.
This work is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License. Attribution: Jean Vieille
Work: ISA8895 Implementation Section: Structure Chapter: Physical Asset
Language: English Version: V3 - 05/2011
Jean Vieille
www.syntropicfactory.info j.vieille@syntropicfactory.info
Research community www.controlchainmanagement.org Consulting group www.controlchaingroup.com
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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CC functional domains
ISA88 ISA95
2_10_ISA8895_Structure_PhysicalAsset
ISA88 + ISA95 TOGAF ITIL
Product Asset Management Inventory Asset Management Physical Asset Management Human Asset Management
3
IT Asset Management
Information Elements
Cliquez pour ajouter Stdtableau un Domain sur l'icôneModel Information elements Product Asset Inventory Asset Physical Asset Human Asset Equipment Control Physical Process Control Physical Process Mngt Operation Process Mngt Product Product Material Physical Equipment Personnel Procedural Procedural Segment Operation Activity ISA88 ISA95 ISA95 ISA88 ISA95 ISA95 ISA88 ISA88 ISA95 ISA95 Product Hierarchy Product Definition Material Resources Equipment Hierarchy Equipment Resources Personnel Hierarchy Personnel Resources Functional Hierarchy Equipment Procedural Elements Physical Processes / Procedural Elements Physical Process Transform Components Segments Operation Processes Activities / Tasks 4
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Objectives of the physical asset modeling
Provide to the system a depiction of the actual composition of the facility Ø We build a consistent image of the world from our social and cultural environment, our senses, our experiences Ø The quite limited perception and computing capabilities of an information system imposes to provide it a structured, preformatted view of its physical environment. This view may be Ø Rigid = corresponding to a typical assembly of its constituting equipment Ø Dynamic = linked to the functional objective of the considered instant § "meccano" view of an entirely dismantled facility, assembled at need to execute a particular "process oriented" functionality
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5
Who's / What's concerned?
PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau Typ.IT app
Customer order processing Production planning & scheduling Production control Material and energy control Procurement Quality assurance Product inventory control Product cost accounting Product shipping administration Maintenance management Research & development Engineering
X X
X
X
R X X 2_10_ISA8895_Structure_PhysicalAsset
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Models overview
The Physical asset models identify the enterprise physical aspects Enterprise physical nature is described in a hierarchical manner 2 models address physical asset modelling Ø ISA88/95 Physical hierarchy model Ø ISA95 Equipment Model By physical, ISA- and ISA-95 refer to 2 different concepts Ø Topology as geographical location such as a workshop, a plant (as logical concepts for designating a place or an organizational entity) Ø "Equipment entities" that can be a machine, a facility (as a collection of equipment) Still quite fuzzy in ISA-95
ISA-88 made some progress by distinguising a physical model for the topology and an Equipment entity model (that associate "control" to make these entity "processing enabled"
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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ISA88/95 Physical Hierarchy Model
This model is global, covering the industrial part of the enterprise Ø Describes the general organization of physical assets hierarchically Ø Matches one aspect of the enterprise decisional structure Ø The ISA88 model was initially "Batch Oriented" Ø ISA95 extends it to cover the whole production system Ø CCM extends it to cover the financial aspects This model is not very constraining, Ø The upper levels describe the logical organization of the enterprise, to match any organisational structures not to guide organization Ø Lower levels are more prescriptive and must be respected, but they can be (mostly) omitted or extended Both ISA88 and ISA95 are critically bound to this model Ø The information system is primarily structured around this model Ø The lower levels starting at the Work Center (Process Cell) level are specifically relevant for the ISA88 standard
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ISA88 Physical Model
7 levels are defined : Ø Organizational Upper levels § Entreprise, Site, Area
Ø
ENTERPRISE SITE AREA
Technical Lower levels § Process Cell, Unit, Equipment Module, Control Module § Address flexibility Control Modules (Lowest level) correspond to the actual equipment. § Other level are compositions of lower levels
PROCESS CELL
UNIT
Ø
EQUIPMENT MODULE CONTROL MODULE
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ISA95 extended physical model (Actual Facility layout)
ENTERPRISE SITE AREA WORK CENTER PROCESS CELL PRODUCTION UNIT PRODUCTION LINE STORAGE ZONE BATCH PROCESS (ISA88) CONTINUOUS PROCESS DISCRETE PROCESS WAREHOUSE
WORK UNIT
UNIT
UNIT
WORK CELL
STORAGE UNIT
EQUIPMENT MODULE CONTROL MODULE
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Upper physical level modeling
ENTERPRISE SITE
Enterprise, Site, Area, Process cell Ø No technical constraints Ø Based on organizational considerations Ø A Process cell corresponds at least to the scope of the Recipes or Process Orders / Production Requests
AREA
WORK CENTER
UNIT EQUIPMENT MODULE CONTROL MODULE
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Example of upper level modeling
LFA & Co
Enterprise Sites
Lyon
Frankfurt
Atlanta
Area
Production
Storage / Shipment
Utilities
Work Center
Building A
Building B
Finihed products
Raw material
Control & Packaging
Steam generatio n
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Example of upper level modeling
Work Centers
Storage zone
Storage zone
Raw material
Finish products
Process Cell
Process Cell
Production Line
Preparation Areas
Production 1
Process Cell
Packaging
Production 2
N2 Steam Water Power Gazeous effluents Condensats Waste water Heat
Process Cell
Utilities
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Extended Physical & Decisional hierarchy
Shareholders Company Enterprise Site Area Work Center Work Unit Equipment Module Control Module
Financial management
Planning
Scheduling
Operations
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Combining Production / Industrial Information Systems
Production System as a physical entity is the Framework (ISA88) Ø Physical hierarchy corresponds to Decision hierarchy Ø Any Information service or process is embedded within a specific Equipment entity, at any level § IIS doesn't exist by itself in the vacuum... Ø Information system is a supporting system, not a leading entity Any part of the production system might need IIS support Ø Or can live without it Equipment elements are equipment entities when associated with information processing features
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Equipment Entity embeds Equipment & Information
Equipment Element
FT
Information Processing
Business Process Management Physical Process Management Physical Process Control Equipment Control
Equipment Entity
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Equipment Entity Example 1
Command Run pump at rate X Status Pump running At rate X
C E E E
Physical Equipment FT Equipment Entity E
E
E
Information Processing
Basic Procedural Coordination
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Equipment Entity Example 2
Command Request Process capabilities Status / Response Processing Capabilities Catalog
C E E E
Physical Equipment Equipment Entity E
E
E
Information Processing Process segment Definition lookup
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Equipment Entity Example 3
Command Optimize Orders' Scheduling Status / Response Optimized Orders' schedule
C E E E
Physical Equipment Equipment Entity E
E
E
Information Processing Schedule Orders
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Information & Equipement
The physical model is the primary framework of information system Ø All functional elements, resources, documents rest on this model Ø No information can be defined outside the context of an equipment entity its physical scope
Ent. Basic control Coordination control Procedural control (Equipment) Procedural control (Recipes) Product definition Objects classes X X X X X X X X X X X X Site Area Pcell Unit EM CM X X
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ISA88 definition for lower physical hierarchy model
Process cell
Ø
A logical grouping of equipment required for production of one or more batches
Units
Ø
A collection of related control modules and equipment modules that can carry out one or more processing activities
Equipment modules
Ø
A functional group of equipment and/or control modules that can carry out a finite number of specific processing activities
Control modules
Ø
A regulating device, a state oriented device, or a combination of both that is operated as a single device
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Role of the Work Center
PROCESS CELL
UNIT EQUIPMENT MODULE
A work centre needs to encompass all the needed Work Units to CONTROL MODULE make a defined product Ø The scope of a Production Request Essentially an organizational level Ø Activity, topology Ø No hard constraints Ø Might help for facilities classification § Ability to replicate a Work Center template
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Work Center for Batch: Process Cell
PROCESS CELL
UNIT EQUIPMENT MODULE
Definition CONTROL MODULE Ø A logical grouping of equipment (Units) required for the production of one or more batches Properties Ø May contain more than one grouping of equipment needed to make a batch § "Train" Ø The equipment actually used for the batch is referred to as the path Ø May contain more than one batch at a time (possibly several independent production order being processed simultaneously)
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Work Center for Batch: Process Cell
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Rules Ø Static geographical structure, defined at the engineering time Ø The batch maintains its integrity Ø The scope of a recipe or production request Ø The action scope of an operator Ø Bounded by input / output material storage (raw matierial / semi-finished products / finished products Examples Ø Building B6 Ø Finishing workshop
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Process Cell Structures
Single-Path "Raw" Material Storage
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Unit 1
Unit 2
"Finished" Material Storage
Multiple-Path "Raw" Material Storage "Finished" Material Storage
Unit 1
Unit 2
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NetworkedPath Process Cell Structure
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Unit 1 "Raw" Material Storage
Unit 2
Unit 3
Unit 4
"Finished" Material Storage
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Example of a 2Unit Process Cell
M
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Ingredient B Premixer
F1
Ingredient A
M
PIC
PIC
Reactor
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Example of a 4Unit Process Cell
#1 #2 #3 #4
FQIC FQIC FQIC FQIC
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
V11 V3
PIC
V11
Vent
V5 V12
N2 Cond V13 C-H2O V14
TIC
V1
PIC
Vent
V1
V12
N2
Premix1
Steam V15 H2O-R V16 Catalyst
Rxtr 1
V8
WI
FSL
V10
V6 V11
Vent
V7
V11 V1
PIC
VENT
V1 V5
Cond V13 C-H2O V14
V1
V2
V12
N2
V4
PIC
V12
N2 Catalyst
Premix2
LI
TIC
Steam V15 H2O-R V16
FSL
Rxtr 2
LI
V8
V10
V6
V7
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Role of Work Unit
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
The « Central » allocation level Ø A relatively autonomous entity for planning/scheduling purpose Ø Batch Processes,
§
A strict batch breakdown : Unit contains one single batch Work Cell is similar to Unit
Ø Ø
Discrete Processes,
§
Warehouses and storage :
Allocation is not confined to a specific level § Storage Units should be recursive not in the standard
§
Ø
Continuous processes
A main equipment, Sub-part of a Production Unit § Can segregate "virtual batches" in a continuous flow
§
Provides and execute product independent process services Ø Implemented by Equipment Procedural Element (EPE) (possibly inherited from embedded Equipment Modules)
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Work Units for Batch: Unit
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Definition Ø Is a collection of Control Modules and Equiment Modules Ø Performs one or more significant processing activities, as product independent Equipment procedural Elements
Combining material, Performing a reaction
Role Ø Basis of procedural control Properties Ø Cannot contain another unit Ø A unit cannot operate on more than one batch of material at any given time
§
Although a unit is allowed to operate on a portion of a single batch Although a batch is allowed to be completed in a single unit
Permanently attached parts to a unit Temporarily attached parts to a unit Totally separate from any unit
Ø Ø
Making a batch often requires multiple units
§
§ § §
May contain a flexible amount of control modules and/or equipment modules
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Work Units for Batch: Unit
PROCESS CELL
UNIT EQUIPMENT MODULE
Rules CONTROL MODULE Ø Essentially dynamic structure, : identified at the engineering time, but physical scope depends on the context Ø Centered around a major piece of equipment Ø Autonomy: May operate independently of other units Examples Ø Reactor, Mixer Ø Washing machine Ø Oven Ø Press
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Example of a Unit in a Process Cell
#1 #2 #3 #4
FQIC FQIC FQIC FQIC
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
V11 V3
PIC
V11
Vent
V5 V12
N2 Cond V13 C-H2O V14
TIC
V1
PIC
Vent
V1
V12
N2
Premix1
Steam V15 H2O-R V16 Catalyst
Rxtr 1
V8
WI
FSL
V10
V6 V11
Vent
V7
V11 V1
PIC
VENT
V1 V5
Cond V13 C-H2O V14
V1
V2
V12
N2
V4
PIC
V12
N2 Catalyst
Premix2
LI
TIC
Steam V15 H2O-R V16
FSL
Rxtr 2
LI
V8
V10
V6
V7
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Roles of Equipment modules
PROCESS CELL
UNIT EQUIPMENT MODULE
2 roles CONTROL MODULE Ø Breakdown of a Work unit § May be used to limit the scope of an EPE § Units building blocks Ø Shared equipment having autonomous process capabilities that can be used with several units § Non-exclusive: distribution of utilities (air, steam, N2, water) § Exclusive: Charging device, transfer lines Not a mandatory element
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Equipment Modules
PROCESS CELL
UNIT EQUIPMENT MODULE
Definition CONTROL MODULE Ø A collection of equipment and/or control modules that can carry out a finite number of specific processing activities § Implements Equipment Procedural Elements by commanding control modules or lower level equipment modules An Equipment module without EPEs is a Control Module An equipment module is technically similar to a unit Properties Ø May contain other EMs Ø Dependent: May be part of a single Work Unit or another Equipment Module for its exclusive usage Ø Autonomous: May be part of a Work Center § can be temporarily "attached" to a Work Unit as a common resource § Can be used in conjunction with several Work Units or other Equipment 2_10_ISA8895_Structure_PhysicalAsset Modules, or even running independently 39
Equipment Modules
PROCESS CELL
UNIT EQUIPMENT MODULE
Rules CONTROL MODULE Ø Essentially dynamic structure, : identified at the engineering time, but physical scope depends on the context Ø Inherited from the Work Unit (part of it) Ø Usually centered around a piece of process equipment such as a process heater or weight tank Examples Ø Weight tank used by a single unit Ø A filter that is only used by a single unit Ø Weight tank shared by multiple units, but only usable by a single unit at a time (an exclusive use resource) Ø An ingredient supply system that shared by multiple units and can be used by many simultaneously (a shared-use resource)
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Equipment Module Implementations
PROCESS CELL
UNIT EQUIPMENT MODULE
Option 1: No equipment modules CONTROL Ø Any EPE of a Unit can allocate (dynamically) any control moduleMODULE within the Work Center / Process Cell Ø A single EPE can execute a transfer between 2 units Option 2: Units without EPEs inheriting EPEs from EMs Ø Typically for embedded equipment modules Option 3: Units with EPEs commanding EPEs from EMs Ø Typically for shared equipment modules
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Example of an EM in a Process Cell
#1 #2 #3 #4
FQIC FQIC FQIC FQIC
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
V11 V3
PIC
V11
Vent
V5 V12
N2 Cond V13 C-H2O V14
TIC
V1
PIC
Vent
V1
V12
N2
Premix1
Steam V15 H2O-R V16 Catalyst
Rxtr 1
V8
WI
FSL
V10
V6 V11
Vent
V7
V11 V1
PIC
VENT
V1 V5
Cond V13 C-H2O V14
V1
V2
V12
N2
V4
PIC
V12
N2 Catalyst
Premix2
LI
TIC
Steam V15 H2O-R V16
FSL
Rxtr 2
LI
V8
V10
V6
V7
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Role of Control modules
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
The lowest, mandatory level in the Physical Hierarchy Ø The only actual equipment entity: all upper level are organizational views with larger or smaller focus Ø The only acting entity (move actuators, run motors) Mechanical engineering consistency Ø CM breakdown corresponds to generic equipment entities Simplification of control: Ø Execute elementary equipment services invoked by EPEs Functional leveling of technological variants Ø Same interface and capabilities, specific control Prevent conflicting equipment usage Ø EPEs can explicitly allocate control modules providing an inherent interlock between conflicting functionalities
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Control Modules
PROCESS CELL
UNIT EQUIPMENT MODULE
Definition CONTROL Ø A piece of processing equipment with associated collection of sensors, MODULE actuators, and other control modules Properties Ø Every piece of equipment is controlled by one (and only one) control module Ø The lowest, mandatory physical level
§
Any part of the actual equipmeNT is part of one, and only one control module
Ø
Provides the only connection to the process
Control modules can content instrumentation § But Control Modules ARE NOT instruments (see Device Modules)
§
Acts as a single entity from a control standpoint Ø Do not contain / cannot execute procedural elements Ø The only real physical entity
Ø
§
All upper levels are more or less focused orgainsational views
Ø
Unknown by the Recipe
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Control modules and flow analysis
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Rules Ø None in ISA88 WBF Flow analysis concepts: Ø Physical flows get through tangible equipment entities (Control modules) Ø A proper breakdown allows to control flows regardless the functional intent. Control modules control ... flows Ø Breakdown rules for control modules § CMs are elementary flow sections § Extension of Delta Nodes / Astrid methodologies Ø The resulting breakdown highlights consistent generic equipment entities
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Flow Analysis rules for breaking down a facility into CMs
PROCESS CELL
UNIT
Identify all flow breaking devices Ø Shut-off valves Ø Doors Ø Traffic lights Ø Removable pipe / Blind flanges Ø ... Control modules are bounded by these devices Several flows may run through a given equipment Ø This equipment may be split into several control modules § Liquid and gaseous part of a tank
EQUIPMENT MODULE CONTROL MODULE
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Control Module examples
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Recirc XV
Commands Circulate To Process Stop
States Circulating Sending Stopped
Pump Process XV
Circulate Start Pompe Stop Pompe Open Recirc XV Close Recirc XV Open Process XV Close Process XV 1 0 1 0 0 1
ToProcess 1 0 0 1 1 0
Stop 0 1 1 0 0 1
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Control Module examples
CM4
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
CM2 PID PID CM1 PID HIC HIC CM3
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Control Module examples
Raw_Matl_Req as enum: 0 None 1 Cream 2 Milk 3 Corn Syrup 4 Water
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Material Selection Control Module
Define Discharge_Flow_SP as 0 60 GPM Define Recirc_Flow_SP as 0 60 GPM Define CIP_Flow_SP as 0 140 GPM
FT
Pump Control Module
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Device Module
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE DEVICE MODULE
Sensors and actuators are not defined in the standard Sensors and actuators can be considered as: Ø First level control modules § Possible because of the recursive nature of the control module § Common practice Ø Device modules, an additional element § The standard allows extensions § Allows to preserve the true nature of the Control Module as an abstraction layer: a control module does not necessarily hold instruments... § Proposed in ISA88 part 5
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Flow Analysis: Device modules attachment to CMs
UNIT EQUIPMENT MODULE
PROCESS CELL
DM are attached to the supporting CM CONTROL MODULE Flow breaking devices are between 2 or more CMs. They may be DEVICE considered as: MODULE Ø Independent CMs : More flexible, WBF current work proposed approach (Directing nodes) Ø Device modules attached to one of the adjacent CM (Current ASTRID or DELTA NODE methods) § Rule 1: A flow breaking device is attached to the upstream CM § Rule 2: A flow breaking device is attached to the user of a shared flow (utility for example) § Rule 3: The second rule prevails on the first one
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Device safety and control
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE DEVICE MODULE
Operator (HMI)
Owning CM (automatic control) Manual control Automatic control
Adjacent CM (Flow control)
Interlocking task Product and equipment protection Safety task Personnel and environment protection (external safety system)
Flow interlocks Flow integrity Content compatibility Capacity constraints
Acting device
Commands Flow Information Interlock
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A Motor Device Module
PROCESS CELL
UNIT EQUIPMENT MODULE
Commands
Status
CONTROL MODULE DEVICE MODULE
Start Stop
Run
Fail
Starter Coil
Single-Speed Motor Module
Motor Rotation Sensor
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Equipment Modules vs. Control Modules
Equipment Module Can contain an EPE Must interface to the process via a control module
Control Module Cannot contain an EPE Directly interfaces to the process via Device Modules
Commonly used as stand alone and shared equipment by other Units or EMs Commonly used to deal with transfers Can contain other EMs and CMs May have a direct link to the recipe procedure via the EPE Can contain other CMS, not EMs Has no direct link to the recipe procedure
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Control modules and Equipment modules : Unit ownership
By design, CMs and EMs Ø can be attached permanently to a unit Ø Can be independent of any unit, part of the whole Process Cell / Work Center § CM et EM can be temporarily attached to any unit to provide the needed Equipment (CMs) or Process (Ems) services needed to achieve its processing function § CM and EM can also be commanded independently
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Example of ISA88 physical hierarchy
Process Cell Unit EM EM EM CM CM CM CM CM CM CM CM
59
Unit
EM
2_10_ISA8895_Structure_PhysicalAsset
Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1 EM3 Unit2
EM1
EM2
CM1 CM2 CM3 CM4 CM5 CM6 CM7 CM8 CM9
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CM10
60
Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1 EM3 Unit2
CM1 CM2 CM3 CM4 CM5 CM6 CM7 CM8 CM9
CM10
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Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1
EPE 1 (EM1) EPE 4 EPE 2 (EM2)
EM3
Unit2
EM3'
CM1
CM2
CM3
EPE 3
CM4
DM1 DM2 DM3 DM4 DM5 DM6 DM7 DM8 DM9 DM10
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Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1
Phase X Phase Y
EM3
Unit2
EM1
No EM: EPEs Dynamically allocates The needed CMs
EM2
EM3'
CM1
CM2
CM3
CM4
DM1 DM2 DM3 DM4 DM5 DM6 DM7 DM8 DM9 DM10
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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ISA95 Hierarchy scope
ISA-95 attaches "Hierarchy scope" to all information objects Ø Resources, process segment, product definition, Ø Previously named "Location" Ø "Hierarchy scope is an attribute used in many other objects. The hierarchy scope attribute identifies where the exchanged information fits within the role based equipment hierarchy. It defines the scope of the exchanged information, such as which site or which area the information is relevant for. The hierarchy scope identifies the associated instance in the role based While ISA-88 attaches "control" to the physical hierarchy, ISA-95 takes the other way around: it attaches a physical hierarchy information to information objects
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Example
ISA-88
ISA-95
Unit
(Equipment Entity)
Process Segment
(Information object)
Work Center
(Hierarchy scope)
Procedural
Element
(Control)
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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ISA95 equipment models
These models identify the physical assets Ø by their role in the facility § The function performed by a machine at the explicit location § Not necessarily always the same, can be replaced without affecting the role Ø By their asset / inventory aspect § The unique machine identifiable by its serial number § Only for "maintainable" equipments, not all physical organisational entities § Similar to Inventory asset Features Ø Implements the physical hierarchy model Ø Defines properties of physical elements Ø Allows Class based definition
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ISA95 Equipment Resource Model: Role based < May be made up of Equipment
0..n
Equipment Class
Has properties of >
0..n 0..n 0..n Is tested by an > 0..n < Defined by 0..n Is tested by an > 0..n
Equipment
Has values for >
Equipment Capability Test Specification
0..n Is tested by an > Defines a procedure for obtaining an > 0..n Maps to 0..n 0..n < Records the execution of
Equipment Capability Test Result
Equipment Class Property
0..n
0..n
Equipment Property
0..n < may contain nested
0..n < may contain nested
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ISA95 Equipment Resource Model: Physical Asset
> May be made up of 0..n > is an instance of
Physical Asset
Has values for >
1..1 0..n Is tested by an > 0..n
0..n 0..n Is tested by an > 0..n
Physical Asset Class
Has properties of >
Physical Asset Capability Test Result
< records the testing of Defines a procedure for obtaining an < 0..n
Physical Asset Capability Test Specification
0..n 0..n Is tested by an < Maps to 0..n
0..n
0..n
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
2_10_ISA8895_Structure_PhysicalAsset
70
ISA95 global Equipment Resource Model
< May be made up of 0..n
> May be made up of 0..n > Implemented by
Equipment Class
Has properties of >
0..n 0..n < Defined by
Equipment
0..1
0..1
< records use and removal of asset to implement equipment
Physical Asset
> is an instance of 0..n
1..1
Physical Asset Class
Has properties of >
Equipment Asset Mapping
0..n 0..n 0..n 0..n Maps to
Equipment Class Property
Maps to
Equipment Property
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
0..n < may contain nested
0..n < may contain nested
2_10_ISA8895_Structure_PhysicalAsset
71
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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72
Physical Asset Models elements (common RBE/PhA)
Properties (Definition) Ø "object denoting an implementation specific characteristic of an entity" Ø Characterization entities for Equipment Classes/Equipment
§
Ex: Capacity, Max Pressure, NominalSpeed, NbOfBagsPerMintute ...
Some properties can match the Equipment constraints defined in Process Element (Product Asset, Process Definition) Property (Value) Ø Valuation of the property as a requirement (for Equipment Class/Equipment) Ø Valuation of a property from actual assessment (For Physical Asset)
Ø
§
Ex: NbOfBagsPerMintute = 1643
Test specification Ø "identify a test for one or more equipment properties" Test Result Ø "Results from a equipment capability test for a specific piece of equipment / physical asset" 2_10_ISA8895_Structure_PhysicalAsset 73
Physical Asset Models elements (specific RBE/PhA)
Role based Equipment Ø Equipment § "A representation of the elements of the equipment hierarchy model" Ø Equipment Class § "a grouping of role based equipment with similar characteristics for purposes of scheduling and planning" Physical Asset Ø Physical Asset § represents information about a physical piece of equipment Ø Physical Asset Class § "grouping of physical assets with similar characteristics for purposes of repair and replacement"
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74
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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75
Exercise (1) : Unit, Equipment module or Control module?
Is a Unit Reactor Fluid Bed Dryer Pasteurizer Pump Multi pump set Ingredient storage tank Washing machine Kitchen blender (& cook) Refrigerator Dishwasher Iron Bred cooker Isn't a Unit (EM or CM)
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76
Exercise (2) Excel spreadsheet
(2.1) Physical Hierarchy Ø Give possible names and examples for the physical hierarchy level
2_10_ISA8895_Structure_PhysicalAsset
77
#1 #2
FQIC FQIC
#3 #4
FQIC
FQIC
V11
Vent
V11 V1 V5
N2
PIC
Vent
V3
PIC
V12
N2
V1 V12
Cond V13 C-H2O V14
Premix1
TIC
Rxtr 1
Steam V15 H2O-R V16 Catalyst
V8
WI
FSL
V10
V6 V11
V7
V11 V1
PIC
VENT
V1
V1 V2 V4 V5
Cond V13 C-H2O V14
PIC
Vent
V12
N2
V12
N2
Catalyst
TIC
Premix2
LI
Rxtr 2
LI
V10 V8
Steam V15 H2O-R V16
2_10_ISA8895_Structure_PhysicalAsset
FSL
V6
V7
78
Exercise (3) : Excel spreadsheet Physical modeling
(1.1) Properties Ø Identify some typical equipment properties: name, range, (1.2) Equipment Test Specification Ø Identify typical Test Specifications (2.2) Equipment classes Ø Identify certain Equipment roles, For different level: WU, EM, CM, DM (2.3) Equipment Ø identify
§ § §
Enterprise, Site, Area, Work Centers/Process Cells Work Units / Units, Device Modules, Flow breaking devices Control modules: Within the process cell, Peripheral facilities: storage, utilities
(3.1) Physical Asset Hierarchy Ø Identify a possible maintenance oriented physical hierarchy (3.2) Physical Asset Class Ø Identify certain machines types (3.3) Physical Asset Ø Identify certain machines
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79
Thank You !
2_10_ISA8895_Structure_PhysicalAsset
80
Work: ISA8895 Implementation Section: Structure Chapter: Physical Asset
Language: English Version: V3 - 05/2011
Jean Vieille
www.syntropicfactory.info j.vieille@syntropicfactory.info
Research community www.controlchainmanagement.org Consulting group www.controlchaingroup.com
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
2_10_ISA8895_Structure_PhysicalAsset
2
CC functional domains
ISA88 ISA95
2_10_ISA8895_Structure_PhysicalAsset
ISA88 + ISA95 TOGAF ITIL
Product Asset Management Inventory Asset Management Physical Asset Management Human Asset Management
3
IT Asset Management
Information Elements
Cliquez pour ajouter Stdtableau un Domain sur l'icôneModel Information elements Product Asset Inventory Asset Physical Asset Human Asset Equipment Control Physical Process Control Physical Process Mngt Operation Process Mngt Product Product Material Physical Equipment Personnel Procedural Procedural Segment Operation Activity ISA88 ISA95 ISA95 ISA88 ISA95 ISA95 ISA88 ISA88 ISA95 ISA95 Product Hierarchy Product Definition Material Resources Equipment Hierarchy Equipment Resources Personnel Hierarchy Personnel Resources Functional Hierarchy Equipment Procedural Elements Physical Processes / Procedural Elements Physical Process Transform Components Segments Operation Processes Activities / Tasks 4
2_10_ISA8895_Structure_PhysicalAsset
Objectives of the physical asset modeling
Provide to the system a depiction of the actual composition of the facility Ø We build a consistent image of the world from our social and cultural environment, our senses, our experiences Ø The quite limited perception and computing capabilities of an information system imposes to provide it a structured, preformatted view of its physical environment. This view may be Ø Rigid = corresponding to a typical assembly of its constituting equipment Ø Dynamic = linked to the functional objective of the considered instant § "meccano" view of an entirely dismantled facility, assembled at need to execute a particular "process oriented" functionality
2_10_ISA8895_Structure_PhysicalAsset
5
Who's / What's concerned?
PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau Typ.IT app
Customer order processing Production planning & scheduling Production control Material and energy control Procurement Quality assurance Product inventory control Product cost accounting Product shipping administration Maintenance management Research & development Engineering
X X
X
X
R X X 2_10_ISA8895_Structure_PhysicalAsset
6
Models overview
The Physical asset models identify the enterprise physical aspects Enterprise physical nature is described in a hierarchical manner 2 models address physical asset modelling Ø ISA88/95 Physical hierarchy model Ø ISA95 Equipment Model By physical, ISA- and ISA-95 refer to 2 different concepts Ø Topology as geographical location such as a workshop, a plant (as logical concepts for designating a place or an organizational entity) Ø "Equipment entities" that can be a machine, a facility (as a collection of equipment) Still quite fuzzy in ISA-95
ISA-88 made some progress by distinguising a physical model for the topology and an Equipment entity model (that associate "control" to make these entity "processing enabled"
2_10_ISA8895_Structure_PhysicalAsset 7
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
2_10_ISA8895_Structure_PhysicalAsset
8
ISA88/95 Physical Hierarchy Model
This model is global, covering the industrial part of the enterprise Ø Describes the general organization of physical assets hierarchically Ø Matches one aspect of the enterprise decisional structure Ø The ISA88 model was initially "Batch Oriented" Ø ISA95 extends it to cover the whole production system Ø CCM extends it to cover the financial aspects This model is not very constraining, Ø The upper levels describe the logical organization of the enterprise, to match any organisational structures not to guide organization Ø Lower levels are more prescriptive and must be respected, but they can be (mostly) omitted or extended Both ISA88 and ISA95 are critically bound to this model Ø The information system is primarily structured around this model Ø The lower levels starting at the Work Center (Process Cell) level are specifically relevant for the ISA88 standard
2_10_ISA8895_Structure_PhysicalAsset 9
ISA88 Physical Model
7 levels are defined : Ø Organizational Upper levels § Entreprise, Site, Area
Ø
ENTERPRISE SITE AREA
Technical Lower levels § Process Cell, Unit, Equipment Module, Control Module § Address flexibility Control Modules (Lowest level) correspond to the actual equipment. § Other level are compositions of lower levels
PROCESS CELL
UNIT
Ø
EQUIPMENT MODULE CONTROL MODULE
2_10_ISA8895_Structure_PhysicalAsset
10
ISA95 extended physical model (Actual Facility layout)
ENTERPRISE SITE AREA WORK CENTER PROCESS CELL PRODUCTION UNIT PRODUCTION LINE STORAGE ZONE BATCH PROCESS (ISA88) CONTINUOUS PROCESS DISCRETE PROCESS WAREHOUSE
WORK UNIT
UNIT
UNIT
WORK CELL
STORAGE UNIT
EQUIPMENT MODULE CONTROL MODULE
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11
Upper physical level modeling
ENTERPRISE SITE
Enterprise, Site, Area, Process cell Ø No technical constraints Ø Based on organizational considerations Ø A Process cell corresponds at least to the scope of the Recipes or Process Orders / Production Requests
AREA
WORK CENTER
UNIT EQUIPMENT MODULE CONTROL MODULE
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12
Example of upper level modeling
LFA & Co
Enterprise Sites
Lyon
Frankfurt
Atlanta
Area
Production
Storage / Shipment
Utilities
Work Center
Building A
Building B
Finihed products
Raw material
Control & Packaging
Steam generatio n
2_10_ISA8895_Structure_PhysicalAsset
13
Example of upper level modeling
Work Centers
Storage zone
Storage zone
Raw material
Finish products
Process Cell
Process Cell
Production Line
Preparation Areas
Production 1
Process Cell
Packaging
Production 2
N2 Steam Water Power Gazeous effluents Condensats Waste water Heat
Process Cell
Utilities
2_10_ISA8895_Structure_PhysicalAsset
14
Extended Physical & Decisional hierarchy
Shareholders Company Enterprise Site Area Work Center Work Unit Equipment Module Control Module
Financial management
Planning
Scheduling
Operations
2_10_ISA8895_Structure_PhysicalAsset
15
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
2_10_ISA8895_Structure_PhysicalAsset
16
Combining Production / Industrial Information Systems
Production System as a physical entity is the Framework (ISA88) Ø Physical hierarchy corresponds to Decision hierarchy Ø Any Information service or process is embedded within a specific Equipment entity, at any level § IIS doesn't exist by itself in the vacuum... Ø Information system is a supporting system, not a leading entity Any part of the production system might need IIS support Ø Or can live without it Equipment elements are equipment entities when associated with information processing features
2_10_ISA8895_Structure_PhysicalAsset
17
Equipment Entity embeds Equipment & Information
Equipment Element
FT
Information Processing
Business Process Management Physical Process Management Physical Process Control Equipment Control
Equipment Entity
2_10_ISA8895_Structure_PhysicalAsset
18
Equipment Entity Example 1
Command Run pump at rate X Status Pump running At rate X
C E E E
Physical Equipment FT Equipment Entity E
E
E
Information Processing
Basic Procedural Coordination
2_10_ISA8895_Structure_PhysicalAsset
19
Equipment Entity Example 2
Command Request Process capabilities Status / Response Processing Capabilities Catalog
C E E E
Physical Equipment Equipment Entity E
E
E
Information Processing Process segment Definition lookup
2_10_ISA8895_Structure_PhysicalAsset
20
Equipment Entity Example 3
Command Optimize Orders' Scheduling Status / Response Optimized Orders' schedule
C E E E
Physical Equipment Equipment Entity E
E
E
Information Processing Schedule Orders
2_10_ISA8895_Structure_PhysicalAsset
21
Information & Equipement
The physical model is the primary framework of information system Ø All functional elements, resources, documents rest on this model Ø No information can be defined outside the context of an equipment entity its physical scope
Ent. Basic control Coordination control Procedural control (Equipment) Procedural control (Recipes) Product definition Objects classes X X X X X X X X X X X X Site Area Pcell Unit EM CM X X
2_10_ISA8895_Structure_PhysicalAsset
22
ISA88 definition for lower physical hierarchy model
Process cell
Ø
A logical grouping of equipment required for production of one or more batches
Units
Ø
A collection of related control modules and equipment modules that can carry out one or more processing activities
Equipment modules
Ø
A functional group of equipment and/or control modules that can carry out a finite number of specific processing activities
Control modules
Ø
A regulating device, a state oriented device, or a combination of both that is operated as a single device
2_10_ISA8895_Structure_PhysicalAsset
23
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
2_10_ISA8895_Structure_PhysicalAsset
24
Role of the Work Center
PROCESS CELL
UNIT EQUIPMENT MODULE
A work centre needs to encompass all the needed Work Units to CONTROL MODULE make a defined product Ø The scope of a Production Request Essentially an organizational level Ø Activity, topology Ø No hard constraints Ø Might help for facilities classification § Ability to replicate a Work Center template
2_10_ISA8895_Structure_PhysicalAsset
25
Work Center for Batch: Process Cell
PROCESS CELL
UNIT EQUIPMENT MODULE
Definition CONTROL MODULE Ø A logical grouping of equipment (Units) required for the production of one or more batches Properties Ø May contain more than one grouping of equipment needed to make a batch § "Train" Ø The equipment actually used for the batch is referred to as the path Ø May contain more than one batch at a time (possibly several independent production order being processed simultaneously)
2_10_ISA8895_Structure_PhysicalAsset
26
Work Center for Batch: Process Cell
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Rules Ø Static geographical structure, defined at the engineering time Ø The batch maintains its integrity Ø The scope of a recipe or production request Ø The action scope of an operator Ø Bounded by input / output material storage (raw matierial / semi-finished products / finished products Examples Ø Building B6 Ø Finishing workshop
2_10_ISA8895_Structure_PhysicalAsset
27
Process Cell Structures
Single-Path "Raw" Material Storage
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Unit 1
Unit 2
"Finished" Material Storage
Multiple-Path "Raw" Material Storage "Finished" Material Storage
Unit 1
Unit 2
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28
NetworkedPath Process Cell Structure
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Unit 1 "Raw" Material Storage
Unit 2
Unit 3
Unit 4
"Finished" Material Storage
2_10_ISA8895_Structure_PhysicalAsset
29
Example of a 2Unit Process Cell
M
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Ingredient B Premixer
F1
Ingredient A
M
PIC
PIC
Reactor
2_10_ISA8895_Structure_PhysicalAsset
30
Example of a 4Unit Process Cell
#1 #2 #3 #4
FQIC FQIC FQIC FQIC
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
V11 V3
PIC
V11
Vent
V5 V12
N2 Cond V13 C-H2O V14
TIC
V1
PIC
Vent
V1
V12
N2
Premix1
Steam V15 H2O-R V16 Catalyst
Rxtr 1
V8
WI
FSL
V10
V6 V11
Vent
V7
V11 V1
PIC
VENT
V1 V5
Cond V13 C-H2O V14
V1
V2
V12
N2
V4
PIC
V12
N2 Catalyst
Premix2
LI
TIC
Steam V15 H2O-R V16
FSL
Rxtr 2
LI
V8
V10
V6
V7
2_10_ISA8895_Structure_PhysicalAsset
31
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
2_10_ISA8895_Structure_PhysicalAsset
32
Role of Work Unit
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
The « Central » allocation level Ø A relatively autonomous entity for planning/scheduling purpose Ø Batch Processes,
§
A strict batch breakdown : Unit contains one single batch Work Cell is similar to Unit
Ø Ø
Discrete Processes,
§
Warehouses and storage :
Allocation is not confined to a specific level § Storage Units should be recursive not in the standard
§
Ø
Continuous processes
A main equipment, Sub-part of a Production Unit § Can segregate "virtual batches" in a continuous flow
§
Provides and execute product independent process services Ø Implemented by Equipment Procedural Element (EPE) (possibly inherited from embedded Equipment Modules)
2_10_ISA8895_Structure_PhysicalAsset
33
Work Units for Batch: Unit
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Definition Ø Is a collection of Control Modules and Equiment Modules Ø Performs one or more significant processing activities, as product independent Equipment procedural Elements
Combining material, Performing a reaction
Role Ø Basis of procedural control Properties Ø Cannot contain another unit Ø A unit cannot operate on more than one batch of material at any given time
§
Although a unit is allowed to operate on a portion of a single batch Although a batch is allowed to be completed in a single unit
Permanently attached parts to a unit Temporarily attached parts to a unit Totally separate from any unit
Ø Ø
Making a batch often requires multiple units
§
§ § §
May contain a flexible amount of control modules and/or equipment modules
2_10_ISA8895_Structure_PhysicalAsset
34
Work Units for Batch: Unit
PROCESS CELL
UNIT EQUIPMENT MODULE
Rules CONTROL MODULE Ø Essentially dynamic structure, : identified at the engineering time, but physical scope depends on the context Ø Centered around a major piece of equipment Ø Autonomy: May operate independently of other units Examples Ø Reactor, Mixer Ø Washing machine Ø Oven Ø Press
2_10_ISA8895_Structure_PhysicalAsset
35
Example of a Unit in a Process Cell
#1 #2 #3 #4
FQIC FQIC FQIC FQIC
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
V11 V3
PIC
V11
Vent
V5 V12
N2 Cond V13 C-H2O V14
TIC
V1
PIC
Vent
V1
V12
N2
Premix1
Steam V15 H2O-R V16 Catalyst
Rxtr 1
V8
WI
FSL
V10
V6 V11
Vent
V7
V11 V1
PIC
VENT
V1 V5
Cond V13 C-H2O V14
V1
V2
V12
N2
V4
PIC
V12
N2 Catalyst
Premix2
LI
TIC
Steam V15 H2O-R V16
FSL
Rxtr 2
LI
V8
V10
V6
V7
2_10_ISA8895_Structure_PhysicalAsset
36
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
2_10_ISA8895_Structure_PhysicalAsset
37
Roles of Equipment modules
PROCESS CELL
UNIT EQUIPMENT MODULE
2 roles CONTROL MODULE Ø Breakdown of a Work unit § May be used to limit the scope of an EPE § Units building blocks Ø Shared equipment having autonomous process capabilities that can be used with several units § Non-exclusive: distribution of utilities (air, steam, N2, water) § Exclusive: Charging device, transfer lines Not a mandatory element
2_10_ISA8895_Structure_PhysicalAsset
38
Equipment Modules
PROCESS CELL
UNIT EQUIPMENT MODULE
Definition CONTROL MODULE Ø A collection of equipment and/or control modules that can carry out a finite number of specific processing activities § Implements Equipment Procedural Elements by commanding control modules or lower level equipment modules An Equipment module without EPEs is a Control Module An equipment module is technically similar to a unit Properties Ø May contain other EMs Ø Dependent: May be part of a single Work Unit or another Equipment Module for its exclusive usage Ø Autonomous: May be part of a Work Center § can be temporarily "attached" to a Work Unit as a common resource § Can be used in conjunction with several Work Units or other Equipment 2_10_ISA8895_Structure_PhysicalAsset Modules, or even running independently 39
Equipment Modules
PROCESS CELL
UNIT EQUIPMENT MODULE
Rules CONTROL MODULE Ø Essentially dynamic structure, : identified at the engineering time, but physical scope depends on the context Ø Inherited from the Work Unit (part of it) Ø Usually centered around a piece of process equipment such as a process heater or weight tank Examples Ø Weight tank used by a single unit Ø A filter that is only used by a single unit Ø Weight tank shared by multiple units, but only usable by a single unit at a time (an exclusive use resource) Ø An ingredient supply system that shared by multiple units and can be used by many simultaneously (a shared-use resource)
2_10_ISA8895_Structure_PhysicalAsset 40
Equipment Module Implementations
PROCESS CELL
UNIT EQUIPMENT MODULE
Option 1: No equipment modules CONTROL Ø Any EPE of a Unit can allocate (dynamically) any control moduleMODULE within the Work Center / Process Cell Ø A single EPE can execute a transfer between 2 units Option 2: Units without EPEs inheriting EPEs from EMs Ø Typically for embedded equipment modules Option 3: Units with EPEs commanding EPEs from EMs Ø Typically for shared equipment modules
2_10_ISA8895_Structure_PhysicalAsset
41
Example of an EM in a Process Cell
#1 #2 #3 #4
FQIC FQIC FQIC FQIC
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
V11 V3
PIC
V11
Vent
V5 V12
N2 Cond V13 C-H2O V14
TIC
V1
PIC
Vent
V1
V12
N2
Premix1
Steam V15 H2O-R V16 Catalyst
Rxtr 1
V8
WI
FSL
V10
V6 V11
Vent
V7
V11 V1
PIC
VENT
V1 V5
Cond V13 C-H2O V14
V1
V2
V12
N2
V4
PIC
V12
N2 Catalyst
Premix2
LI
TIC
Steam V15 H2O-R V16
FSL
Rxtr 2
LI
V8
V10
V6
V7
2_10_ISA8895_Structure_PhysicalAsset
42
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
2_10_ISA8895_Structure_PhysicalAsset
43
Role of Control modules
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
The lowest, mandatory level in the Physical Hierarchy Ø The only actual equipment entity: all upper level are organizational views with larger or smaller focus Ø The only acting entity (move actuators, run motors) Mechanical engineering consistency Ø CM breakdown corresponds to generic equipment entities Simplification of control: Ø Execute elementary equipment services invoked by EPEs Functional leveling of technological variants Ø Same interface and capabilities, specific control Prevent conflicting equipment usage Ø EPEs can explicitly allocate control modules providing an inherent interlock between conflicting functionalities
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44
Control Modules
PROCESS CELL
UNIT EQUIPMENT MODULE
Definition CONTROL Ø A piece of processing equipment with associated collection of sensors, MODULE actuators, and other control modules Properties Ø Every piece of equipment is controlled by one (and only one) control module Ø The lowest, mandatory physical level
§
Any part of the actual equipmeNT is part of one, and only one control module
Ø
Provides the only connection to the process
Control modules can content instrumentation § But Control Modules ARE NOT instruments (see Device Modules)
§
Acts as a single entity from a control standpoint Ø Do not contain / cannot execute procedural elements Ø The only real physical entity
Ø
§
All upper levels are more or less focused orgainsational views
Ø
Unknown by the Recipe
2_10_ISA8895_Structure_PhysicalAsset
45
Control modules and flow analysis
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Rules Ø None in ISA88 WBF Flow analysis concepts: Ø Physical flows get through tangible equipment entities (Control modules) Ø A proper breakdown allows to control flows regardless the functional intent. Control modules control ... flows Ø Breakdown rules for control modules § CMs are elementary flow sections § Extension of Delta Nodes / Astrid methodologies Ø The resulting breakdown highlights consistent generic equipment entities
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46
Flow Analysis rules for breaking down a facility into CMs
PROCESS CELL
UNIT
Identify all flow breaking devices Ø Shut-off valves Ø Doors Ø Traffic lights Ø Removable pipe / Blind flanges Ø ... Control modules are bounded by these devices Several flows may run through a given equipment Ø This equipment may be split into several control modules § Liquid and gaseous part of a tank
EQUIPMENT MODULE CONTROL MODULE
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47
Control Module examples
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Recirc XV
Commands Circulate To Process Stop
States Circulating Sending Stopped
Pump Process XV
Circulate Start Pompe Stop Pompe Open Recirc XV Close Recirc XV Open Process XV Close Process XV 1 0 1 0 0 1
ToProcess 1 0 0 1 1 0
Stop 0 1 1 0 0 1
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48
Control Module examples
CM4
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
CM2 PID PID CM1 PID HIC HIC CM3
2_10_ISA8895_Structure_PhysicalAsset
49
Control Module examples
Raw_Matl_Req as enum: 0 None 1 Cream 2 Milk 3 Corn Syrup 4 Water
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE
Material Selection Control Module
Define Discharge_Flow_SP as 0 60 GPM Define Recirc_Flow_SP as 0 60 GPM Define CIP_Flow_SP as 0 140 GPM
FT
Pump Control Module
2_10_ISA8895_Structure_PhysicalAsset
50
Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Device Module
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE DEVICE MODULE
Sensors and actuators are not defined in the standard Sensors and actuators can be considered as: Ø First level control modules § Possible because of the recursive nature of the control module § Common practice Ø Device modules, an additional element § The standard allows extensions § Allows to preserve the true nature of the Control Module as an abstraction layer: a control module does not necessarily hold instruments... § Proposed in ISA88 part 5
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52
Flow Analysis: Device modules attachment to CMs
UNIT EQUIPMENT MODULE
PROCESS CELL
DM are attached to the supporting CM CONTROL MODULE Flow breaking devices are between 2 or more CMs. They may be DEVICE considered as: MODULE Ø Independent CMs : More flexible, WBF current work proposed approach (Directing nodes) Ø Device modules attached to one of the adjacent CM (Current ASTRID or DELTA NODE methods) § Rule 1: A flow breaking device is attached to the upstream CM § Rule 2: A flow breaking device is attached to the user of a shared flow (utility for example) § Rule 3: The second rule prevails on the first one
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53
Device safety and control
PROCESS CELL
UNIT EQUIPMENT MODULE CONTROL MODULE DEVICE MODULE
Operator (HMI)
Owning CM (automatic control) Manual control Automatic control
Adjacent CM (Flow control)
Interlocking task Product and equipment protection Safety task Personnel and environment protection (external safety system)
Flow interlocks Flow integrity Content compatibility Capacity constraints
Acting device
Commands Flow Information Interlock
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54
A Motor Device Module
PROCESS CELL
UNIT EQUIPMENT MODULE
Commands
Status
CONTROL MODULE DEVICE MODULE
Start Stop
Run
Fail
Starter Coil
Single-Speed Motor Module
Motor Rotation Sensor
2_10_ISA8895_Structure_PhysicalAsset
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Equipment Modules vs. Control Modules
Equipment Module Can contain an EPE Must interface to the process via a control module
Control Module Cannot contain an EPE Directly interfaces to the process via Device Modules
Commonly used as stand alone and shared equipment by other Units or EMs Commonly used to deal with transfers Can contain other EMs and CMs May have a direct link to the recipe procedure via the EPE Can contain other CMS, not EMs Has no direct link to the recipe procedure
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Control modules and Equipment modules : Unit ownership
By design, CMs and EMs Ø can be attached permanently to a unit Ø Can be independent of any unit, part of the whole Process Cell / Work Center § CM et EM can be temporarily attached to any unit to provide the needed Equipment (CMs) or Process (Ems) services needed to achieve its processing function § CM and EM can also be commanded independently
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Example of ISA88 physical hierarchy
Process Cell Unit EM EM EM CM CM CM CM CM CM CM CM
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Unit
EM
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Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1 EM3 Unit2
EM1
EM2
CM1 CM2 CM3 CM4 CM5 CM6 CM7 CM8 CM9
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CM10
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Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1 EM3 Unit2
CM1 CM2 CM3 CM4 CM5 CM6 CM7 CM8 CM9
CM10
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Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1
EPE 1 (EM1) EPE 4 EPE 2 (EM2)
EM3
Unit2
EM3'
CM1
CM2
CM3
EPE 3
CM4
DM1 DM2 DM3 DM4 DM5 DM6 DM7 DM8 DM9 DM10
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Example of ISA88 physical hierarchy (Cont'd)
Process Cell Unit1
Phase X Phase Y
EM3
Unit2
EM1
No EM: EPEs Dynamically allocates The needed CMs
EM2
EM3'
CM1
CM2
CM3
CM4
DM1 DM2 DM3 DM4 DM5 DM6 DM7 DM8 DM9 DM10
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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ISA95 Hierarchy scope
ISA-95 attaches "Hierarchy scope" to all information objects Ø Resources, process segment, product definition, Ø Previously named "Location" Ø "Hierarchy scope is an attribute used in many other objects. The hierarchy scope attribute identifies where the exchanged information fits within the role based equipment hierarchy. It defines the scope of the exchanged information, such as which site or which area the information is relevant for. The hierarchy scope identifies the associated instance in the role based While ISA-88 attaches "control" to the physical hierarchy, ISA-95 takes the other way around: it attaches a physical hierarchy information to information objects
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Example
ISA-88
ISA-95
Unit
(Equipment Entity)
Process Segment
(Information object)
Work Center
(Hierarchy scope)
Procedural
Element
(Control)
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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ISA95 equipment models
These models identify the physical assets Ø by their role in the facility § The function performed by a machine at the explicit location § Not necessarily always the same, can be replaced without affecting the role Ø By their asset / inventory aspect § The unique machine identifiable by its serial number § Only for "maintainable" equipments, not all physical organisational entities § Similar to Inventory asset Features Ø Implements the physical hierarchy model Ø Defines properties of physical elements Ø Allows Class based definition
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ISA95 Equipment Resource Model: Role based < May be made up of Equipment
0..n
Equipment Class
Has properties of >
0..n 0..n 0..n Is tested by an > 0..n < Defined by 0..n Is tested by an > 0..n
Equipment
Has values for >
Equipment Capability Test Specification
0..n Is tested by an > Defines a procedure for obtaining an > 0..n Maps to 0..n 0..n < Records the execution of
Equipment Capability Test Result
Equipment Class Property
0..n
0..n
Equipment Property
0..n < may contain nested
0..n < may contain nested
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ISA95 Equipment Resource Model: Physical Asset
> May be made up of 0..n > is an instance of
Physical Asset
Has values for >
1..1 0..n Is tested by an > 0..n
0..n 0..n Is tested by an > 0..n
Physical Asset Class
Has properties of >
Physical Asset Capability Test Result
< records the testing of Defines a procedure for obtaining an < 0..n
Physical Asset Capability Test Specification
0..n 0..n Is tested by an < Maps to 0..n
0..n
0..n
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
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ISA95 global Equipment Resource Model
< May be made up of 0..n
> May be made up of 0..n > Implemented by
Equipment Class
Has properties of >
0..n 0..n < Defined by
Equipment
0..1
0..1
< records use and removal of asset to implement equipment
Physical Asset
> is an instance of 0..n
1..1
Physical Asset Class
Has properties of >
Equipment Asset Mapping
0..n 0..n 0..n 0..n Maps to
Equipment Class Property
Maps to
Equipment Property
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
0..n < may contain nested
0..n < may contain nested
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Physical Asset Models elements (common RBE/PhA)
Properties (Definition) Ø "object denoting an implementation specific characteristic of an entity" Ø Characterization entities for Equipment Classes/Equipment
§
Ex: Capacity, Max Pressure, NominalSpeed, NbOfBagsPerMintute ...
Some properties can match the Equipment constraints defined in Process Element (Product Asset, Process Definition) Property (Value) Ø Valuation of the property as a requirement (for Equipment Class/Equipment) Ø Valuation of a property from actual assessment (For Physical Asset)
Ø
§
Ex: NbOfBagsPerMintute = 1643
Test specification Ø "identify a test for one or more equipment properties" Test Result Ø "Results from a equipment capability test for a specific piece of equipment / physical asset" 2_10_ISA8895_Structure_PhysicalAsset 73
Physical Asset Models elements (specific RBE/PhA)
Role based Equipment Ø Equipment § "A representation of the elements of the equipment hierarchy model" Ø Equipment Class § "a grouping of role based equipment with similar characteristics for purposes of scheduling and planning" Physical Asset Ø Physical Asset § represents information about a physical piece of equipment Ø Physical Asset Class § "grouping of physical assets with similar characteristics for purposes of repair and replacement"
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Agenda
Introduction ISA88/95 Physical hierarchy model ISA88 Equipment entity model Ø Process Cell / Work Center Ø Unit / Work Unit Ø Equipment Module Ø Control Module Ø Device Module Ø Exploit the model ISA95 Hierarchy scope ISA95 Equipment Model Practice
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Exercise (1) : Unit, Equipment module or Control module?
Is a Unit Reactor Fluid Bed Dryer Pasteurizer Pump Multi pump set Ingredient storage tank Washing machine Kitchen blender (& cook) Refrigerator Dishwasher Iron Bred cooker Isn't a Unit (EM or CM)
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Exercise (2) Excel spreadsheet
(2.1) Physical Hierarchy Ø Give possible names and examples for the physical hierarchy level
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#1 #2
FQIC FQIC
#3 #4
FQIC
FQIC
V11
Vent
V11 V1 V5
N2
PIC
Vent
V3
PIC
V12
N2
V1 V12
Cond V13 C-H2O V14
Premix1
TIC
Rxtr 1
Steam V15 H2O-R V16 Catalyst
V8
WI
FSL
V10
V6 V11
V7
V11 V1
PIC
VENT
V1
V1 V2 V4 V5
Cond V13 C-H2O V14
PIC
Vent
V12
N2
V12
N2
Catalyst
TIC
Premix2
LI
Rxtr 2
LI
V10 V8
Steam V15 H2O-R V16
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FSL
V6
V7
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Exercise (3) : Excel spreadsheet Physical modeling
(1.1) Properties Ø Identify some typical equipment properties: name, range, (1.2) Equipment Test Specification Ø Identify typical Test Specifications (2.2) Equipment classes Ø Identify certain Equipment roles, For different level: WU, EM, CM, DM (2.3) Equipment Ø identify
§ § §
Enterprise, Site, Area, Work Centers/Process Cells Work Units / Units, Device Modules, Flow breaking devices Control modules: Within the process cell, Peripheral facilities: storage, utilities
(3.1) Physical Asset Hierarchy Ø Identify a possible maintenance oriented physical hierarchy (3.2) Physical Asset Class Ø Identify certain machines types (3.3) Physical Asset Ø Identify certain machines
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Thank You !
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Johann Sebastian Bach. the music closest to silence, closest, in spite of its being so highly organized, to pure, one-hundred-degree proof Spirit" (Aldous Huxley, Island)