Applying ISA-95

in the Oil & Gas Industry

MESA Oil & Gas Working Group
April 26, 2007

Dave Emerson Keith Unger

ISA-95 Committee ISA-95 Chairman
Standards Principal Principal Manufacturing
Certification
Education & Training Systems Architect IT Consultant
Publishing
Conferences & Exhibits 1
Why a Standards Based Approach?

• Lowers Total Cost of Ownership (TCO)

• Economies of scale
– Widely distributes costs to develop, operate & maintain products
– More rapid transfusion of IT to process industries
• Removes costs from entire supply chain
– Process manufacturers, System suppliers
– Integration costs reduced
• Enables interoperability
– Without standards interoperability
is a point-to-point solution
• Differentiation does not disappear
– Moves to higher value areas

Adoption is critical
2
Some End Users of the ISA-95 Standard
• Energy • Life Sciences
– ExxonMobil, Inc – Eli Lilly and Co.
– Kuwait National Petroleum Company – Merck
– ExxonMobil Neftegas Limited – Genentech
– BP – Roche Diagnostics
– British Gas – TEVA
– Caspian Pipeline Consortium • Food and Beverage
– U.S. Department of Energy – Nestle
– GasOil Resources LLC – Coca-Cola North America
– Sakhalin Energy – Arla Foods
– Westinghouse Savannah River – United Biscuits Verkade Zaandam
• Discrete Manufacturing – Van Dijk Food Products Zeewolde
– Advanced Micro Devices – Cerveceria Polar
– JDS Uniphase – GumLink
– Computer Sciences Corporation – SAB Miller
– GE Lighting – Frito-Lay
– GE Aircraft Engines – Red Gold Tomatoes
– Lucent • Consumer Goods
– Alcatel – P&G
– Cummins – British American Tobacco
• Other • Chemical
– International Paper – DOW Chemical
– Dupont
– SABIC (Saudi Arabia)
– Polaroid

3
 Removing Cost From the Supply Chain
Scenario 1 – to be avoided.. Scenario 2 – to be achieved:
Using several vendors proprietary ”standard” solutions Using one generic standard solution

SAP R/3 SAP R/3

MM – PP-PI – QM MM – PP-PI – QM
… PI-PCS … … PI-PCS …
SAP Business Connector / XML

S95/WBF standard
(B2MML XML)

MES MES MES

System X System Y System ..
Factory X Factory Y Factory ..
MES/PCS MES/PCS MES/PCS
Factory X Factory Y Factory ..
PCS PCS PCS

Application X Application Y
... Display
Application
Trend
Application
OPC OPC

4
What is ISA-95?

• Framework for integration projects

• Separation of
business processes
from manufacturing processes
• Focus on functions,
not systems, organizations
or individuals

5
Product Information and Material Pipelines

Information Pipeline
Materials Product Operations Asset Distribution Order Customer
Purchasing Development Planning Management & Logistics Management Service

Suppliers Consumers
Business Planning
& Logistics

Manufacturing
Operations Management

Batch Continuous Discrete

Control Control Control

Product Pipeline
Raw Storage & Unit Intermediate Unit Storage & Distribution
Material Transport Processing Storage Processing Transport

6
ISA-95 Physical Model

ENTERPRISE
ISA-95 Level 4 activities typically
deal with these objects Legend

WORK SITE contains 0 or more

contains 1 or more
WORK AREA
Represents a process cell, production
unit, production line, or storage zone
WORK
ISA-95 Level 3 activities CENTER
Represents a unit, work cell, or
typically deal with storage unit
these objects
WORK UNIT
Defines the role of the equipment

WORK
EQUIPMENT Defines the physical asset

WORK
ASSET

7
ISA-95 Categories of Data Exchange

Business planning &

logistics information
Plant production scheduling,
operational management, etc

Resource
Production Product Production Production
Information
(Personnel, capability definition schedule response
Equipment, information information information information
Material, (What resources (What must be (What to (What was
Segments) are available) defined to make make and use) made and used)
a product)

Manufacturing operations &

control information
Production operations, maintenance
operations, quality operations, etc

8
ISA-95 Part 3 Operations Management

Information Pipeline
Materials Product Operations Asset Distribution Order Customer
Purchasing Development Planning Management & Logistics Management Service

Operations Operations Operations Operations

definition capability request response
Business Planning
& Logistics
Detailed
scheduling

Resource
Tracking
Manufacturing management

Operations Management Production

Dispatching Analysis
Maintenance
Inventory
Definition Data
Quality management collection
Batch Continuous Discrete
Control Control Control Execution
management

parameters and Process

commands responses
procedures specific data

Product Pipeline
Raw Storage & Unit Intermediate Unit Storage & Distribution
Material Transport Processing Storage Processing Transport

9
Adding Vertical Detail to ISA-95

The SP95 committee wants to work with industry groups to

add vertical detail to the ISA-95 standards

(CPG) Consumer
Packaged Goods
Pharmaceutical
Fine Chemical
Downstream

PetroChem

Automotive
Electronics

Aerospace
Upstream

Chemical

Continuous Batch Discrete

ISA-95 Cross-Industry Framework

10
 ISA-95 Continuous Improvement Cycle

Inputs
AIAG
Development Feedback

Improvement Feedback
UN/CEFACT

MIMOSA Industry Adoption

ISA-95 ISA-95 Vertical WBF

User
Harmonization Maintenance Extension OAG

ISO/IEC Release Updates

ISA88/95

Strategic Direction
ProdML

11
Condition Based Operation

Supply Chain Mgmt. ERP System Supply Chain Mgmt.

Production Forecasting & Scheduling

Asset Capability Forecasting &

Asset Optimization DSS
Control & SCADA
Systems and
Data Historians Enterprise Asset
Asset
Management (EAM)
Condition Health DSS Condition
Based System Asset Registry
Operational Based
Maintenance Maintenance
Advisories
Work & Parts Mgmt.
FOUNDATION

FOUNDATION
Advisories

Asset Measurements & Inspections

Electrical/ I&C Device Portable Quality Protection Online Sample
Rotation Monitoring Device analysers Monitors Transient Monitoring
monitoring Monitoring Monitors Monitor

12
Benefits of ISA-95 Convergence

F O U N D A T I O N

POSC Caesar

Process Hybrid
Process
Discrete Discrete
Models Models
Models Models

Stronger Input From Discrete & Process Industries

Resulting In A Standard That Is More Broadly Applicable
13
Process Industry Trends

Trends Industry Responses Your Challenges

Strong product Higher capacity Maintaining

demand utilization asset utilization

Heavier, sour crude. Increased refining

Regional Enabling flexible
complexity and
requirements. production
richer product mix

Health, safety,
environmental Strict compliance Optimizing safety
pressure and prevention and availability

Diminishing in-house Choosing the

knowledge and Outsourcing and
right technology
expertise new technologies
and partner

14
Daily vs. Production Data Closure

1st May 2nd May 3rd May 4th May

Onsite Operation Mode
CDU Kerosene max Jet Kerosene max

Normal Bond Normal

Reformer RON 100 RON 95

FCC Gasoline Max Conversion Max

Offsite Task Feed from TK201

to CCR
Charge to
TK202
Blending

Unloading to
TK105

• Hourly vs Daily closure of balance data, for Continuous Processes

– Minute updates available for Batch type processes
• Faster Notification of schedule deviation
• Data Collection in each mode of operation for reporting and analysis
15
How Best to Apply
Oil & Gas Vertical Detail to ISA-95?

• Annexes to the standard

Upstream Downstream
• Technical Reports
• Whitepapers Petroleum Industry
• Joint Working Groups
Chemical & Petroleum Industry
• …
ISA-95 Cross-Industry Framework

The SP95 committee will work with

each vertical industry group
to determine the best vehicle for publication
16
Thank You

The ISA SP95 committee is open to all interested parties.

For information on how to participate contact
• Charlie Robinson at ISA
crobinson@ISA.org
• Keith Unger, ISA-95 Chairman
kunger@stonetek.com
• Dave Emerson
dave.emerson@us.yokogawa.com

17