overviewing the standards: isa 88 and isa...
TRANSCRIPT
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
National Symposium on
Automation & Digital Transformation of
Food & Beverage Industry26th & 27th February 2016
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Sunil S Shah, PhD
Secretary, ISA Bangalore Section
Overviewing the Standards:
ISA 88 and ISA 95
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Academic:
- B. E. (Chemical Engineering), Regional Engineering College (now NIT), Rourkela
- Ph. D. (Systems and Control Engineering), IIT- Bombay
Currently working with:
- Owner of Startup, Communications, Diagnostics, and Controls/ CDC
Worked With:
- GE Oil and Gas, Sr Product Manager (Global), Rotating Machinery Controls
- GE Global Research Center, Bangalore leading the Electromechanical Control Systems Lab
- CAD Center, Indian Institute of Technology- Bombay , Mumbai as Principal Research Engineer
- Davy Powergas India Pvt Ltd (now Kvaerner Powergas), Bombay as Principal Process Engineer
Association:
- Senior Member and Secretary (Bangalore Section), International Society of Automation (ISA)
- Senior Member and Ex-Secretary, IEEE Control Systems Society, Bengaluru Chapter
Sunil S Shah
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• Introducing Standards
• ISA’s Standards for Automation
• Overview and need for implementation
• ISA 88- Batch Control Systems
• ISA 95 - Enterprise - Control System Integration
• Path forward
• Developing the Standards Team
Agenda
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A “Standard” is an authoritative document, developed in accordance with a
strict predefined methodology, embodying such principles as balance of
interests and consensus and incorporating stringent review and
documentation process
Special status-
RAGAGEP: Recognized and Generally Accepted Good Engineering
Practice
Not regulatory: Can be adopted by regulatory body under the “general
duty” clause- “The employer shall document that equipment/ process
complies with RAGAGEP”
Source of Collective Wisdom
Well implemented standards can lead to:
Productivity improvement
Savings
What is a Standard?
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Reduce Confusion
Standards emphasize good practice
Long-term value when implementing continuous
improvement projects
Standards outline
Common functions
Methods of interaction that are repeatedly
used to accomplish associated tasks
Reduce Development Cost and Time-To-Market
Standards promote the reuse of functions
Lead to a quick development and deployment
Standard functions provides less risk, and reduces
the validation and commissioning effort
Why Standards?
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Reduces Maintenance
Standards breakdown complex functions into smaller
pieces
Allow them to be managed on a smaller and simpler
level
Low risk in additions or modifying smaller sections of
the control code
Minimal effort to support continuous improvement projects
Reduces Total Cost of Ownership
Why Standards? Contd…
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Standards- The Down Side…
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Developed in a collaborative and consensus-based process with
participation from key stake holders- End users, Suppliers, …
NOT government regulations, rather voluntary documents
Often contracts between private entities include requirements to follow
specific ISA standards
ISA is accredited by the American National Standards Institute (ANSI) to
develop industry standards following approved processes
The current ISA standards portfolio:
>150 published standards, recommended practices and technical
reports
ISA Standards
Visit
www.isa.org/standards
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Substantial global participation:
100 committees and subgroups
> 2000 participating organizations
> 3500 participating individuals from over 40 countries
Extensive use of teleconferences and web meetings
ISA Standards- Global Presence
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Process Instrumentation Symbols & Diagrams (ISA5)
Management of Alarms (ISA18)
Instrument Specification Forms (ISA20)
Fossil & Nuclear Power Plants (ISA77 and ISA67)
Functional Safety for the Process Industries (ISA84)
Batch Process Control (ISA88)
Enterprise-Control System Integration (ISA95)
Industrial Automation & Control Systems Security (ISA99)
Wireless Systems for Automation (ISA100)
Human-Machine Interface (ISA101)
Commissioning, Loop Checks, & Factory/Site Acceptance (ISA105)
Procedure Automation for Continuous Process Operations (ISA106)
Intelligent Device Management (ISA108)
Key ISA Standards
…
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Several original ISA Standards are the basis of major International
Electrotechnical Commission (IEC) standards:
IEC 62682: Management of Alarms (ISA18)
IEC 61511: Functional Safety (ISA84)
IEC 61512: Batch Control (ISA88)
IEC 62264: Enterprise Control-System Integration (ISA95)
IEC 62443: Industrial Automation & Control Systems Security (ISA99)
ISA Standards and Global Impact
Full Member
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ANSI/ISA-88
IEC 61512
Batch Control Systems
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Defining Batch Process…
MaterialStorage 1
MaterialStorage 2
MaterialStorage 3
Minor Additions
Packaging Line 1
Packaging Line 2
FeedTank 1
FeedTank 2
SprayDryer 1
SprayDryer 2
Mixer
BATCH
DISCRETE
CONTINUOUS
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Traditional Batch Operation…
Enterprise Operations
Local Control System
Multi Vendor & Varied Technologies
Vendor-A
Planning and
Scheduling
Application
Homemade
Excel Reports
Paper Copies of
SOPs
Improvised
Modifications 3rd Party Data
Historian
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BATCH
Traditional Batch Operation…
No prescribed form of batch operation
Missing common terminology
Difficult to establish requirements
Labour and time intensive
Difficult integrating different vendor offerings
Everyone had their own standards
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Need of the day…
Enterprise wide multi product portfolio
Local raw materials
Varied equipment configuration
Multi vendor control system platforms
Handle obsolescence
Agile lab-to-market strategy
Nimble merger of acquisitions
Enterprise Integration
Equipment Flexibility
Agile Product
Development
Multi Plant Integration
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General guidelines developed specifically for batch industries:
Food and Beverage, Specialty chemicals, Pharmaceuticals, …
Model and methodology for designing and operating control systems for
flexible manufacturing
Independent of the underlying control system (PLC, DCS, or IPC)
Independent of the underlying basic control algorithms
Enable with ease verified and validated recipe and automation changes
Provision to handle abnormal conditions/ situations
Defines programming standards for batch control
Widely adopted configuration standards for manufacturing
Introducing ISA-88.0x …
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ANSI/ISA-88.00.01-2010
Batch Control Part 1: Models and Terminology
ANSI/ISA-88.00.02-2001
Batch Control Part 2: Data Structures and Guidelines for
Languages
ANSI/ISA-88.00.01-2010
Batch Control Part 3: General and Site Recipe Models and
Representation
ANSI/ISA-88.00.04-2006
Batch Control Part 4: Batch Production Records
ISA-88.00.05-Draft
Batch Control Part 5: Implementation Models & Terminology for
Modular Equipment Control
ISA-88.0x Nomenclature…
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Benefits of ISA-88.0x …
Reduce cost of automating systems
Reduced life cycle engineering effort:
Reduced time to market
Improved flexibility
Improved process quality
Rapid batch recipe development
Applied today around the world, with proven and identifiable benefits
₹
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Core Benefit End-User Perspective Vendor Perspective
Improved
Flexibility
Accommodate more products
with faster changeover time
with same equipment
Structured approach enables
more options with quicker
swapping of options
Quicker to
Market
New consumer products are
delivered to market faster
New equipment is delivered to
end-users faster
Improving
ROI
NPV
Modular library with easy replication
Reinventing the wheel minimized
Benefits of ISA-88.0x …
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ISA 88.0x Philosophy
Separation of the mind and the body
Recipes
• Minimum set of information that
uniquely defines the manufacturing
requirements of a product
• Provides production information,
formula, procedure, equipment
requirements
Independent Recipe Development
Multiple Products- Same Equipment
Physical Assets
• Manufacturing Plant
• Equipment
• Control System
• …
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RECIPES
Recipe Model
Header Information
Formula- Process Parameters
Procedure including Controls
Equipment Requirements
Safety and Regulatory Compliance
Administrative Information
Raw Materials, quantities,
specifications, …
MOC, Heating/ Cooling,…
Process, operation strategy,
…
Safety and
compliance information,…
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RECIPES
Recipe Types
General Recipe
Site Recipe
Master Recipe
Control Recipe
Product specific
process information
Site specific
Information
Batch ID, batch size, operator
and system specific information
Equipment Specific
Information
Ensures Uniform Product Specification- Enterprise wide
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Procedure
Procedural Model
Procedure
Unit Procedure
Operation
Phase
Procedure
Procedural Model
Command the
equipment in the
physical model to
perform a process task
Controls to direct the
equipment’s actions to
perform process
oriented tasks
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Procedure
Procedural Model
Procedure
Unit Procedure
Operation
Phase
Procedure
Detailed strategy for
making a batch
Consists of an ordered
sequence of unit
procedures
Ex Bread Making,
Fortified Juice making
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Procedure
Procedural Model
Procedure
Unit Procedure
Operation
Phase
Unit Procedure
Consists of an ordered
set of operations
Ensure a continuous
production sequence
within a unit
One unit procedure in
a unit at any time
Unit procedure
completed in a single
unit
Ex
Esterify
Strip
Neutralize
Filter
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Procedure
Procedural Model
Procedure
Unit Procedure
Operation
Phase
Operation
An ordered set of
phases that defines a
major processing
sequence
Takes the material
being processed from
one state to another
Usually involved a
chemical or physical
change to the material
Carried to completion
in a single unit
Ex Charge, React,
Transfer,…
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Procedure
Procedural Model
Procedure
Unit Procedure
Operation
Phase
Phase
The smallest element of
procedural control that
can accomplish a
process-oriented task
The logic or set of steps
that make up a phase is
equipment specific, and
not part of the recipe
Phases for the charge
operation are: Initialize
Add material A at 20L/min
Add material B at 20L/min
Mix for 20 minutes
Usually the link to
equipment
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Unit Procedure
Procedure
Unit Procedure
Operation
Operation
PhasePhase
Phase
Procedural Model- Flow Sequence
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Procedure Examples Illustration
Procedure
Unit Procedure 1 Unit Procedure 2
Phase 1
Unit Operation 1 Unit Operation 4
Unit Operation 2 Unit Operation 3
Phase 2
Phase 3
Phase 4
Phase 5
Phase 6
Phase 7
Phase 8
Procedure Make Product A
Make Product B
Unit Procedure Any set of Operations
Unit Operation Filtration
Reaction
Distillation
Solution Preparation
Phase Agitate
Heat
Cool
Transfer
Charge
Recycle
Procedural Model- Conceptual Example
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ENTERPRISE-SITE-AREA-…
Physical Model
Process Cell
Unit
Equipment Module(s)
Control Module(s)
Process Cell
A.K.A. Train
Logical grouping of
equipment required for
production of one or
more batches
May contain +1 grouping
of equipment
May contain +1 batch at
a time
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Process Cell- Example
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ENTERPRISE-SITE-AREA-…
Physical Model
Process Cell
Unit
Equipment Module(s)
Control Module(s)
Unit
Usually centred on a
major piece of process
equipment
Frequently operates on,
or contains the complete
batch
Cannot operate on, or
contain more than one
batch at a time
May operate on, or
contain, only part of the
complete batch
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ENTERPRISE-SITE-AREA-…
Physical Model
Process Cell
Unit
Equipment Module(s)
Control Module(s)
Equipment Module
A collection of control modules or other equipment modules
Can carry out a finite number of minor processing activities, i.e., phases
Contains all the necessary processing equipment to carry out these processing activities
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ENTERPRISE-SITE-AREA-…
Physical Model
Process Cell
Unit
Equipment Module(s)
Control Module(s)
Control Module
A collection of sensors, actuators, other control modules, and associated processing equipment
Acts as a single entity from a control standpoint
Is the direct connection to the process through its sensor and actuators
Procedures do not run on control modules
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Unit, Equipment, and Control Modules
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Connecting Procedural and Physical
Models
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Transitioning from Abstract to Physical…
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S88.01 is not only for batch processes
Extendible for discrete and continuous industries
Continuous
Startup - Shutdown
Grade change
Discrete
Product Change
Extending S88…
Packaging Line 1
Packaging Line 2
DISCRETE
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ISA 88 provides an excellent framework for developing batch systems
Separation of product information (recipes) from equipment capability is
key to designing flexible systems
Applies to both automated and manually-controlled batches
Common set of terminology, definitions, data structures
Flexible guidelines that outline the base concepts to be used in a system
design
Supports multi-use instances to minimize and simplify the coding using
modular functions
The concept also applied to continuous processes, and discrete manufacturing
Summarizing…
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Inflight Reading- Practical Batch Process Management, M Barker, J
Rawtani
Heavy Reading- ISA.org (Standards Section- accessible to members)
Manufacturing Operations Management, D Brandl, P Owen
Web Surfing- blogs by D Brandl
Web Surfing- WBF/ MESA publications
References and Further Reading…
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ANSI/ISA 95/
IEC/ISO 62264
Enterprise - Control System
Integration
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Operation Technology (OT), focused on
safe and secure physical value creation and
manufacturing processes
Information Technology (IT),
agglomeration of technologies for
information processing.
- Typically a network of computers and
software required to operate an enterprise
How much is my stuff worth?
Where is my stuff?
IT/ OT Defined
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Business Systems
Time Horizons
Long-term view
Model detail
Linear route structures
Control emphasis
Product cost and overall profitability
Modeling criteria:
Accounting reference points
Has inventory value changed significantly? If not, don’t model separately
View from the boardroom
Manufacturing Systems
Time Horizons
Real-time view
Model detail
Complex routes with rework paths
Control emphasis
Physical movement & accountability
Modeling criteria:
Material movement reference points
Does product stop moving? If not, don’t model separately
View from the work center
Independent Evolution of IT/ OT
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Integration of business and manufacturing domains is challenging:
Differing automation & IT cultures, knowledge bases
Lack of consistent representation of data
Differing “What is important?”
Differing “Critical success factors”
Strong business drivers to integrate:
Supply chain optimization
Asset efficiency
Agile manufacturing
Available to promise & available to profit
Salient Features…
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IT/ OT Gap…
Years
Months
Weeks
Days
Hours
Minutes
Seconds
Milli/micro seconds
Gap of Unmet Needs
Handled well by
DCS/PLC systems
Handled well by ERP systems
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Enterprise / Business Operations
Manufacturing Operations Management
Control
Devices
Field
I
T
O
T
Harmonized IT and OT Strategies
Common governance and process models
Integrated Security Framework
Skilled Man Power Proficient in both IT and
OT
Converged Platform
IT/ OT Convergence
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Framework for integration projects
Separation of business processes from manufacturing processes
Focus on functions, not systems, organizations or individuals
SITE
AREA AREA AREA
CONTINUOUS
PRODUCTION
UNIT
DISCRETE
PRODUCTION
LINE
ENTERPRISE95.01 & 2
BATCH
PROCESS
CELL
95.01: Models and Terminology95.02: Object Attributes
95.03: Activity Models of Manufacturing Operations Management
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
95.03
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, …
Interface
ISA 95 Mandate and Scope
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ANSI/ISA-95.00.01-2010
Enterprise-Control System Integration Part 1: Models and Terminology
ANSI/ISA-95.00.02-2010
ECS Integration Part 2: Object Model Attributes
ANSI/ISA-95.00.03-2013
ECS Integration Part 3: Activity Models of MOM
ANSI/ISA-95.00.04-2012
ECS Integration Part 4: Objects and Attributes for MOM Integration
ANSI/ISA-95.00.05-2013
ECS Integration Part 5: Business-to-Manufacturing Transactions
ANSI/ISA-95.00.06-2014
ECS Integration Part 5: Messaging Service Model
ISA-95.0x Nomenclature…
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Enterprise Information
Plant Production Scheduling,
Operational Management, …
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, …
Product
Definition
Information
(How to make
a product)
Production
Capability
Information
(What is
available
for use)
Production
Schedule
(What to
make and
use)
Production
Performance
(What was
made and
used)
Information crossing
the boundaries
ISA 95.01 and 95.02
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Manufacturing Operations Functions
Production
resource
management
Production
capability
Analysis
Production
data
collection
Production
execution
Production
dispatching
Production
tracking
Production
performance
Detailed
production
scheduling
Production
schedule
Level 2 Process Control
Product
definition
management
Product
definition
Equipment and Process
Specific Production Rules
Equipment and Process
Specific Data
Operational
Responses
Operational
Commands
ISA 95.03
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Maintenance Functions and so on…
Maintenance
resource
management
Maintenance
capability
Analysis
Maintenance
data
collection
Maintenance
execution
Maintenance
dispatching
Maintenance
tracking
Maintenance
Response
Detailed
Maintenance
scheduling
Maintenance
Request
Level 2 Equipment
Maintenance
definition
management
Maintenance
definition
ISA 95.03…
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ISA 95 Manufacturing Architecture
Enterprise application integration
PLM ERP SCM CRM
ANSI/ISA –95 Part 1 and 2 Object model information
ANSI/ISA –95 Part 3 Activity models of Manufacturing Operations
Product definition (what
to make)
Product capability (what and how much is available to make)
Product schedule (what to make and
use)
Product response (what was made
and used)
Defi
nit
ion
Sc
he
du
lin
g
Dis
pa
tch
ing
Re
so
urc
e M
an
ag
em
en
t
Ex
ec
uti
on
Data
co
lle
cti
on
Pe
rfo
rma
nc
e A
na
lys
is
Tra
ck
ing
Production
QualityInventory
Maintenance
Process Control (Field instruments, DCS, PLC, sensors, etc.)
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Level 1
Level 2
One Instance Per
Process Cell
Automation Network
Area Operations Information Network
Ethernet
Ethernet
High AlarmLow AlarmComm. Err.HMI
Viewer
Packaged EquipPLC
Level 3Site
Information
Network
High AlarmLow AlarmComm. Err.
Eng Tools
Diag Tools
Non operations tools
and views into data
VLAN
Switch
ERPConnection
VLAN
Switch
2 way Firewall
DNSDomain Ctrl
DCS
XM
L
Network
Management
Router
Network
Management
Router
Network
Management
Router
DNSDomain Ctrl
Historian
Reporter
Configuration
ServerMES
Server
Batch
Execution
Gateway
Historian
Collection
HMI Server
OPC
DataBase
Servers
Embedded PC
Physical Architecture- ISA 88 & ISA 95
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B2MML – XML Schemas for ISA S95
XML schema- Agreement between businesses on expressing data
Team from World Batch Forum (WBF) was formed to produce a set of XML
schemas for the data models defined in ISA-95.00.01/2- B2MML
B2MML provides a set of XML schemas based on ANSI/ISA-95
B2MML may be used to integrate business with manufacturing systems
Communication Language and Models…
<OperationsDefinitionInformation>
<ID> F2 </ID>
<Description> Embedded drum toner cartridges
<HierarchyScope>
<OperationsType>Production
<PublishedDate> 2012-12-08
<OperationsDefinition>
<ID> TN6600
<Version> V0
<Description> For Brother HL series
<WorkDefinition> TN6600
<OperationsSegment>
<ID> S1
<Description> Make Enclosure
< OperationsSegment >
<ID> S2
<Description> Make Ink
<PersonnelInformation>
<Description> Personnel of SuperToner
<PublishedDate> 2012-12-08
<PersonnelClass>
<ID>Molder
<Description> Molder
<PersonnelClassProperty>
<ID> MolderQualif
<Description> Molder Qualification test
<Value> 1 or 2
<QualificationTestSpecificationID> TestLevel
<PersonID>
<Person>
<ID> P1
<PersonName> Albert
<PersonnelClassID> Molder
<PersonProperty>
<ID> MolderQualif
<Value> 1
<TestResult> PassExample B2MML Models
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• Integrated execution systems are crucial for:
• Reduced direct costs; increased productivity
• Improved traceability; reduced “witch hunt” expense
• Near-theoretical cycle times: customer responsiveness, reduced WIP
inventory
• Greater agility: smaller lot sizes, more premium products in the mix, happier
customers, happier shareholders!
• S95/88 defines the currency for manufacturing object and information exchange
• Faster project implementation cycles
• Flexibility to integrate and realign as corporate structures change
Conclusion
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Path Forward…
Special Interest Group under ISA Bangalore Section
Objectives:
Understanding and Implementing Standards
Customizing for Indian Conditions
Training
Go to team
Plans:
Regular meetings
Workshops and Tutorial Sessions
Participate in Global Meetings
Initial Focus- ISA88, ISA95, ISA99 and ISA100
You are welcome- please drop a mail!
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Inflight Reading- MES Guide for Executives, Bianca Scholten
Heavy Reading- ISA.org (Standards Section- accessible to members)
Getting Started with ANSI/ISA-95, Bob Mick
Manufacturing Operations Management, D Brandl, P Owen
Web Surfing- blogs by D Brandl
Web Surfing- WBF/ MESA publications
References and Further Reading…