National Symposium on Automation & Digital Transformation of Food & Beverage Industry 26th & 27th February 2016 Overviewing the Standards: ISA 88 and ISA 95 1 Standards Certification Sunil S Shah, PhD Education & Training Secretary, ISA Bangalore Section /20160226/Slide No. /20160226/Slide Publishing [email protected] Symp Conferences & Exhibits ISAB/F&B Basics of Modern Industrial Automation Sunil S Shah 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 2 Association: - Senior Member and Secretary (Bangalore Section), International Society of Automation (ISA) /20160226 /Slide No. No. /20160226 /Slide Symp - Senior Member and Ex-Secretary, IEEE Control Systems Society, Bengaluru Chapter ISAB /F&B ISAB Basics ofAgenda Modern Industrial Automation • 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 3 • Developing the Standards Team /20160226 /Slide No. No. /20160226 /Slide Symp ISAB /F&B ISAB BasicsWhat of Modern is a Standard? Industrial Automation . 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 4 S T . Well implemented standards can lead to: A N D A . Productivity improvement R D S /20160226 /Slide No. No. /20160226 /Slide . Savings Symp ISAB /F&B ISAB BasicsWhy of Modern Standards? Industrial Automation 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 5 . Standards promote the reuse of functions . Lead to a quick development and deployment . Standard functions provides less risk, and reduces /20160226 /Slide No. No. /20160226 /Slide the validation and commissioning effort Symp ISAB /F&B ISAB BasicsWhy of Modern Standards? Industrial Contd… Automation 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 6 Reduces Total Cost of Ownership /20160226 /Slide No. No. /20160226 /Slide Symp ISAB /F&B ISAB BasicsStandards of Modern -IndustrialThe Down Automation Side… 7 /20160226 /Slide No. No. /20160226 /Slide Symp ISAB /F&B ISAB BasicsISA of ModernStandards Industrial Automation . 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 8 /20160226 /Slide No. No. /20160226 /Slide Visit Symp www.isa.org/standards ISAB /F&B ISAB BasicsISA of ModernStandards Industrial- Global Automation Presence . Substantial global participation: . 100 committees and subgroups . > 2000 participating organizations . > 3500 participating individuals from over 40 countries . Extensive use of teleconferences and web meetings 9 /20160226 /Slide No. No. /20160226 /Slide Symp ISAB /F&B ISAB BasicsKey of Modern ISA Standards Industrial Automation . 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) 10 . Human-Machine Interface (ISA101) . Commissioning, Loop Checks, & Factory/Site Acceptance (ISA105) . Procedure Automation for Continuous Process Operations (ISA106) /20160226 /Slide No. No. /20160226 /Slide Symp . Intelligent Device Management (ISA108) ISAB /F&B ISAB BasicsISA of ModernStandards Industrial and AutomationGlobal Impact . 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) 11 Full Member /20160226 /Slide No. No. /20160226 /Slide Symp 11 ISAB /F&B ISAB Basics of Modern Industrial Automation ANSI/ISA-88 IEC 61512 Batch Control Systems 12 /20160226 /Slide No. No. /20160226 /Slide Symp ISAB /F&B ISAB BasicsDefining of Modern Batch Industrial Process… Automation Material Material Material Storage 1 Storage 2 Storage 3 Feed Feed Tank 1 Tank 2 CONTINUOUS Minor Additions Mixer Spray Spray Dryer 1 Dryer 2 BATCH 13 Packaging Line 1 /20160226 /Slide No. No. /20160226 /Slide Packaging Line 2 Symp DISCRETE ISAB /F&B ISAB BasicsTraditional of Modern Industrial Batch Operation… Automation Enterprise Operations Vendor-A Planning and Homemade Scheduling Excel Reports Application Paper Copies of SOPs Improvised rd 14 Modifications 3 Party Data Historian /20160226 /Slide No. No. /20160226 /Slide Local Control System Symp Multi Vendor & Varied Technologies ISAB /F&B ISAB BasicsTraditional of Modern Industrial Batch Operation… Automation . No prescribed form of batch operation . Missing common terminology . Difficult to establish requirements . Labour and time intensive . Difficult integrating different vendor offerings 15 BATCH /20160226 /Slide No. No. /20160226 /Slide Symp Everyone had their own standards ISAB /F&B ISAB BasicsNeed of Modern of the Industrial day… Automation . Enterprise wide multi product portfolio . Local raw materials . Varied equipment configuration . Multi vendor control system platforms . Handle obsolescence Multi Plant Enterprise . Agile lab-to-market strategy Integration Integration . Nimble merger of acquisitions 16 Agile Equipment Product /20160226 /Slide No. No. /20160226 /Slide Flexibility Development Symp ISAB /F&B ISAB BasicsIntroducing of Modern Industrial ISA-88.0x Automation … . 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 17 . Widely adopted configuration standards for manufacturing /20160226 /Slide No. No. /20160226 /Slide Symp ISAB /F&B ISAB BasicsISA of -Modern88.0x Nomenclature…Industrial Automation . ANSI/ISA-88.00.01-2010 Batch Control Part 1: Models and Terminology . ANSI/ISA-88.00.02-2001 S T A Batch Control Part 2: Data Structures and Guidelines for N D A R D Languages S . ANSI/ISA-88.00.01-2010 Batch Control Part 3: General and Site Recipe Models and Representation . ANSI/ISA-88.00.04-2006 18 Batch Control Part 4: Batch Production Records . ISA-88.00.05-Draft /20160226 /Slide No. No. /20160226 /Slide Symp Batch Control Part 5: Implementation Models & Terminology for ISAB /F&B ISAB Modular Equipment Control BasicsBenefits of Modern of Industrial ISA-88.0x Automation … . 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 19 /20160226 /Slide No. No. /20160226 /Slide ₹ Symp ISAB /F&B ISAB BasicsBenefits of Modern of Industrial ISA-88.0x Automation … Core Benefit End-User Perspective Vendor Perspective Accommodate more products Structured approach enables Improved with faster changeover time more options with quicker Flexibility with same equipment swapping of options Quicker to New consumer products are New equipment is delivered to Market delivered to market faster end-users faster Improving Modular library with easy replication 20 ROI NPV Reinventing the wheel minimized /20160226 /Slide No. No. /20160226 /Slide Symp ISAB /F&B ISAB BasicsISA of Modern88.0x Philosophy