Overviewing the Standards: ISA 88 and ISA...

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

[email protected]

Overviewing the Standards:

ISA 88 and ISA 95

Basics of Modern Industrial Automation

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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

…

https://www.isa.org/isa5/














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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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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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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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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…

Overviewing the Standards: ISA 88 and ISA...

Documents

Transcript of Overviewing the Standards: ISA 88 and ISA...