COOLING WATER
RETURN

VENT CONDENSER
H-108

CONDENSER
H-106

COOLING WATER
SUPPLY

VACUUM PUMP
P-109
CHILLED WATER
RETURN

TC
107
TT
107

CHILLED WATER
SUPPLY
LC
107

REFLUX
DRUM
T-107

LAL
107
LT
107

UC
110

HS
110

LV
107

REFLUX PUMP
P-110
FV
107

FT
107

FC
107

44

Copyright 2007 ISA. All rights reserved.

DISTILLATION
COLUMN
C-104
FEED TANK
T-101

HS
109

LAH

LI
101

TT
104

LAL
101

FROM
FAL-106

LT
101

UC
104

LAL
104
LT
104

UC
102

TC
104

TAH
TAL

LC
104
TV
104
HIGH PRESSURE
STEAM

HS
102
T
UC
111

STEAM
CONDENSATE

HS
111
LV
104

FEED PUMP
P-102
FAL
101

FC
101

FT
101

BOTTOMS PUMP
P-111
FV
101

ANSI/ISA5.06.012007

TO
UC-104

FEED
ECONOMIZER
H-103

CONTINUOUS
DISTILLATION COLUMN
P&ID
DRAWING # P-104

Figure 14 Continuous Distillation Column P&ID

 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.

Copyright 2007 ISA. All rights reserved.

P&ID

POINT TYPE
**

DEVICE TYPE

SIGNAL TYPE

I/O TAGS

I/O ADDRESSES *

FC-101

T-101

P-104

LOOP

ORIFICE / PDT();
GLOBE VALVE

4-20 MA

FT, FV

AI (1), AO (1)

LI-101

T-101

P-104

AI

PDT

4-20 MA

LT

AI (1)

HS-102

P-103

P-104

MOTOR

PUMP

120 VAC

XI, XS

DI (1), DO (1)

LC-104

C-104

P-104

LOOP

PDT;
GLOBE VALVE

FIELDBUS

LT,LV

AI (1), AO (1)

TC-104

C-104

P-104

LOOP

PT RTD / TT(chr);
GLOBE VALVE

FIELDBUS

TT, TV

AI (1), AO (1)

FAL-106

H-106

P-104

ALARM-1

FSL

24 VDC

FSL

DI (1)

PC-106

C-104

P-104

LOOP

PT(abs);
GLOBE VALVE

FIELDBUS

PT, PV

AI (1), AO (1)

TI-106

C-104

P-104

AI

PT RTD / TT(chr)

4-20 MA

TT

AI (1)

FC-107

T-107

P-104

LOOP

PDT;
GLOBE VALVE

4-20 MA

FT, FV

AI (1), AO (1)

LC-107

T-107

P-104

LOOP

PDT;
GLOBE VALVE

4-20 MA

LT, LV

AI (1), AO (1)

TC-107

H-106

P-104

LOOP

PT RTD / TT(char);
GLOBE VALVE

4-20 MA

TT, TV

AI (1), AO (1)

HS-109

P-109

P-104

MOTOR

PUMP

120 VAC

XI, XS

DI (1), DO (1)

HS-110

P-110

P-104

MOTOR

PUMP

120 VAC

XI, XS

DI (1), DO (1)

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)

Figure 15a Database I/O information

46

LOCATION

ANSI/ISA5.06.012007

Copyright 2007 ISA. All rights reserved.

CM TAG

CM TAG

SCALE
LOCATION

ENG.

P&ID
LOW

HIGH

UNITS

DESCRIPTOR

KEYWORD

T-101

P-104

10

100

LPM

COLUMN FEED RATE

FEED FLO

LI-101

T-101

P-104

50000

LITER

FEED TANK LEVEL

FEED LVL

HS-102

P-103

P-104

FEED PUMP

FEED PMP

LC-104

C-104

P-104

100

COLUMN BOTTOM LEVEL

BOTM LVL

TC-104

C-104

P-104

250

Deg. C

BOTTOMS TEMPERATURE CONTROL

BOTM TMP

FAL-106

H-106

P-104

CONDENSER LOW WATER FLOW

CWR FSL

PC-106

C-104

P-104

800

mmHg abs

COLUMN OVERHEAD PRESS

OVHD PRS

TI-106

C-104

P-104

250

Deg. C

COLUMN OVERHEAD TEMP

OVHD TMP

FC-107

T-107

P-104

200

LPM

REFLUX FLOW RATE

RFLX FLO

LC-107

T-107

P-104

100

REFLUX DRUM LEVEL

RFLX LVL

TC-107

H-106

P-104

250

Deg. C

CONDENSATE TEMP

COND TMP

HS-109

P-109

P-104

COLUMN VACUUM PUMP

VACM PMP

HS-110

P-110

P-104

REFLUX PUMP

REFL PMP

HS-111

P-111

P-104

COLUMN BOTTOMS PUMP

BOTM PMP

ANSI/ISA5.06.012007

Figure 15b Database HMI information

47

Copyright 2007 ISA. All rights reserved.

FC-101

ALARM FUNCTIONS
LOCATION

P&ID
TYPE

SP

PRIORITY

OUTPUT
DIRECTION

CONTROLLERS
TYPE

ALGORITHM

ACTION

DIRECT

M/A/SUP

P,I,D

REVERSE

T-101

P104

FAL

15

HIGH

LI-101

T-101

P104

LAH
LAL

40000
2500

HIGH
MED

HS-102

P-103

P104

FB_ERR

3
SEC

MED

DIRECT

M/A

LC-104

C-104

P104

LAL

10

MED

DIRECT

M/A/SUP

P,I,D

DIRECT

TC-104

C-104

P104

TAH
TAL

135
115

MED
MED

DIRECT

M/A/SUP

P,I,D

REVERSE

FAL-106

H-106

P104

STATE

PC-106

C-104

P104

PAH
PAL

DIRECT

M/A

P,I,D

DIRECT

TI-106

C-104

P104

FC-107

T-107

P104

DIRECT

M/A

P,I,D

REVERSE

LC-107

T-107

P104

DIRECT

M/A/SUP

P,I,D

DIRECT

TC-107

H-106

P104

REVERSE

M/A/SUP

P,I,D

DIRECT

HS-109

P-109

P104

FB_ERR

3
SEC

MED

DIRECT

M/A

HS-110

P-110

P104

FB_ERR

3
SEC

MED

DIRECT

M/A

HS-111

P-111

P104

FB_ERR

3
SEC

MED

DIRECT

M/A

LAL

HIGH
120
80

10

MED
MED

MED

Figure 15c Database operating information

48

Copyright 2007 ISA. All rights reserved.

FC-101

ANSI/ISA5.06.012007

CM TAG

INITIATING DEVICES
(FAULT)

CONTROL DEVICES (ACTION)

SETPOINTS

LOGIC

UC-102

LI-101 < 2500 L

(LAL-101 ON)

SAFETY
INTEGRITY
LEVEL

OPERATING MODE

INTERLOCK PURPOSE

STOP P-102
(HS-102 OFF)

LOW

MANUAL RESET

PROTECT FEED PUMP

UC-104

{FAL-106 IN ALARM
(ALSO HARDWIRED)} OR
{LC-104 < 5%
(LAL-104 ON)}

CLOSE TV-104
(TIC-104 OUTPUT = 0)

MEDIUM

MANUAL RESET

PROTECT REBOILER &

COLUMN

UC-110

LC-107 < 10%

(LAL-107 ON)

STOP P-110
(HS-110 OFF)

LOW

MANUAL RESET

PROTECT REFLUX
PUMP

UC-111

LC-104 < 5%
(LAL-104 ON)

STOP P-111
(HS-111 OFF)

LOW

MANUAL RESET

PROTECT BOTTOMS
PUMP

Copyright 2007 ISA. All rights reserved.

49

HAZARD
LEVEL

ID NUMBER

Figure 16 Interlock matrix

ANSI/ISA5.06.012007

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.

Copyright 2007 ISA. All rights reserved.

OPERATIONS

PREPARATION

RUN

END

PHASES
CONTROL DEVICES

DISCRETE
CONTROL
MODULES

INITIAL
(1)

START-UP
(2)

DISTILL
(3)

DRAIN
(4)

CLEAN
(5)

SHUTDOWN
(6)

RUN

STOP (1)

STOP

STOP

CM TAG

KEYWORD

HS-102

FEED PMP

STOPPED

HS-109

VACM PMP

STOPPED

RUN (2)

RUN

STOP (1)

STOP

STOP

HS-110

REFL PMP

STOPPED

RUN (5B)

RUN

STOP (3A)

STOP

STOP

STOP

STOP

RUN (4C);
STOP (6C)

STOP (1);
HS-111

BOTM PMP

STOPPED

RUN (5A)

RUN

RUN (3B);
STOP (5)

FEED FLO

LC-104

BOTM LVL

OP = 30 (4C);

OP = 0 (1)

SP = 75 (5C)

OP = 0

OP = 0 (1);

OP = 20 (5A);

OP = 0

WAIT UNTIL

SP = 50 (6A)

PV < 10 (4)

OP LIC104 (3A);

TC-104

BOTM TMP

TC-107

COND TMP

PC-106

OVHD PRS

SP = 85 (2)

OP = 0 (1)

OP = 0

LC-107

RFLX LVL

SP > 20 (7B)

OP = 0 (1)

OP = 0

SP = 125 (4A)
OP = 100 (1);
SP < 40 (4B)

OP = 0 (1)

OP = 0

OP = 0 (5)

OP = 0

51

Copyright 2007 ISA. All rights reserved.

ANALOG
CONTROL
MODULES

FC-101

OP = 100 (1);
FC-107

RFLX FLO

OP = 20 (5B);

WAIT UNTIL

SP = 35 (6B)

PV < 10 (2A);

OP = 0

OP = 0 (3A)

LI-101 > 40,000

ALLOWABLE
PHASE
TRANSITIONS

OPERATOR
MESSAGES

READY TO
START

ALL PV TARGETS

OPERATOR INITIATED OR

SATISFIED

LI-101 < 1000

2, 5

5
REDIRECT C104
BOTMS TO BLWDN &
CONFIRM(2B)

Figure 17a Normal sequence matrix for Unit C-104 (URS format)

1, 2

ANSI/ISA5.06.012007

END OF PHASE
CONDITIONS

OPERATIONS

PREPARATION

RUN

END
CLEAN

PHASES
INITIAL

START-UP

DISTILL

DRAIN

SHUTDOWN

(1)

(2)

(3)

(4)

(4)

KEYWORD

CM TAG

HS-102

FEED PMP

STOP

DISCRETE

HS-109

VACM PMP

STOP

MODULES

HS-110

REFL PMP

STOP

N O

HS-111

BOTM PMP

STOP

LI-101

FEED LVL

IF PV < 15K

FC-101

FEED FLO

IF PV < 20

LC-104

BOTM LVL

IF PV < 5

ANALOG

TC-104

BOTM TMP

120 > PV > 150

MODULES

TC-107

COND TMP

20 > PV > 40

PC-106

OVHD PRS

75 > PV > 95

IF PV < 125

LC-107

RFLX LVL

FC-107

RFLX FLO

25 > PV > 45

IF PV > 0

T D
I

T I
I

N N
G S

IF PV > 2000

IF PV > 1

ELAPSED TIME
HOLD ACTIONS

STOP HS-102,
HS-111
PROBLEMS
WITH SYSTEM
DRAIN

OPERATOR MESSAGES

RECOVERY

GO TO
START-UP

RESUME

Figure 17b Hold sequence matrix for Unit C-104 (URS format)

52

Copyright 2007 ISA. All rights reserved.

A T

(5)

ANSI/ISA5.06.012007

CONTROL DEVICES

C104.STARTUP

PHASE
PARAM.
SCOPE

PARAMETERS

INTERNAL
(FINAL SP)

INTERNAL
(INIT VAL)

CORRESPONDING ACTUAL VALUE

.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

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

STEP
SEQUENCE
DIAGRAM

Figure 17c Sequence matrix for C-104 Startup phase in FRS format (continues on next page)

ANSI/ISA5.06.012007

NORMAL SEQUENCE

IDENTIFIER

53

Copyright 2007 ISA. All rights reserved.

INTERNAL
(REF VAL)

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

3A

4A

NORMAL SEQUENCE

6A
3B
4B
5B
6B
7B
3C
4C

5C

INITIATING
CONDITIONS

HOLD
SEQUENCE

6C

None defined

STEP#
H1

Figure 17c Sequence matrix for C-104 Startup phase in FRS format (continued from previous page)

54

Copyright 2007 ISA. All rights reserved.

5A

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

ANSI/ISA5.06.012007

PHASE
STEP#
1

 55

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.

Copyright 2007 ISA. All rights reserved.

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