Total Automation: The Next Frontier Is Sensor to Cloud

“Through all layers, the objective of total automation is to use disruptive technology to streamline and automate all processes,” Mustard said.

Brandl agrees that a total automation standard would apply to all layers of the ISA 95 model (Figure 1). “Layer 2 is covered by existing ISA and automation standards. Layer 1 is partially covered by the standards on maintenance and security (automated calibration, automated cleaning, automated alignment, automated error detection, etc.). Layer 3 is mostly covered by ISA 99, 95, and 88. The concept of interoperable distributed workflows helps fill in some of the missing pieces, in my opinion,” he said.

• Reliability/maintenance of rotating equipment, valves, etc.

• Integrity (corrosion/erosion) of piping and vessels.

• Safety (including health and environment): safety showers, manual valves, etc.

• Production/quality would require sensors in place of mechanical gauges.

The technology that supports a proposed standard does not define an architecture per se. It does, however, imply a definite increased sensor count—more sensors in existing architectures. Sensors are selected, installed, configured, and supported by instrument and control personnel, many of whom are members of ISA, according to Bergeee.

In addition, this standard will make plants more sustainable. By using the appropriate sensors, collected data would detect and pinpoint energy overconsumption, emissions, and equipment inefficiency. It could monitor cleaning optimization and help reduce flaring. Downtime would be reduced due to more predictive maintenance, failure prediction, and reduced loss of containment. Plants will be safer because of reduced human error, and fewer manual valves and leaks. Finally, automating existing manual data collection will enable plants to be more productive.