The Digital Twin in the water business in context with ISA 95

Transcription

1 The Digital Twin in the water business in context with ISA 95 From Data to value Frei verwendbar Siemens AG 2018 siemens.com

2 Agenda What s behind ISA-95? Idea of the digital twin Benefit of the digital twin Dgital twin in context with ISA-95 The digital twin and ISA 95 in the water business Frei verwendbar Siemens AG 2018 Page 2

3 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 Frei verwendbar Siemens AG 2018 Page 3

4 ISA-95 in the environment of business and manufacturing work processes Frei verwendbar Siemens AG 2018 Page 4

5 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 ) Frei verwendbar Siemens AG 2018 Page 5

6 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. Frei verwendbar Siemens AG 2018 Page 6

7 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 Frei verwendbar Siemens AG 2018 Page 7

8 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. Frei verwendbar Siemens AG 2018 Page 8

9 The digital twin as part of the integrated engineering and a continous data model for the overall life time cycle Integrated Engineering Control 2D 3D Integrated Engineering over all subsections of a plant; engineering tools combined with control systems and field devices, i.e. measurement devices, analytics 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 data based on the common data model Product design Process -/ plant design Engineering Operation Services Frei verwendbar Siemens AG 2018 Page 9

10 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 Process & Engineering & 1 Product design 2 Operation plant design 3 commissionug 4 5 Service Frei verwendbar Siemens AG 2018 Page 10

11 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 App(lication) Cloud dataservices 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 Communikation Digital twin Reliable data interconnections backbone of integration as well as for remote operation process -and Konstruktion/ Produktdesign and services, complete interoperability and extended remote operation and Betrieb services by all-over connectivity plantngestaltung Inbetriebsetzung Service Technology: Hardware Software Frei verwendbar Siemens AG 2018 Page 11

12 The digital twin enables process optimization due to simulation, i. e. for water treatment plants Plant simulation... enabled by the digital twin 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 Water treatment plant Core elements of the portfolio 1 Consulting service for process-analysis 1 Technical experts Consulting: Understand the target scenario Configuring the system 2 Simulation model and environment 2 Plant Simulation Simulationsenvironment including pre-configured libraries Frei verwendbar Siemens AG 2018 Page 12

13 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 Frei verwendbar Siemens AG 2018 Page 13

14 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. Frei verwendbar Siemens AG 2018 Page 14

15 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.. Frei verwendbar Siemens AG 2018 Page 15

16 Thank you very much! Digitalization in the water business Frei verwendbar Siemens AG 2018 Page 16