Isa95 For Food - Muy Bueno

National Symposium on
Automation & Digital Transformation of

Food & Beverage Industry
26th & 27th February 2016
Overviewing the Standards:

ISA 88 and ISA 95
ISAB/F&B Symp/20160226/Slide No. 1
Standards
Certification Sunil S Shah, PhD
Education & Training Secretary, ISA Bangalore Section
Publishing sunilsshah@outlook.com
Conferences & Exhibits
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
ISAB /F&B Symp /20160226 /Slide No. 2
Association:
- Senior Member and Secretary (Bangalore Section), International Society of Automation (ISA)
- Senior Member and Ex-Secretary, IEEE Control Systems Society, Bengaluru Chapter
Agenda
• 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

Basics of Modern
What Industrial Automation
is a Standard?
 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
S
 Well implemented standards can lead to: T
A
N
D
 Productivity improvement A
R
D
S
 Savings
Basics of Modern
Why Industrial Automation
Standards?
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
Basics Standards?
of Modern Contd…
Industrial 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
Reduces Total Cost of Ownership

Basics The Down
of Modern Industrial
Standards- Side…
Automation
Basics of Modern
ISA Industrial Automation
Standards
 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
Visit
www.isa.org/standards
Basics of Modern
ISA Industrial
Standards- Automation
Global 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
Basics of Modern
Key Industrial Automation
ISA Standards
 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)
Basics of Modern
ISA Industrial
Standards and Automation
Global 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)
Full Member
11
ANSI/ISA-88
IEC 61512
Batch Control Systems
Defining
Basics Batch
of Modern Process…
Industrial 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
Packaging Line 1
Packaging Line 2
DISCRETE
Traditional
Basics Batch Operation…
of Modern Industrial Automation
Enterprise Operations
Vendor-A
Planning and Homemade
Scheduling Excel Reports
Application
Paper Copies of
SOPs
Improvised
Modifications 3rd Party Data
Historian
Local Control System

Multi Vendor & Varied Technologies
Traditional
Basics Batch Operation…
 No prescribed form of batch operation

 Missing common terminology
 Difficult to establish requirements
 Labour and time intensive
 Difficult integrating different vendor offerings
BATCH
Everyone had their own standards

Need
Basics of theIndustrial
of Modern day… Automation
 Enterprise wide multi product portfolio

 Local raw materials
 Varied equipment configuration
 Multi vendor control system platforms
 Handle obsolescence
Multi Plant Enterprise
Integration Integration
 Agile lab-to-market strategy
 Nimble merger of acquisitions
Agile
Equipment
Product
Flexibility
Development
Basics of Modern Industrial
Introducing 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
 Widely adopted configuration standards for manufacturing

Basics of ModernNomenclature…
ISA-88.0x Industrial Automation
 ANSI/ISA-88.00.01-2010
Batch Control Part 1: Models and Terminology
 ANSI/ISA-88.00.02-2001
S
T
Batch Control Part 2: Data Structures and Guidelines for A

N
D
A
R
Languages D
S
 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
Basics of Modern
Benefits ofIndustrial
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
₹
Basics of Modern
Benefits ofIndustrial
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

ROI
NPV Reinventing the wheel minimized
Basics of Modern
88.0x Philosophy
Separation of the mind and the body
Recipes Physical Assets

• Minimum set of information that • Manufacturing Plant
uniquely defines the manufacturing • Equipment
requirements of a product • Control System
• Provides production information, • …
formula, procedure, equipment
requirements
Independent Recipe Development

Multiple Products- Same Equipment
Basics of Modern
Recipe Industrial Automation
Model
RECIPES
Header Information Administrative Information
Formula- Process Parameters Raw Materials, quantities,

specifications, …
Procedure including Controls Process, operation strategy,

…
Equipment Requirements MOC, Heating/ Cooling,…

Safety and Regulatory Safety and

Compliance
compliance information,…
Basics of Modern
Recipe Industrial Automation
Types
RECIPES
General Recipe Product specific

process information
Site specific
Site Recipe
Information
Master Recipe Equipment Specific

Information
Batch ID, batch size, operator

Control Recipe and system specific information
Ensures Uniform Product Specification- Enterprise wide

Procedural Model Automation
Procedural Model
Procedure
Procedure
 Command the
Procedure equipment in the
physical model to
perform a process task
Unit Procedure
 Controls to direct the

equipment’s actions to
Operation perform process
oriented tasks
Phase
Procedure Procedure
Procedure  Detailed strategy for

making a batch
 Consists of an ordered
Unit Procedure sequence of unit
procedures
Operation  Ex Bread Making,

Fortified Juice making
Phase
Unit Procedure
Procedure
 Consists of an ordered
Procedure set of operations
 Ensure a continuous
production sequence
within a unit
Unit Procedure  One unit procedure in
a unit at any time
 Unit procedure
Operation completed in a single
unit
 Ex
 Esterify
Phase  Strip
 Neutralize
 Filter
Operation
Procedure
 An ordered set of
Procedure phases that defines a
major processing
sequence
 Takes the material
Unit Procedure being processed from
one state to another
 Usually involved a
Operation chemical or physical
change to the material
 Carried to completion
in a single unit
Phase  Ex Charge, React,
Transfer,…
Phase
Procedure  The smallest element of
procedural control that
Procedure can accomplish a
process-oriented task
 The logic or set of steps
that make up a phase is
Unit Procedure equipment specific, and
not part of the recipe
 Phases for the charge
Operation operation are:
 Initialize
 Add material A at 20L/min

Add material B at 20L/min

 Mix for 20 minutes
Phase
 Usually the link to
equipment
Procedural Model- Automation
Flow Sequence
Procedure
Unit Procedure
Operation
Phase Phase
Phase
Operation
Unit Procedure
Procedural Model- Automation
Conceptual Example
Procedure Examples Illustration
Procedure Make Product A Procedure

Make Product B
Unit Procedure Any set of Operations Unit Procedure 1 Unit Procedure 2
Unit Operation Filtration
Reaction Unit Operation 1 Unit Operation 4
Distillation Unit Operation 2 Unit Operation 3
Solution Preparation
Phase Agitate
Heat
Cool Phase 3
Phase 1 Phase 5 Phase 7
Transfer
Phase 2 Phase 4 Phase 6 Phase 8

Charge
Recycle
Basics of Modern
Physical Industrial Automation
Model
Process Cell
ENTERPRISE-SITE-AREA-…
 A.K.A. Train
Process Cell
 Logical grouping of
equipment required for
production of one or
Unit more batches
 May contain +1 grouping

Equipment Module(s) of equipment
 May contain +1 batch at

a time
Control Module(s)
Basics of Modern
Process Industrial
Cell- ExampleAutomation
Basics of Modern
Model
Unit
ENTERPRISE-SITE-AREA-…  Usually centred on a
major piece of process
Process Cell equipment
 Frequently operates on,

or contains the complete
Unit batch
 Cannot operate on, or

Equipment Module(s) contain more than one
batch at a time
 May operate on, or

Control Module(s) contain, only part of the
complete batch
Basics of Modern
Model
Equipment Module
 A collection of control
Process Cell modules or other
equipment modules
 Can carry out a finite

Unit number of minor
processing activities, i.e.,
phases
Equipment Module(s)  Contains all the

necessary processing
equipment to carry out
these processing
Control Module(s) activities
Basics of Modern
Model
Control Module
 A collection of sensors,
Process Cell actuators, other control
modules, and
associated processing
equipment
Unit
 Acts as a single entity
from a control standpoint
Equipment Module(s)  Is the direct connection

to the process through
its sensor and actuators
Control Module(s)  Procedures do not run

on control modules
Basics of Modern
Unit, Industrial
Equipment, andAutomation
Control Modules
Connecting Automation
Procedural and Physical
Models
Transitioning
Basics from Automation
of Modern Industrial Abstract to Physical…
Extending
Basics S88… Automation
of Modern Industrial
 S88.01 is not only for batch processes

 Extendible for discrete and continuous industries
 Continuous
 Startup - Shutdown
 Grade change
 Discrete
 Product Change
Packaging Line 1
Packaging Line 2
DISCRETE
Summarizing…
 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

References
Basics and Further
of Modern Industrial Reading…
Automation
 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
ANSI/ISA 95/
IEC/ISO 62264
Enterprise - Control System
Integration
Basics
IT/ofOT
Modern Industrial Automation
Defined
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?
Operation Technology (OT), focused on

safe and secure physical value creation and
manufacturing processes
Where is my stuff?
Independent Automation
Evolution of IT/ OT
Business Systems Manufacturing Systems

 Time Horizons  Time Horizons
 Long-term view  Real-time view
 Model detail  Model detail
 Linear route structures  Complex routes with rework paths
 Control emphasis  Control emphasis
 Product cost and overall  Physical movement &
profitability accountability
 Modeling criteria:  Modeling criteria:
 Accounting reference points  Material movement reference
 Has inventory value changed points
significantly? If not, don’t model  Does product stop moving? If not,

separately don’t model separately
 View from the boardroom  View from the work center
Salient
Basics Features…
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
IT/ofOT
Basics Gap…
Years
Months
Handled well by ERP systems
Weeks
Days
Hours Gap of Unmet Needs

Minutes
Seconds
Handled well by
Milli/micro seconds DCS/PLC systems

Basics
IT/ofOT
Convergence
Enterprise /
Business
Operations
I
Manufacturing T
Operations  Harmonized IT and OT Strategies
Management
 Common governance and process models
 Integrated Security Framework
Control  Skilled Man Power Proficient in both IT and
OT
O Converged Platform
Devices
T
Field
Basics of Modern
ISA Industrial
95 Mandate andAutomation
Scope
 Framework for integration projects

 Separation of business processes from manufacturing processes
 Focus on functions, not systems, organizations or individuals
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, …
ENTERPRISE Interface 95.01: Models and Terminology

95.01 & 2 95.02: Object Attributes
SITE 95.03: Activity Models of Manufacturing

Operations Management
95.03
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
AREA AREA AREA
CONTINUOUS BATCH DISCRETE

PRODUCTION PROCESS PRODUCTION
UNIT CELL LINE
Basics of ModernNomenclature…
ISA-95.0x Industrial Automation
 ANSI/ISA-95.00.01-2010
Enterprise-Control System Integration Part 1: Models and Terminology
 ANSI/ISA-95.00.02-2010
S
ECS Integration Part 2: Object Model Attributes T
A
N
D
 ANSI/ISA-95.00.03-2013 A
R
D
S
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
Basics of Modern
ISA Industrial
95.01 and 95.02Automation
Enterprise Information
Plant Production Scheduling,
Operational Management, …
Production
Product Production Production
Capability
Definition Schedule Performance
Information Information crossing
Information (What to (What was
(What is the boundaries
(How to make make and made and
available
a product) use) used)
for use)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, …
Basics of Modern
ISA 95.03 Industrial Automation
Product Production Production Production

definition capability schedule performance
Detailed
production
scheduling
Production
Production
resource
tracking
management
Production
Analysis
dispatching
Product Production
definition data
management collection
Production
execution
Equipment and Process Operational Operational Equipment and Process

Specific Production Rules Commands Responses Specific Data
Level 2 Process Control
Manufacturing Operations Functions

ISA
Basics 95.03…Industrial Automation
of Modern
Maintenance Maintenance Maintenance Maintenance

definition capability Request Response
Detailed
Maintenance
scheduling
Maintenance
Maintenance
resource
tracking
management
Maintenance
Analysis
dispatching
Maintenance Maintenance
definition data
management collection
Maintenance
execution
Level 2 Equipment
Maintenance Functions and so on…

Basics of Modern
95 Manufacturing Architecture
PLM ERP SCM CRM

Enterprise application integration
ANSI/ISA –95 Part 1 and 2 Object model information
Product Product capability Product schedule Product response
definition (what (what and how much (what to make and (what was made
to make) is available to make) use) and used)
ANSI/ISA –95 Part 3 Activity models of Manufacturing Operations

Maintenance
Inventory
Quality
Production Resource Management
Performance Analysis
Data collection
Dispatching
Scheduling
Execution
Definition
Process Control (Field instruments, DCS, PLC, sensors, etc.) Tracking

Basics of Modern
Architecture- ISA 88 & ISA 95
XML
DataBase
Servers Historian
Level 3
Domain Ctrl ERP
Reporter DNS Site Connection
VLAN Information
Switch 2 way Firewall Network
Network Eng Tools
Management Configuration
High Alarm
Diag Tools Domain Ctrl

MES
Low Alarm
VLAN
Comm. Err.
Router DNS
Switch Server Server
Non operations tools

and views into data
Area Operations Information Network
Network Ethernet
Management
Router
HMI Server
Historian HMI
High Alarm
Low Alarm
Comm. Err. Batch Level 2
Viewer Execution
Collection
Gateway OPC
One Instance Per
Process Cell
Automation Network
Network Ethernet
Management
Router
PLC DCS Embedded PC Packaged Equip Level 1
Communication
Basics Language
of Modern Industrial and Models…
Automation
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

<OperationsDefinitionInformation> <PersonnelInformation>
<ID> F2 </ID> <Description> Personnel of SuperToner
<Description> Embedded drum toner cartridges <PublishedDate> 2012-12-08
<HierarchyScope> <PersonnelClass>
<OperationsType>Production <ID>Molder
<PublishedDate> 2012-12-08 <Description> Molder
<OperationsDefinition> <PersonnelClassProperty>
<ID> TN6600 <ID> MolderQualif
<Version> V0 <Description> Molder Qualification test
<Description> For Brother HL series <Value> 1 or 2

<WorkDefinition> TN6600 <QualificationTestSpecificationID> TestLevel
<OperationsSegment> <PersonID>
<ID> S1 <Person>
<Description> Make Enclosure <ID> P1
< OperationsSegment > <PersonName> Albert
<ID> S2 <PersonnelClassID> Molder
<Description> Make Ink <PersonProperty>
<ID> MolderQualif
<Value> 1
Example B2MML Models <TestResult> Pass
Conclusion
• 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
Path
Basics 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!
References
Basics and Further
of Modern Industrial Reading…
Automation
 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

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National Symposium on

Automation & Digital Transformation of

Overviewing the Standards:

- Ph. D. (Systems and Control Engineering), IIT- Bombay

Currently working with:

• ISA’s Standards for Automation

• Overview and need for implementation

• ISA 88- Batch Control Systems

• ISA 95 - Enterprise - Control System Integration

Developing the Standards Team

 A “Standard” is an authoritative document, developed in accordance with a

Reduce Development Cost and Time-To-Market

 Lead to a quick development and deployment

Reduces Total Cost of Ownership

 Developed in a collaborative and consensus-based process with

 Substantial global participation:

 Process Instrumentation Symbols & Diagrams (ISA5)

 Commissioning, Loop Checks, & Factory/Site Acceptance (ISA105)

 Several original ISA Standards are the basis of major International

Material Material Material

Mixer Spray Spray

Local Control System

 No prescribed form of batch operation

Everyone had their own standards

 Enterprise wide multi product portfolio

 General guidelines developed specifically for batch industries:

 Widely adopted configuration standards for manufacturing

Batch Control Part 2: Data Structures and Guidelines for A

Batch Control Part 4: Batch Production Records

 Reduce cost of automating systems

Core Benefit End-User Perspective Vendor Perspective

Accommodate more products Structured approach enables

Quicker to New consumer products are New equipment is delivered to

Improving Modular library with easy replication

Separation of the mind and the body

Recipes Physical Assets

Independent Recipe Development

Header Information Administrative Information

Formula- Process Parameters Raw Materials, quantities,

Procedure including Controls Process, operation strategy,

Equipment Requirements MOC, Heating/ Cooling,…

Safety and Regulatory Safety and

General Recipe Product specific

Master Recipe Equipment Specific

Batch ID, batch size, operator

Ensures Uniform Product Specification- Enterprise wide

 Controls to direct the

Procedure  Detailed strategy for

Operation  Ex Bread Making,

Add material B at 20L/min

Procedure Examples Illustration

Procedure Make Product A Procedure

Phase 2 Phase 4 Phase 6 Phase 8

 May contain +1 grouping

 May contain +1 batch at

 Frequently operates on,

 Cannot operate on, or

 May operate on, or

 Can carry out a finite

Equipment Module(s)  Contains all the

Equipment Module(s)  Is the direct connection

Control Module(s)  Procedures do not run

 S88.01 is not only for batch processes