IBM Chemical and Petroleum Solutions
© 2008 IBM Corporation
Building an Integrated Operations Enabling System with the Reference Semantic Model September 2008Ron Montgomery/Vish Narayan/Udo Pletat Worldwide C&P Industrial Solutions
Chemical and Petroleum Solutions
© 2008 IBM Corporation2
Overview
Trends in C&P industry
Objectives of RSM and IIF
Looking at RSM
RSM Model management
(Architectural) summary
Chemical and Petroleum Solutions
© 2008 IBM Corporation3
A Confluence of Trends
Source: Cambridge Energy Research Associates.20807-14
Monitoring
Real Time
Automation
Improved OperationalEffectiveness
Increased Recovery
• Shorter decision cycles
• Higher productivity
• Integrated surface,downhole and reservoirdecision making
Demographics?
Reduced Downtime
Oil price?
Chemical and Petroleum Solutions
© 2008 IBM Corporation4
Data Information Management / Integration Development Progression
Process InformationVolume Growth
“Unified”
Information ModelsTechnical Standards
Enterprise Information Access Services
HDA Client JMS
Publisher
CallbackEvents
TSDAHSDA
GDA ClientGDA
ModelData
Real TimeData
-HistoricalData
Event Data
Composite Services
ConditionedMonitoringComplex
Event Handler
DA Client
Web Services & Composite ServicesInformation Services Access Across the Enterprise
Chemical and Petroleum Solutions
© 2008 IBM Corporation5
Chemical & Petroleum Integration and Information ChallengesSpecific Challenges:– Numerous different applications deployed across the enterprise at both the business
and production levels to manage and record operations performance.
– Each application instance has its own unique reference and data model.– Process Tag information and its context to equipment is not conveyed in real time
system integration, thus a heavy reliance on engineering interpretation
– Process events, alerts cannot be easily defined, distributed and “subscribed to”across the enterprise to initiate business processes or personnel collaboration or prompt attention
– Production Analysis Calculations are done off line requiring data replication and are not accessible for reuse and access by dash boards, portals, KPI’s etc.
– Cross location and cross work process transactions and events are also not captured in the context of equipment configurations or production relevant events.
– Operational views are incomplete; overall analysis is sub-optimal and localized by the domain coverage of applications. Complex views spanning divisions/plants/process areas requires new “one-off” application developments. Integrating additional facilities or introducing new functionality is often difficult, time consuming and costly.
Chemical and Petroleum Solutions
© 2008 IBM Corporation6
Homogeneous view on enterprise - heterogeneous IT systems
Enterprise
Enterprise IT System
ProductionSite IT System
ProductionSite IT SystemN Sites
N IT Systems
N*N interfacesProduction
SiteProduction
Site
Chemical and Petroleum Solutions
© 2008 IBM Corporation7
Overview
Trends in C&P industry
Objectives of RSM and IIF
Looking at RSM
RSM Model management
(Architectural) summary
Chemical and Petroleum Solutions
© 2008 IBM Corporation8
C&P Framework Manufacturing Operations Concept
Integrated Information Framework (IIF) addresses the needs for improved IT solutions on two levelsIndustry specific content & semantics– A technology neutral lingua franca reference framework enterprise model
based on recognized global standards– Global visibility into manufacturing information and performance– Ability to effectively maintain equipment relationships, track events and
conditions across multiple fields.– Presentation of information in the context of equipment geological formation– Foundation for internal manufacturing collaboration (Performance
Improvement) and execution (Operational Excellence)– A federation and aggregation of data, not a replication
Industry neutral advanced IT technology– Enterprise application integration SOA– Realtime event processing EDA– Up-to-date visualization WEB 2.0
Chemical and Petroleum Solutions
© 2008 IBM Corporation9
OLF – Information Integration Platform (IIP) Project
So how to get from here, to
there
here
Chemical and Petroleum Solutions
© 2008 IBM Corporation10
The IIF Vision
Engineering Leadership’s Vision for new capabilities
IT’s new tools and approachesto achieve the vision
Intelligent Manufacturing
Partnership between Engineering Leadership and IT
Chemical and Petroleum Solutions
© 2008 IBM Corporation11
An Integrated Information Framework – providing an efficient pipeline for real-time data transfer
and analysis of data
Vendor
Vendor
Field data• Drilling & well
operations• Reservoir &
production operations
• Operation & maintenance
A Real-Time Information Pipeline leveraging the
Reference Semantic Model standard
IBM C&P Model Based SOA Integrated Manufacturing Solution
Frame Work
Web-service enabled applicationsField 1
Field 2
Operator
The RSM is composed of:• OPC information mapped to the RSM
ontology Measurement, MeasurementValue & other classes
• ISA S88/S95, ISO 15926, IEEE 61970/68 for asset and physical hierarchy representation
• ISO 15926, Mimosa for asset life cycle management
Chemical and Petroleum Solutions
© 2008 IBM Corporation12
An Integrated Information Framework – providing an efficient pipeline for real-time data transfer
and analysis of data
Vendor
A Real-Time Information Pipeline leveraging the
Reference Semantic Model standard
Vendor
Refinery data• Refinery
Planning• Refinery
Operations• Engineering &
Maintenance
Operator
IBM C&P Model Based SOA Integrated Manufacturing Solution
Frame Work
Web-service enabled applications
The RSM is composed of:• OPC information mapped to the RSM
ontology Measurement, MeasurementValue & other classes
• ISA S88/S95, ISO 15926, IEEE 61970/68 for asset and physical hierarchy representation
• ISO 15926, Mimosa for asset life cycle management
Refinery 1
Refinery 2
Chemical and Petroleum Solutions
© 2008 IBM Corporation13
MimosaAssetModel
Federated Role Based ProcessModels
MaintenanceRequest
MaintenanceRequest
MaintenanceWork Order
MaintenanceWork Order
MaintenanceResponse
MaintenanceResponse
May be generated for0..n
1..1
1..1
1..1
EquipmentClass Property
EquipmentClass Property
EquipmentProperty
EquipmentProperty
EquipmentCapability TestSpecification
EquipmentCapability TestSpecification
EquipmentClass
EquipmentClass
Hasvalues for
0..n
0..n
0..n
0..n
0..n
EquipmentEquipment
EquipmentCapability Test
Result
EquipmentCapability Test
Result
0..n
0..n1..n
Hasproperties
of
Is testedby a
Maps to
Defined by
Records theexecution of
0..n
0..n May result in
0..1
May be up of Is against
Is madeagainst
0..n
0..n
Defines aprocedure forobtaining a
MaintenanceRequest
MaintenanceRequest
MaintenanceWork Order
MaintenanceWork Order
MaintenanceResponse
MaintenanceResponse
May be generated for0..n
1..1
1..1
1..1
EquipmentClass Property
EquipmentClass Property
EquipmentProperty
EquipmentProperty
EquipmentCapability TestSpecification
EquipmentCapability TestSpecification
EquipmentClass
EquipmentClass
Hasvalues for
0..n
0..n
0..n
0..n
0..n
EquipmentEquipment
EquipmentCapability Test
Result
EquipmentCapability Test
Result
0..n
0..n1..n
Hasproperties
of
Is testedby a
Maps to
Defined by
Records theexecution of
0..n
0..n May result in
0..1
May be up of Is against
Is madeagainst
0..n
0..n
Defines aprocedure forobtaining a
Well Platform
Refinery or Chemical Process
ProcessTags
Local Process Models Federated to represent aSingle enterprise model name space
MaintenanceRequest
MaintenanceRequest
MaintenanceWork Order
MaintenanceWork Order
MaintenanceResponse
MaintenanceResponse
May be generated for0..n
1..1
1..1
1..1
EquipmentClass Property
EquipmentClass Property
EquipmentProperty
EquipmentProperty
EquipmentCapability TestSpecification
EquipmentCapability TestSpecification
EquipmentClass
EquipmentClass
Hasvalues for
0..n
0..n
0..n
0..n
0..n
EquipmentEquipment
EquipmentCapability Test
Result
EquipmentCapability Test
Result
0..n
0..n1..n
Hasproperties
of
Is testedby a
Maps to
Defined by
Records theexecution of
0..n
0..n May result in
0..1
May be up of Is against
Is madeagainst
0..n
0..n
Defines aprocedure forobtaining a
0..1
> Implemented by
< records useand removal of
asset toimplement
equipment
0..n
> May be made up of
PhysicalMakeAndModel0..n
> is an instance of
PhysicalAsset
Property
Hasvalues for >
0..n
PhysicalMakeAndModel
Property
0..n
Haspropertiesof >
Maps to
PhysicalAsset Utilization
History
1..1PhysicalAsset
0..1
Physical AssetCapability TestSpecification
0..n0..n
0..n 1..n
defines a procedurefor how to test >
< records thetesting of
< is usedto test
Physical AssetCapability Test
Result
0..1
> Implemented by
< records useand removal of
asset toimplement
equipment
0..n
> May be made up of
PhysicalMakeAndModel0..n
> is an instance of
PhysicalAsset
Property
Hasvalues for >
0..n
PhysicalMakeAndModel
Property
0..n
Haspropertiesof >
Maps to
PhysicalAsset Utilization
History
1..1PhysicalAsset
0..1
Physical AssetCapability TestSpecification
0..n0..n
0..n 1..n
defines a procedurefor how to test >
< records thetesting of
< is usedto test
Physical AssetCapability Test
Result
Link
ISA-S95Part 4
Reference Semantic Model
ISA-S95/88augmented
model
WITSML/PRODML Entities
Enterprise monitoring interface sees two tags with similar namesbut they are uniquely named and identified in the process models
ProcessTags
Wel
l Ser
vice
Sys
tem
Proc
ess
His
toria
ns
Proc
ess
His
toria
ns
Value of the RSM applied asset & physical hierarchy representation
Chemical and Petroleum Solutions
© 2008 IBM Corporation14
Service enablement requires standardsEstablishing Industry relevance bringing real-time data to the enterprise
Automation and Control e.g., SCADA systems; DCSs
REAL-TIME OFF-LINE, BATCHEDTRANSACTIONAL
Historians
OI Frameworks
OPE
RA
TIO
NS
PRO
CES
SB
USI
NES
SO
PER
ATI
ON
SPR
OC
ESS
BU
SIN
ESS
MES Operational Data Stores
Pure BI/ Data
Warehouses
Business systems:ERP, EAM, SCM, APS
AdvancedAnalytics
and Modeling Tools
OI
LATENCY OF ANALYTICAL INFORMATION
CO
NTI
NU
UM
OF
OPE
RA
TIN
G C
ON
TEXT
S
How is the business performing?
How is the process performing?
How does process performance correlatewith business performance?
Interfaces to ERP/EAM(ERP or 3rd party capability)
ANSI ISA S95/S88
BatchControl
ContinuousControl
DiscreteControl
Business Planning & Logistics
Plant Production Demand,Operational Management, etc
Manufacturing Operations Management
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
BatchControl
ContinuousControl
DiscreteControl
Business Planning & Logistics
Plant Production Demand,Operational Management, etc
Manufacturing Operations Management
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
Level 4
Level 1
Level 2
Level 3
1 - Sensing the production process, manipulating the production process
2 - Monitoring, supervisory control and automated control of the production process
3 - Work flow / recipe control, stepping to produce the desired end products. Maintaining records and optimizing the production process.
Time FrameShifts, hours, minutes, seconds
4 - Establishing the basic plant schedule -production, material use, delivery, and shipping. Determining inventory levels.
Time FrameMonths, weeks, days, shifts
Standards based enterprise taxonomy / ontology = Model Driven Business Transformation
Reference
Semantic
Model
Chemical and Petroleum Solutions
© 2008 IBM Corporation15
Standards Leveraged in the RSM
ISA-88/BatchML
ISA-95/B2MML
Augmented by ISO-15926 (design lifecycle and physical connectivity)
IEC61970/68 (electrical model)
ISO13374 (maintenance – e.g. Mimosa)
UN-CEFACT (over-arching guidance –e.g. currency, units, etc...)
UTF (time representation/GMT)
OPC (measurements and quality definitions)
Open GIS
……..maybe more, Energistics inclusion, PIDX, CIDX, etc.
Chemical and Petroleum Solutions
© 2008 IBM Corporation16
Reference Semantic Model Objectives and FunctionsThe RSM essentially answers the Open Operations and Maintenance model requirements (Leverages MIMOSA and Open O&M transactions, ISA 95 Part 4)
Connects measurements, equipment, planning and scheduling, life cycle management, etc. throughout an enterprise
The RSM is not a data model and does not constrain the way applications implement the information contained within the model.
The RSM facilitates the exchange of information it does not store or replicate data. Federates instances of the IIF/RSM across the enterprise.
The RSM provides a “Contextual Naming Service for equipment and measurements, keeps track of “equipment and process states”.
The RSM provides multiple enterprise navigation methods that allows the access of process equipment, measurements, and document connectivity for visualization, and provides a “role based” information capability
The RSM can be “queried” to find equipment and related information to like documents and “pseudo static” data by Web Service based applications.
The RSM provides a base for “Model Aware Adapters”
Chemical and Petroleum Solutions
© 2008 IBM Corporation17
Building blocks for the C&P SOA is built with standards and industry participationRSM Team
MIMOSA- Alan T. Johnson, Ken BeaverOAGi – Dave ConnellyWBF – Dave EmersonISA 88 – Dennis BrandlISA 95 – Keith UngerOLF – Tore Langeland, Magne Valen-SendstadOSIsoft – Jack AudeDNV - Henrik Smith-MeyerDOW – Russ DickinsonSISCO – Herb FalkIBM – Lorenzo Childress, Jon Siudut, Karthik Seetharaman, Jerry KopeckyOPC – Vishwanath Narayan
RSM Team Objectives/MilestonesObjectives
– Advance the modeling work
– Insure compliance with the participating standards
Milestones
– Identify the appropriate standards community to own the RSM
– Initial release of the RSM in the October timeframe
Chemical and Petroleum Solutions
© 2008 IBM Corporation18
So What’s A Reference ModelCombining ISA-95 and ISA-88
ISA-88 and 95 Together Specify:
An equipment / asset physical model– For batch, continuous and discrete
manufacturing processes
Batch process equipment entities
Recipe management models
Process segments that carryout manufacturing operations
Equipment, material and personnel resources
Information exchanges for enterprise integration
Standards Included:
S95 S88 ISO15926
MIMOSA IEEE 619/6870 UN/CEFACT
Implicit linkages needto be explicitly defined
Chemical and Petroleum Solutions
© 2008 IBM Corporation19
The RSM Models the Whole Enterprise
Identified by ISA-88
Must Contain 1 or More
May Contain 1 or more
Area
Site
Enterprise
May Contain 1 or more
Must Contain1 or More
May Contain
May Contain
BatchOperations
ProcessCell
Unit
MayContain
MayContain
Equipment Module
Control Module
Specified by ISA-88
Must Contain1 or More
Must Contain1 or More
DiscreteOperations
InventoryOperations
ContinuousOperations
Work Cell
ProductionUnit
StorageZone
Unit
Must Contain1 or More
StorageUnit
Area
Site
Enterprise
Specified by ISA-95
ManufacturingLine
Chemical and Petroleum Solutions
© 2008 IBM Corporation20
Problem: Traditional Tag Deployment
1. Transfer tags from engineering documents / design applications to target.
2. Define tag relationships –usually a functional view.
3. Repeat for other applications – each will be different.
4. As other tags are defined / needed, synchronize across all applications –likely to be out of synch somewhere.
Reactor 1Tank 1
EU501Agitator 1
MV 101PID 101Out 101
FQISH101Feed Supply
EU101
MV 201PID 201Out 201
FQISH201Additives
EU201
Unit 1
Chemical and Petroleum Solutions
© 2008 IBM Corporation21
Introducing structure to orginze information
Enterprise
Area A
Site 1
Site 2
Production
Unit A
Production
Unit B
WorkEquip
Pump 1
Measurement
Flow
Meas-Value
FT-1
Measurement
Pressure
Meas-Value
PT-1
Chemical and Petroleum Solutions
© 2008 IBM Corporation22
Overview
Trends in C&P industry
Objectives of RSM and IIF
Looking at RSM
RSM Model management
(Architectural) summary
Chemical and Petroleum Solutions
© 2008 IBM Corporation23
Definition of RSM
The RSM is defined as a UML model
Various packages bundeling information from different standards
Use classes & relationships of ‚parent standards‘
Add ‚glue‘ and ‚gap fillers‘ where appropriate
Chemical and Petroleum Solutions
© 2008 IBM Corporation24
ISA-95 Part 1, Figure 4 – Equipment hierarchy
May contain 1 or more
May contain 1 or more
May contain 1 or more
May contain 1 or more
Must contain 1 or more May contain 1 or more
ProductionUnitProcess Cell
May contain 1 or more
Area
Site
Enterprise
ProductionLine
Unit Work Cell
Level 4 activitiestypically deal withthese objects
Lowest LevelsOf Equipment
TypicallyScheduled
By Levels 3 or 4
Level 3 activitiestypically deal withthese objects
Lower levelequipment used
in batch operations.
Lower level equipment usedin repetitive or
discrete operations.
Lower levelequipment used
in continuousoperations.
Chemical and Petroleum Solutions
© 2008 IBM Corporation25
ISA-95 Part 3, Figure 7 – Typical Expanded Equipment Hierarchy
ENTERPRISE
SITE
AREA
PRODUCTIONLINE
WORKCELL
PROCESSCELL
Level 4 activitiestypically deal with
these objects
Level 3 activitiestypically
deal with these
objectsSTORAGE
ZONE
STORAGEUNITUNITUNIT
Legend
contains 0 or more
contains 1 or more
PRODUCTIONUNIT
Equipment usedin batch
production
Equipment usedin repetitive or
discrete production
Equipment usedfor storage or
movement
Equipment usedin continuous
production
Chemical and Petroleum Solutions
© 2008 IBM Corporation26
ISA-95 Part 4 Draft
AREA
ENTERPRISE
SITE
PRODUCTIONLINE
WORKCELL
PRODUCTIONUNIT
PROCESSCELL
STORAGEZONE
STORAGEUNIT
WORKCENTERS
UNIT
Legend
contains 0 or more
contains 1 or more
UNITWORKUNITS
Chemical and Petroleum Solutions
© 2008 IBM Corporation27
AREA
ENTERPRISE
SITE
PRODUCTIONLINE
WORKCELL
PRODUCTIONUNIT
PROCESSCELL
STORAGEZONE
STORAGEUNIT
WORKCENTERS
UNITWORKUNITS
Legend
contains 0 or more
contains 1 or more
UNIT
ControlModule
EquipmentModule Equipment used
in repetitive ordiscrete production
Equipment usedin continuous
production
Equipment usedfor storage or
movement
ISA-95 Level 3
activitiestypically
deal with these
objects
ISA-95 Level 4 activitiestypically deal with
these objects
Batch process activities based on ISA-88
typically deal with these
objects
Part 4 A Draft - Figure x from SP88-95 JWG
Chemical and Petroleum Solutions
© 2008 IBM Corporation28
How the RSM models this
Chemical and Petroleum Solutions
© 2008 IBM Corporation29
Visualizing KPI‘s based on RSM definitions
Chemical and Petroleum Solutions
© 2008 IBM Corporation30
Measurements/ MeasurementValues
Chemical and Petroleum Solutions
© 2008 IBM Corporation31
Measurements and KPI‘s
Chemical and Petroleum Solutions
© 2008 IBM Corporation32
RSM Supports KPI’s and Production Calculations
Chemical and Petroleum Solutions
© 2008 IBM Corporation33
The RSM Models Down to the Equipment and the Tag Level
PROCESSCell
PROCESSCell
EQUIPMODULEEQUIP
MODULE
PressureControl
PIC
Recirculate
Transfer
Add Material F1
TemperatureControl
TICCoolHot
UNITUNITAgitate
M
CONTROL MODULE
CONTROL MODULE
Chemical and Petroleum Solutions
© 2008 IBM Corporation34
High Level P&ID View: Using the RSM
Chemical and Petroleum Solutions
© 2008 IBM Corporation35
Different ViewsTopology View (Visualization)
F1
Process View
T01
CV02
S01CV03 F1 S01CV03
CV01P01
Add MaterialCV01CV02CV03
S01
Equipment View
CV01P01 CV02
Connectivity
F1
CV01P01
CV03
CV02
S01
Mv( pump speed ) Mv( state )
Mv( flow )
Measurement View
CAD file transformations is a source for process
connectivity
Chemical and Petroleum Solutions
© 2008 IBM Corporation36
RSM and ISO15926 classes relevant for P&ID information
Chemical and Petroleum Solutions
© 2008 IBM Corporation37
RSM – Classes for typical P&ID content
Chemical and Petroleum Solutions
© 2008 IBM Corporation38
Overview
Trends in C&P industry
Objectives of RSM and IIF
Looking at RSM
RSM Model management
(Architectural) summary
Chemical and Petroleum Solutions
© 2008 IBM Corporation39
Topics for model management
Meta-model evolutionadd new concepts & information to RSM
Model instance creationuse RSM for building applications on top of it
Model instance populationfill RSM instance with enterprise data
Model instance migrationmigrate model instance content due to meta-model changes
Chemical and Petroleum Solutions
© 2008 IBM Corporation40
RSM meta-model, model instances and their evolution paths
meta-model evolutionRSM
Meta-ModelVersion 1
RSM Meta-ModelVersion 2
RSM Model
Instance A.0
RSM Model
Instance B.0
RSM Model
Instance C.0
RSM Model
Instance D.0
Instance allocation
SQL
UM
L
instance migration
Initial load
RSM Model
Instance A.1
RSM Model
Instance B.1
RSM Model
Instance C.1
RSM Model
Instance D.1instance migration
Incremental update
RSM Model
Instance A.2
RSM Model
Instance B.2
RSM Model
Instance C.2
RSM Model
Instance D.2instance migration
Chemical and Petroleum Solutions
© 2008 IBM Corporation41
RSM Model Extensibility – single industryNeed to distiguish between
meta-model extensions concepts for representing oil rigs
pre-populated model instances a ‚typical‘ oil rig consists of ...
customer‘s model instance a customer‘s specific oil rig
C&P customer
rigA
C&P customer
rigB
C&P customer enterprise
RSM C&P industry model instance
RSM Base meta-model
RSM C&P customer model instanceRSM C&P Customer meta-model
RSM Chemical&Petroleum meta-model
Meta-model Model instance
Chemical and Petroleum Solutions
© 2008 IBM Corporation42
RSM for multiple industries
RSM Automotive meta-model
RSM Base meta-model
RSM C&P meta-model
RSM C&P Customer meta-model
Model instance Meta-model Model instance
RSM Automotive Customer meta-model
RSM Automotive Customer
Model instance
RSM C&P Customer
Model instance
Chemical and Petroleum Solutions
© 2008 IBM Corporation43
Overview
Trends in C&P industry
Objectives of RSM and IIF
Looking at RSM
RSM Model management
(Architectural) summary
Chemical and Petroleum Solutions
© 2008 IBM Corporation44
A Sample Real Time Integration Layout
IMS
Jalapeno IV Tabasco II
”Gulf of Mexico”Onshore Texas
MS Excel
Matrikon ProcessNet
OSIsoft OPC Client
Matrikon OPC Explorer
IIF Workbench
TransmitterSurveillance
App
ABB WebServices Client
OPC Client
Adapter
RT Model Visualization
Server
AnalysisApp
OPC Client
Adapter
AnalysisApp
OPC Client
Adapter
AnalysisApp
OPC Client
Adapter
AnalysisApp
OPC ServerAdapter
OPC ServerAdapter
RT Enterprise Model Services
Browser
REST/HTTP
SOAP/HTTP
•Matrikon OPC Tunneler Client
OPC Tunneler
ClientOPC Tunneler Server
•Matrikon OPC Tunneler Server
Bus apps / svcs
IBM SystemsArchitectural construct
•IIF UIB Server Adapter•JMS Libs•DBMS client
WebSphereESB/Process Server
OSIsoft PITest data
OSIsoft PITest data
ES
B
DCS DCS
IMS
JMS/MQ
OPC Tunneler
Client
RT Model Core Server
•IIF UIB Core•DBMS (Oracle 9i)
C&P IIF Solution
EnterpriseApplication
Chemical and Petroleum Solutions
© 2008 IBM Corporation45
Summary
Customer projects drive evolution of existing industry standards
RSM takes a ‚pragmatic‘ approach– Pick what you need from existing standards– Extend where necessary
Modern service-oriented and event-driven architecture concepts allow to combine – The real-time IT world– The enterprise IT
Many things around RSM you have not seen today– Check out for IBM ONS 2008 announcements to learn more on the entire
approach
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