Building an Integrated Operations Enabling System …...Building an Integrated Operations Enabling...

IBM Chemical and Petroleum Solutions

© 2008 IBM Corporation

Building an Integrated Operations Enabling System with the Reference Semantic Model September 2008Ron Montgomery/Vish Narayan/Udo Pletat Worldwide C&P Industrial Solutions

Chemical and Petroleum Solutions

© 2008 IBM Corporation2

Overview

Trends in C&P industry

Objectives of RSM and IIF

Looking at RSM

RSM Model management

(Architectural) summary



A Confluence of Trends

Source: Cambridge Energy Research Associates.20807-14

Monitoring

Real Time

Automation

Improved OperationalEffectiveness

Increased Recovery

• Shorter decision cycles

• Higher productivity

• Integrated surface,downhole and reservoirdecision making

Demographics?

Reduced Downtime

Oil price?



Data Information Management / Integration Development Progression

Process InformationVolume Growth

“Unified”

Information ModelsTechnical Standards

Enterprise Information Access Services

HDA Client JMS

Publisher

CallbackEvents

TSDAHSDA

GDA ClientGDA

ModelData

Real TimeData

-HistoricalData

Event Data

Composite Services

ConditionedMonitoringComplex

Event Handler

DA Client

Web Services & Composite ServicesInformation Services Access Across the Enterprise



Chemical & Petroleum Integration and Information ChallengesSpecific Challenges:– Numerous different applications deployed across the enterprise at both the business

and production levels to manage and record operations performance.

– Each application instance has its own unique reference and data model.– Process Tag information and its context to equipment is not conveyed in real time

system integration, thus a heavy reliance on engineering interpretation

– Process events, alerts cannot be easily defined, distributed and “subscribed to”across the enterprise to initiate business processes or personnel collaboration or prompt attention

– Production Analysis Calculations are done off line requiring data replication and are not accessible for reuse and access by dash boards, portals, KPI’s etc.

– Cross location and cross work process transactions and events are also not captured in the context of equipment configurations or production relevant events.

– Operational views are incomplete; overall analysis is sub-optimal and localized by the domain coverage of applications. Complex views spanning divisions/plants/process areas requires new “one-off” application developments. Integrating additional facilities or introducing new functionality is often difficult, time consuming and costly.



Homogeneous view on enterprise - heterogeneous IT systems

Enterprise

Enterprise IT System

ProductionSite IT System

ProductionSite IT SystemN Sites

N IT Systems

N*N interfacesProduction

SiteProduction

Site



Overview



Looking at RSM





C&P Framework Manufacturing Operations Concept

Integrated Information Framework (IIF) addresses the needs for improved IT solutions on two levelsIndustry specific content & semantics– A technology neutral lingua franca reference framework enterprise model

based on recognized global standards– Global visibility into manufacturing information and performance– Ability to effectively maintain equipment relationships, track events and

conditions across multiple fields.– Presentation of information in the context of equipment geological formation– Foundation for internal manufacturing collaboration (Performance

Improvement) and execution (Operational Excellence)– A federation and aggregation of data, not a replication

Industry neutral advanced IT technology– Enterprise application integration SOA– Realtime event processing EDA– Up-to-date visualization WEB 2.0



OLF – Information Integration Platform (IIP) Project

So how to get from here, to

there

here



The IIF Vision

Engineering Leadership’s Vision for new capabilities

IT’s new tools and approachesto achieve the vision

Intelligent Manufacturing

Partnership between Engineering Leadership and IT



An Integrated Information Framework – providing an efficient pipeline for real-time data transfer

and analysis of data

Vendor

Vendor

Field data• Drilling & well

operations• Reservoir &

production operations

• Operation & maintenance

A Real-Time Information Pipeline leveraging the

Reference Semantic Model standard

IBM C&P Model Based SOA Integrated Manufacturing Solution

Frame Work

Web-service enabled applicationsField 1

Field 2

Operator

The RSM is composed of:• OPC information mapped to the RSM

ontology Measurement, MeasurementValue & other classes

• ISA S88/S95, ISO 15926, IEEE 61970/68 for asset and physical hierarchy representation

• ISO 15926, Mimosa for asset life cycle management

http://www.statoil.com/statoilcom/svg00990.nsf/Attachments/plattformer/$FILE/statfjordC_l.jpg



































An Integrated Information Framework – providing an efficient pipeline for real-time data transfer

and analysis of data

Vendor

A Real-Time Information Pipeline leveraging the

Reference Semantic Model standard

Vendor

Refinery data• Refinery

Planning• Refinery

Operations• Engineering &

Maintenance

Operator

IBM C&P Model Based SOA Integrated Manufacturing Solution

Frame Work

Web-service enabled applications

The RSM is composed of:• OPC information mapped to the RSM

ontology Measurement, MeasurementValue & other classes

• ISA S88/S95, ISO 15926, IEEE 61970/68 for asset and physical hierarchy representation

• ISO 15926, Mimosa for asset life cycle management

Refinery 1

Refinery 2



MimosaAssetModel

Federated Role Based ProcessModels

MaintenanceRequest

MaintenanceRequest

MaintenanceWork Order


MaintenanceResponse

MaintenanceResponse

May be generated for0..n

1..1

1..1

1..1

EquipmentClass Property


EquipmentProperty

EquipmentProperty

EquipmentCapability TestSpecification


EquipmentClass

EquipmentClass

Hasvalues for

0..n

0..n

0..n

0..n

0..n

EquipmentEquipment

EquipmentCapability Test

Result


Result

0..n

0..n1..n

Hasproperties

of

Is testedby a

Maps to

Defined by

Records theexecution of

0..n

0..n May result in

0..1

May be up of Is against

Is madeagainst

0..n

0..n

Defines aprocedure forobtaining a

MaintenanceRequest

MaintenanceRequest



MaintenanceResponse

MaintenanceResponse


1..1

1..1

1..1



EquipmentProperty

EquipmentProperty



EquipmentClass

EquipmentClass

Hasvalues for

0..n

0..n

0..n

0..n

0..n

EquipmentEquipment


Result


Result

0..n

0..n1..n

Hasproperties

of

Is testedby a

Maps to

Defined by


0..n

0..n May result in

0..1


Is madeagainst

0..n

0..n


Well Platform

Refinery or Chemical Process

ProcessTags

Local Process Models Federated to represent aSingle enterprise model name space

MaintenanceRequest

MaintenanceRequest



MaintenanceResponse

MaintenanceResponse


1..1

1..1

1..1



EquipmentProperty

EquipmentProperty



EquipmentClass

EquipmentClass

Hasvalues for

0..n

0..n

0..n

0..n

0..n

EquipmentEquipment


Result


Result

0..n

0..n1..n

Hasproperties

of

Is testedby a

Maps to

Defined by


0..n

0..n May result in

0..1


Is madeagainst

0..n

0..n


0..1

> Implemented by

< records useand removal of

asset toimplement

equipment

0..n

> May be made up of

PhysicalMakeAndModel0..n

> is an instance of

PhysicalAsset

Property

Hasvalues for >

0..n

PhysicalMakeAndModel

Property

0..n

Haspropertiesof >

Maps to

PhysicalAsset Utilization

History

1..1PhysicalAsset

0..1

Physical AssetCapability TestSpecification

0..n0..n

0..n 1..n

defines a procedurefor how to test >

< records thetesting of

< is usedto test

Physical AssetCapability Test

Result

0..1

> Implemented by

< records useand removal of

asset toimplement

equipment

0..n

> May be made up of

PhysicalMakeAndModel0..n

> is an instance of

PhysicalAsset

Property

Hasvalues for >

0..n

PhysicalMakeAndModel

Property

0..n

Haspropertiesof >

Maps to

PhysicalAsset Utilization

History

1..1PhysicalAsset

0..1

Physical AssetCapability TestSpecification

0..n0..n

0..n 1..n

defines a procedurefor how to test >

< records thetesting of

< is usedto test

Physical AssetCapability Test

Result

Link

ISA-S95Part 4

Reference Semantic Model

ISA-S95/88augmented

model

WITSML/PRODML Entities

Enterprise monitoring interface sees two tags with similar namesbut they are uniquely named and identified in the process models

ProcessTags

Wel

l Ser

vice

Sys

tem

Proc

ess

His

toria

ns

Proc

ess

His

toria

ns

Value of the RSM applied asset & physical hierarchy representation



Service enablement requires standardsEstablishing Industry relevance bringing real-time data to the enterprise

Automation and Control e.g., SCADA systems; DCSs

REAL-TIME OFF-LINE, BATCHEDTRANSACTIONAL

Historians

OI Frameworks

OPE

RA

TIO

NS

PRO

CES

SB

USI

NES

SO

PER

ATI

ON

SPR

OC

ESS

BU

SIN

ESS

MES Operational Data Stores

Pure BI/ Data

Warehouses

Business systems:ERP, EAM, SCM, APS

AdvancedAnalytics

and Modeling Tools

OI

LATENCY OF ANALYTICAL INFORMATION

CO

NTI

NU

UM

OF

OPE

RA

TIN

G C

ON

TEXT

S

How is the business performing?

How is the process performing?

How does process performance correlatewith business performance?

Interfaces to ERP/EAM(ERP or 3rd party capability)

ANSI ISA S95/S88

BatchControl

ContinuousControl

DiscreteControl

Business Planning & Logistics

Plant Production Demand,Operational Management, etc

Manufacturing Operations Management

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

BatchControl

ContinuousControl

DiscreteControl

Business Planning & Logistics

Plant Production Demand,Operational Management, etc

Manufacturing Operations Management

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

Level 4

Level 1

Level 2

Level 3

1 - Sensing the production process, manipulating the production process

2 - Monitoring, supervisory control and automated control of the production process

3 - Work flow / recipe control, stepping to produce the desired end products. Maintaining records and optimizing the production process.

Time FrameShifts, hours, minutes, seconds

4 - Establishing the basic plant schedule -production, material use, delivery, and shipping. Determining inventory levels.

Time FrameMonths, weeks, days, shifts

Standards based enterprise taxonomy / ontology = Model Driven Business Transformation

Reference

Semantic

Model

http://www.iso.ch/iso/en/ISOOnline.frontpage



Standards Leveraged in the RSM

ISA-88/BatchML

ISA-95/B2MML

Augmented by ISO-15926 (design lifecycle and physical connectivity)

IEC61970/68 (electrical model)

ISO13374 (maintenance – e.g. Mimosa)

UN-CEFACT (over-arching guidance –e.g. currency, units, etc...)

UTF (time representation/GMT)

OPC (measurements and quality definitions)

Open GIS

……..maybe more, Energistics inclusion, PIDX, CIDX, etc.



Reference Semantic Model Objectives and FunctionsThe RSM essentially answers the Open Operations and Maintenance model requirements (Leverages MIMOSA and Open O&M transactions, ISA 95 Part 4)

Connects measurements, equipment, planning and scheduling, life cycle management, etc. throughout an enterprise

The RSM is not a data model and does not constrain the way applications implement the information contained within the model.

The RSM facilitates the exchange of information it does not store or replicate data. Federates instances of the IIF/RSM across the enterprise.

The RSM provides a “Contextual Naming Service for equipment and measurements, keeps track of “equipment and process states”.

The RSM provides multiple enterprise navigation methods that allows the access of process equipment, measurements, and document connectivity for visualization, and provides a “role based” information capability

The RSM can be “queried” to find equipment and related information to like documents and “pseudo static” data by Web Service based applications.

The RSM provides a base for “Model Aware Adapters”



Building blocks for the C&P SOA is built with standards and industry participationRSM Team

MIMOSA- Alan T. Johnson, Ken BeaverOAGi – Dave ConnellyWBF – Dave EmersonISA 88 – Dennis BrandlISA 95 – Keith UngerOLF – Tore Langeland, Magne Valen-SendstadOSIsoft – Jack AudeDNV - Henrik Smith-MeyerDOW – Russ DickinsonSISCO – Herb FalkIBM – Lorenzo Childress, Jon Siudut, Karthik Seetharaman, Jerry KopeckyOPC – Vishwanath Narayan

RSM Team Objectives/MilestonesObjectives

– Advance the modeling work

– Insure compliance with the participating standards

Milestones

– Identify the appropriate standards community to own the RSM

– Initial release of the RSM in the October timeframe



So What’s A Reference ModelCombining ISA-95 and ISA-88

ISA-88 and 95 Together Specify:

An equipment / asset physical model– For batch, continuous and discrete

manufacturing processes

Batch process equipment entities

Recipe management models

Process segments that carryout manufacturing operations

Equipment, material and personnel resources

Information exchanges for enterprise integration

Standards Included:

S95 S88 ISO15926

MIMOSA IEEE 619/6870 UN/CEFACT

Implicit linkages needto be explicitly defined



The RSM Models the Whole Enterprise

Identified by ISA-88

Must Contain 1 or More

May Contain 1 or more

Area

Site

Enterprise

May Contain 1 or more

Must Contain1 or More

May Contain

May Contain

BatchOperations

ProcessCell

Unit

MayContain

MayContain

Equipment Module

Control Module

Specified by ISA-88



DiscreteOperations

InventoryOperations

ContinuousOperations

Work Cell

ProductionUnit

StorageZone

Unit


StorageUnit

Area

Site

Enterprise

Specified by ISA-95

ManufacturingLine



Problem: Traditional Tag Deployment

1. Transfer tags from engineering documents / design applications to target.

2. Define tag relationships –usually a functional view.

3. Repeat for other applications – each will be different.

4. As other tags are defined / needed, synchronize across all applications –likely to be out of synch somewhere.

Reactor 1Tank 1

EU501Agitator 1

MV 101PID 101Out 101

FQISH101Feed Supply

EU101

MV 201PID 201Out 201

FQISH201Additives

EU201

Unit 1



Introducing structure to orginze information

Enterprise

Area A

Site 1

Site 2

Production

Unit A

Production

Unit B

WorkEquip

Pump 1

Measurement

Flow

Meas-Value

FT-1

Measurement

Pressure

Meas-Value

PT-1



Overview



Looking at RSM





Definition of RSM

The RSM is defined as a UML model

Various packages bundeling information from different standards

Use classes & relationships of ‚parent standards‘

Add ‚glue‘ and ‚gap fillers‘ where appropriate



ISA-95 Part 1, Figure 4 – Equipment hierarchy

May contain 1 or more




Must contain 1 or more May contain 1 or more

ProductionUnitProcess Cell


Area

Site

Enterprise

ProductionLine

Unit Work Cell

Level 4 activitiestypically deal withthese objects

Lowest LevelsOf Equipment

TypicallyScheduled

By Levels 3 or 4

Level 3 activitiestypically deal withthese objects

Lower levelequipment used

in batch operations.

Lower level equipment usedin repetitive or

discrete operations.

Lower levelequipment used

in continuousoperations.



ISA-95 Part 3, Figure 7 – Typical Expanded Equipment Hierarchy

ENTERPRISE

SITE

AREA

PRODUCTIONLINE

WORKCELL

PROCESSCELL

Level 4 activitiestypically deal with

these objects

Level 3 activitiestypically

deal with these

objectsSTORAGE

ZONE

STORAGEUNITUNITUNIT

Legend

contains 0 or more

contains 1 or more

PRODUCTIONUNIT

Equipment usedin batch

production

Equipment usedin repetitive or

discrete production

Equipment usedfor storage or

movement

Equipment usedin continuous

production



ISA-95 Part 4 Draft

AREA

ENTERPRISE

SITE

PRODUCTIONLINE

WORKCELL

PRODUCTIONUNIT

PROCESSCELL

STORAGEZONE

STORAGEUNIT

WORKCENTERS

UNIT

Legend

contains 0 or more

contains 1 or more

UNITWORKUNITS



AREA

ENTERPRISE

SITE

PRODUCTIONLINE

WORKCELL

PRODUCTIONUNIT

PROCESSCELL

STORAGEZONE

STORAGEUNIT

WORKCENTERS

UNITWORKUNITS

Legend

contains 0 or more

contains 1 or more

UNIT

ControlModule

EquipmentModule Equipment used

in repetitive ordiscrete production

Equipment usedin continuous

production

Equipment usedfor storage or

movement

ISA-95 Level 3

activitiestypically

deal with these

objects

ISA-95 Level 4 activitiestypically deal with

these objects

Batch process activities based on ISA-88

typically deal with these

objects

Part 4 A Draft - Figure x from SP88-95 JWG



How the RSM models this



Visualizing KPI‘s based on RSM definitions



Measurements/ MeasurementValues



Measurements and KPI‘s



RSM Supports KPI’s and Production Calculations



The RSM Models Down to the Equipment and the Tag Level

PROCESSCell

PROCESSCell

EQUIPMODULEEQUIP

MODULE

PressureControl

PIC

Recirculate

Transfer

Add Material F1

TemperatureControl

TICCoolHot

UNITUNITAgitate

M

CONTROL MODULE

CONTROL MODULE



High Level P&ID View: Using the RSM



Different ViewsTopology View (Visualization)

F1

Process View

T01

CV02

S01CV03 F1 S01CV03

CV01P01

Add MaterialCV01CV02CV03

S01

Equipment View

CV01P01 CV02

Connectivity

F1

CV01P01

CV03

CV02

S01

Mv( pump speed ) Mv( state )

Mv( flow )

Measurement View

CAD file transformations is a source for process

connectivity



RSM and ISO15926 classes relevant for P&ID information



RSM – Classes for typical P&ID content



Overview



Looking at RSM





Topics for model management

Meta-model evolutionadd new concepts & information to RSM

Model instance creationuse RSM for building applications on top of it

Model instance populationfill RSM instance with enterprise data

Model instance migrationmigrate model instance content due to meta-model changes



RSM meta-model, model instances and their evolution paths

meta-model evolutionRSM

Meta-ModelVersion 1

RSM Meta-ModelVersion 2

RSM Model

Instance A.0

RSM Model

Instance B.0

RSM Model

Instance C.0

RSM Model

Instance D.0

Instance allocation

SQL

UM

L

instance migration

Initial load

RSM Model

Instance A.1

RSM Model

Instance B.1

RSM Model

Instance C.1

RSM Model

Instance D.1instance migration

Incremental update

RSM Model

Instance A.2

RSM Model

Instance B.2

RSM Model

Instance C.2

RSM Model

Instance D.2instance migration



RSM Model Extensibility – single industryNeed to distiguish between

meta-model extensions concepts for representing oil rigs

pre-populated model instances a ‚typical‘ oil rig consists of ...

customer‘s model instance a customer‘s specific oil rig

C&P customer

rigA

C&P customer

rigB

C&P customer enterprise

RSM C&P industry model instance

RSM Base meta-model

RSM C&P customer model instanceRSM C&P Customer meta-model

RSM Chemical&Petroleum meta-model

Meta-model Model instance



RSM for multiple industries

RSM Automotive meta-model

RSM Base meta-model

RSM C&P meta-model

RSM C&P Customer meta-model

Model instance Meta-model Model instance

RSM Automotive Customer meta-model

RSM Automotive Customer

Model instance

RSM C&P Customer

Model instance



Overview



Looking at RSM





A Sample Real Time Integration Layout

IMS

Jalapeno IV Tabasco II

”Gulf of Mexico”Onshore Texas

MS Excel

Matrikon ProcessNet

OSIsoft OPC Client

Matrikon OPC Explorer

IIF Workbench

TransmitterSurveillance

App

ABB WebServices Client

OPC Client

Adapter

RT Model Visualization

Server

AnalysisApp

OPC Client

Adapter

AnalysisApp

OPC Client

Adapter

AnalysisApp

OPC Client

Adapter

AnalysisApp

OPC ServerAdapter

OPC ServerAdapter

RT Enterprise Model Services

Browser

REST/HTTP

SOAP/HTTP

•Matrikon OPC Tunneler Client

OPC Tunneler

ClientOPC Tunneler Server

•Matrikon OPC Tunneler Server

Bus apps / svcs

IBM SystemsArchitectural construct

•IIF UIB Server Adapter•JMS Libs•DBMS client

WebSphereESB/Process Server

OSIsoft PITest data

OSIsoft PITest data

ES

B

DCS DCS

IMS

JMS/MQ

OPC Tunneler

Client

RT Model Core Server

•IIF UIB Core•DBMS (Oracle 9i)

C&P IIF Solution

EnterpriseApplication



Summary

Customer projects drive evolution of existing industry standards

RSM takes a ‚pragmatic‘ approach– Pick what you need from existing standards– Extend where necessary

Modern service-oriented and event-driven architecture concepts allow to combine – The real-time IT world– The enterprise IT

Many things around RSM you have not seen today– Check out for IBM ONS 2008 announcements to learn more on the entire

approach

Building an Integrated Operations Enabling System …...Building an Integrated Operations Enabling...

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