The Digital Twin in the water business in context with ISA 95...ISA-95 is a norm for integration of business- and manufacturing management level. ISA-95 is based on ISA-88, extended

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The Digital Twin in the water business in

context with ISA 95From Data to value

Frei verwendbar © Siemens AG 2018 Page 2

Agenda

What‘s behind ISA-95 ?

Benefit of the digital twin

Dgital twin in context with ISA-95

Idea of the digital twin

The digital twin and ISA 95 in the water business


What’s behind ISA-95 ?

International Standard ANSI / ISA-95 ( ISA: Instrumentation, Systems and Automation Society )

ISA-95 is a norm for integration of business- and manufacturing management level.

ISA-95 is based on ISA-88, extended from control system level for batch operation to plant management level

for discrete and continuous processes

ISA S95 closes the gap between business- and manufacturing processes.

Connecting business administration with operation: ERP ( Enterprise Ressource Planning ) with MES (

Manufacturing Execution Systems via:

- Models of exchanged information between business logistic systems and manufacturing information systems

- Models of activities in manufacturing operations systems

- Models of exchanged information within manufacturing operations systems


ISA-95 in the environment of business and manufacturing work processes


ISA-95 components in the environment of a DCS

Every ISA -95 functional bubble

corresponds to one component

in an IT architecture for a DCS

( Distributed Control System )


Example: SIMATIC IT and ISA-95

SIMATIC IT ( Siemens ) is an approach for manufacturer management / MES which is in line with ISA-95.

Each functional ISA-95 section corresponds to one component of SIMATIC IT

SIMATIC IT links and integrates business level with manufacturing level, provides communication, process

synchronisation and coordination within the plant or several plants, it coordinates the complete supply chain.

SIMATIC IT provides industry – specific, configurable applications

A flexible tool package allows users to develop fast and quick their own applications to fulfill their specific

requirements and operational procedures, which can be stored in reusable librairies for a fast prototype

generation and built up companywide standards

SIMATIC IT communicates with all functions and events of the DCS platform SIMATIC PCS 7

SIMATIC IT shares a common Historian and gets thereby direct access to PCS 7 process data.


Idea of the „digital twin“

What‘s in the digital twin ?

The digital twin consiss of 3 components:

• the real plant

• the digital twin in the virtual space ( data model )

• The informations, which are connecting both

The digital twin combines the following functionality:

• the digital twin connects the real and the virtual world. The digital twin is the virtual model of the process

• the digital twin uses real process data

• the digital twin is a module of Integrated Engineering

• the digital twin is a module of Integrated Operation

The digital twin is an image of the whole plant and will be used during the overall life time cycle


What can the digital twin achieve?

For the overall life time cycle of the plant:

First phase „design“:

Handling complex project requirements, short time for realization.

By means of the digital twin, impact of different design alternatives can be explored, simulations and tests can be initiated to

ensure, that the project design fulfills the requirements.

Second phase „erection“:

The digital twin can help to increasse efficiency, quality during the erection phase.

Third phase „operation“:

The digital twin can be used to improve the availibility and the efficiency of processes.

Furthermore the digital twin can be used to generate sceanrios offside of the real plant to support planning of migrations,

maintenance, expansion, revamps to reduce non-conformity costs and costs for proof-of-concept activities.

The interconnection between the real and virtual world enables to analyse data, problems will be identified in a very early stage

before faults will arise.

Down-times can be reduced or avoided.


The digital twin as part of the integrated engineering and a continous data

model for the overall life time cycle

Integrated Engineering

3D

2DControl

Simulation and 3D-visualisation enables i.a authoring, virtual commissioning or operator trainings and supports maintenance activities

Digital twin of the real plant in actual status („as is“), integration of plant - and process databased on the common data model

Integrated Engineering over all subsections of a plant; engineering tools combined with control systems and field devices, i.e. measurement devices, analytics

Product design Process -/ plant design Engineering Operation Services


Integrated Engineering for the water business:

Digital twin and 3D visualisation of the plant

During the enginering – phase the digital twin arises

before the real plant will exists

… this creates the possibility for 3D visualization of the

plant, i.e. for training purposes of operators

Product designProcess &

plant design

Engineering &

commissionugOperation Service1 2 3 4 5


Produktdesignprocess -andplantngestaltung

Konstruktion/Inbetriebsetzung

Betrieb Service

Integrated data from all sections supports decisions, optimizing productivity

and enables new control schemes by means of the digital twin

Integrated Operation

Higher Productivity and decision support by providing more transparency, analytics and

services, optimizing by (cloud-based) real-time data analysis, high sophisticated tools /

services and simulation

High sophisticated, scalable control system including remote control, interoperability,and proved safety, modularisation and virtualization via scalable plc‘s, optimized

interoperability and open interfaces

Simply integration of the field level (libraries, connectivity) and higher intelligence,

digitalisation of the feld level with complete and simple integration („Plug&Produce“),

embedded intelligence

Reliable data interconnections backbone of integration as well as for remote operation

and –services, complete interoperability and extended remote operation and services

by all-over connectivity

Dig

ital tw

in

Co

mm

un

ika

tion

Technology: Hardware Software

App(lication)data-

services

Cloud


The „digital twin“ enables process optimization

due to simulation, i. e. for water treatment plants

Plant simulation... …enabled by the digital twin

Consulting service

for process-analysis

Simulation model

and environment

Core elements

of the portfolio

1

2

1

2

Plant simulation for modelling, simulation and analysing of the

complete process for

• Visualisation of dynamic process behaviour, taking in

consideration all restrictions of the process

• Generating a base for improvement and Investment decisisons

Technical experts –Consulting:

• Understand the target scenario

• Configuring the system

Plant Simulation –Simulations-

environment including pre-configured

libraries

Water treatment plant

3

2

1


Benefit of the digital twin

Benefit of the digital twin for the user:

• Simulation for the engineering-phase / commissioning-phase

• Simulation for operation optimization

• Simulation for planning of expansions, revamps, migrations, maintenance

• Higher transparency because of comprehensive documentation

• Faster and more secure commissioning

• Optimal as built documentation after commissioning

• Documentation more easy to handle after expansions, revamps, migrations, maintenance

• All participants in planning, operation, maintenance are getting all identical informationen from all sectors and –disciplines at the

same time

• Faster, less-effort, more focused trouble shooting during commissioning or operation

All of the above mentioned items are leading at the end to an increase of availibility of the plant and as a

consequence to cost reduction


Digital twin in context with ISA-95

High level of standardization helps to generate the digital twin easier and more entirely

Following ISA-95 standards, ERP ( Enterprise Ressource Planning ) data can be integrated into the digital twin.

Thus, business processes can be taken into consideration in simulation scenarios.

Simulation of scenarios can run based on real capacity / resource status

Helps to generate optimal planning regarding personal, material, resources by taking data from ERP into

consideration by simulating different operational scenarios.

Examples for the water business:

- Energy cost optimization i.e. by using flexible tariffs for real-time purchase / sales ( of own energy )

- More detailed planning of revamps, migration / restructuring activities, maintenance etc. by taking into

considerations more details regarding personal capacities, material, storage capacities, warehouse etc.

- Rapid feedback about consequences of rescheduling of subsections ( or plant-wide ) not only on a technical

level, but also on a business level.


The digital twin and ISA 95 in the water business

Advantages of the digital twin and ISA 95:

• Enables fast generation with less effort of various scenarios for supporting of extensions, revamps, maintenance, migrations

etc. Thereby availibility and operational safety will be inreased.

• Facilitates the implementation of others ( i.e. system integrators ) for commisioning, extensions, revamps, maintenance.

• Increase the level of independency from single providers and system integrators

• Makes integration easier and increases the value of systems like GIS or BIM.

• Ideal training for operators and maintenance staff available

• Cost reduction during all life cycle phases and applications

• „State of the Art“

Disadvantages:

• Investment

• Maintenance

• Skills and training

Conclusion:

the digital twin supports to increase availability and

efficiency as well as protecting investments and

accounts for an important contribution in the water

business.

By using ISA 95, this will boosts this effects.

.


Digitalization in the water business

Thank you very much !

Documents

The Digital Twin in the water business in context with ISA 95...ISA-95 is a norm for integration of business- and manufacturing management level. ISA-95 is based on ISA-88, extended