Live from WBF 2008--The ISA88 Area Model...More than Just a Pretty Face

Scott Sommer from Jacobs Engineering and Doug Bourgeois of Complete Systems Automation, presented a paper on the use of the ISA88 Area Model. Part 1-Understand Project Phase Deliverables Part 2- Understand the Role of the S88 Area Model in the Project Timeline Part 3- Learn How to Use the S88 Area Model to Develop the Optimal Batch Control Strategy Part 4- Recognize Benefits of Early Development and Deployment of the S88 Area Model Part 5- Identify the Critical Activities Which Maximize the Benefits of the S88 Area Model Project Phases Conceptual Design Business Case Developed Process Flow/Block Diagram Architectural Concepts / Initial Floor Plan Permitting and Construction Strategy Automation Vision Initial Cost Estimate (Factored) Milestone Schedule Preliminary Design (BOD) Operating Philosophy Developed (SOO) URS Developed Instrumentation & Equipment Specifications P&ID’s Developed – IFD Floor Plan Frozen Permitting Packages Submitted System Architecture Diagrams Detailed Cost Estimate (+/-10%) Level 2 Schedule Detailed Design SOO’s Issued – SOP’s drafted P&ID’s Issued for Construction Equipment Specifications Issued for Bid Coordinated Spatial Design Construction Permits Received System Architecture - IFC Functional Specifications Issued Level 3 Schedule Understanding the Role of the S88 Model in the Project Timeline Typically, S88 Model is developed in Detailed Design Phase: PID’s Complete Instrumentation Specs IFB System Architecture Set SI Coming on Board This is too late!-- Operating Philosophy Developed (SOO) SI must “work around” system architecture to meet recipe requirements Either too much or too little hardware & application software estimated Automation boundaries and process system boundaries disconnected Excess of control and equipment modules required based on process and instrument design Workflow considerations not addressed To achieve the most efficient, value-added batch automation implementation, the S88 Model must be developed during Preliminary Engineering (BOD Phase). Challenge:  Convince Project Managers of the benefits of spending the time and funds during BOD to define the S88 Model. Using the S88 Model to Develop the Optimal Batch Control Strategy Should be defined during P&ID Development: Coordination with system boundaries Required for proper control system  segmentation Allows ‘like’ functions to be designed in a ‘like’ manner (CM and EM) Allows proper instrumentation strategies to be designed which meet user requirements Provides basis for logical divisions of process descriptions Gives realistic basis for cost estimate for automation Should be defined during BOD activities: Provides confirmation of completeness of Sequence of Operations Validates workflows and operator interactions with control system Provides definitive scope and most accurate basis for estimate Validates that the overall control strategy works within the process framework Helps identify gaps in the process and automation designs Facilitates spatial planning (HMI location, etc.) Setting up S88 Model can aid in: Determining best instrument technologies to use Determine proper segmentation of instrument busses Identification of CM classes Required data inputs/outputs for control strategies (VFDs, PID, etc.) S88 Model can help determine: Best segmentation of process Proper boundaries for operations and control strategies to support flexibility and operational requirements. Optimum controller locations Most efficient panel layouts Proper scope of panel components (controllers, IO, etc.) S88 Model can help: Determine phase classes Required facilities for meeting user requirements (barcodes, manual procedures, reporting, etc.) Proper scope of phase control based on process and operational requirements Development of the S88 Procedural Model helps to: Identify system boundaries and equipment classes Determine optimal segmentation of the process Identify special material addition cases and “one-off” procedures Determine interactions between units and equipment modules Determine which operations and modules should be shared Development of the S88 Model should be a part of the planning process. The first-cut model can be derived from the PFD’s or Rev. A P&ID’s. The model can help determine how the Automation Vision should be implemented to meet the operational requirements. The S88 Model should be revised as required during the BOD phase as the P&ID’s change. The S88 model should be shared and reviewed along with the P&ID’s. The S88 Model should be an item on the Level 2 schedule. The S88 Model should be linked to P&ID development, SOO development, URS development, and System Architecture development. The S88 Model should be a BOD deliverable and sign-off should be an Automation milestone. Benefits from an Early Deployment of the S88 Model Project Unity Aligns project deliverables and expectations of different disciplines through a common and uniting workflow model Engineering Automation Validation Operations I&C Construction System Integrator Skid Vendors Improve Cost Estimating Provides key information necessary for a realistic and complete +/- 10 % cost estimate +/- 10% accuracy is difficult to realize in BOD without early release of S88 model Better Documentation Quantifies the scope and number of workflow documents required. Provides a baseline model that can be used to identify the scope of integration services required Provides a baseline model that can be used to create informative and well engineered bid packages (Request for Proposal) Your cost estimate accuracy is directly related to the quality and completeness of the documentation that request the proposals Better Documentation Provides a model as to how the Sequence of Operations (SOO’s) should be organized and the process control descriptions presented Improves language of SOO’s so that they easily translate into Functional Specification language Authors are better antiquated with how process equipment is controlled resulting in a more informative SOO. Encourages Validation Input Earlier (If Required) Provides a basis on which to validate the system architecture, system boundaries, panel boundaries, and control schemes Aligns Validation expectations with Automation expectations Apple to Apple comparison between Validation and Automation project Planning & Scheduling and Cost Estimating More Efficient Detailed Design Phase Improved SOO’s resulting from the early release of the S88 model creates the foundation for accurate and complete Functional and Detailed Design Specifications A more efficient Detailed Design phase can be realized! Well Designed Automation Code Less customization required Better control schemes deployed Improved standardization Repeatable and manageable code Well designed traceability between documentation and code Easily expandable code for those Future expansions Summary Standardization of project management activities across different departments and companies Allows for complete and realistic cost estimation Encourages a common hierarchy and structure of workflow documentation formatting and content Develops the proper dependencies between Automation, Validation, I&C, and Construction Improves the quality of information presented to the Detailed Design phase participants A more efficient Detailed Design phase can be obtained Better Code! Better System Architecture! Critical task of every good S88 Area Model “Thou shall” Thou shall Define Process Areas and organize PID’s and workflow documentation, schedules, budgets, etc. likewise……….align with validation! Thou shall Define Process Cells within Areas Thou shall Define Unit Classes within Process Cells and decide how to structure workflow documentation such as FR’s/SDS’s. (Per Unit Class or per Process Cell?) Thou shall Define Phase Classes and their association with parent Unit Classes Thou shall Define Equipment Modules and understand their importance at all levels of design………include references to EM’s in SOO’s and Process Control Descriptions! Thou shall Identify Shared Resources and analyze potential bottlenecks Thou shall Study Unit to Unit transfers and the impact of cross controller communications Study Process Cell to Process Cell transfers Define data transfer requirements between PLC’s & DCS & PC’s