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HVAC standardisation HVAC standardisation @ Janssen Pharmaceutica Belgium :@ Janssen Pharmaceutica Belgium : status updatestatus update

SIEMENS Life SIEMENS Life Science DAY 2009Science DAY 2009

Mario Don Porto CareroMario Don Porto CareroJanssen PharmaceuticaJanssen Pharmaceutica

June 2009

HVAC standardisation HVAC standardisation @ Janssen Pharmaceutica Belgium :@ Janssen Pharmaceutica Belgium : status updatestatus update

Speakers CornerCase study 1Once upon a time….Siemens PLC S7 (Janssen Pharmaceutica anno 2003)

Siemens Desigo (Johnson & Johnson anno 2009)

Case study 2 (Chemical Development Pilot Plant)

Lessons Learned

HVAC standardisation HVAC standardisation Speakers Corner

Mario Don Porto Carerosenior manager HVAC @ Johnson & Johnson

HVAC engineer since 1992Different roles and responsibilities- technical owner- start up/commissioning & verification manager- HVAC design engineer

Contacttel +32 14 60 2412email [email protected]

HVAC standardisation HVAC standardisation Case study 1 : Siemens Blocks

The project URSThe project URS

‐‐a new building with : 1 front door / 3 windows / a new building with : 1 front door / 3 windows / roofroof

A contractor is involved, he is an expert in A contractor is involved, he is an expert in composing blockscomposing blocks

This is Siemen, he’s the future user of a new project …


First approachFirst approach

100% compliance with URS but 100% compliance with URS but not what the user had in mindnot what the user had in mind

Total project time (>30 minutes Total project time (>30 minutes / parts were missing)/ parts were missing)


Second approach : Second approach : use of small predefined functional blocksuse of small predefined functional blocks? ? how to combine these small functional blocks ?how to combine these small functional blocks ?

Result : more Result : more similarities with similarities with what user had in what user had in mind but still many mind but still many points of discussionpoints of discussion(project time 25 min) (project time 25 min)


Third approach : A detailed functional description is Third approach : A detailed functional description is now available. now available.

But the Siemen is still But the Siemen is still not completely not completely satisfied :satisfied :1 mistake was made1 mistake was madeand it takes too long (7 and it takes too long (7 min 29 sec) min 29 sec)


From previous projects they learned that they need From previous projects they learned that they need always a door, walls with windows, a roof and a always a door, walls with windows, a roof and a certain floor lay outcertain floor lay out……..

Having these Having these functional functional combinations combinations available upfrontavailable upfront……they might be able to they might be able to complete the job complete the job faster and with the faster and with the same qualitysame quality


Final resultFinal resultproject finished in 50 seconds : 0 mistakesproject finished in 50 seconds : 0 mistakes

a happy customera happy customer

HVAC standardisation HVAC standardisation Once upon a time….

HistoryHistory

Early 90Early 90’’‐‐ start using typical PID objects (see next page)start using typical PID objects (see next page)

Late 90Late 90’’‐‐ mechanical contractor (Keysers) : 8 standard PIDmechanical contractor (Keysers) : 8 standard PID’’s for AHUs for AHU‐‐ start using copy / paste of system descriptionstart using copy / paste of system description

20032003‐‐ generic PID (incl. Tagging) (see p19) generic PID (incl. Tagging) (see p19) ‐‐ generic functionalities in DSD generic functionalities in DSD ‐‐ generic functionalities in programgeneric functionalities in program


HistoryHistory‐‐ Question from system owner (2002)Question from system owner (2002)““How can we defend the cost for Siemens PLC controllers to our How can we defend the cost for Siemens PLC controllers to our customers ?customers ?””Are we still doing the right thing ?Are we still doing the right thing ?

‐‐ SurveySurvey* matrix containing different items (project, life cycle, * matrix containing different items (project, life cycle, quality, costs, quality, costs, ……))* weight factors for different items* weight factors for different items* facts and figures* facts and figures* scores* scores* conclusion and decision via committee* conclusion and decision via committee


HistoryHistoryResults and conclusionsResults and conclusionsSiemens +: organisation, quality procedures, free Siemens +: organisation, quality procedures, free programming possibleprogramming possibleSiemens Siemens ‐‐ : HVAC knowledge is depending on integrator : HVAC knowledge is depending on integrator DDC provider+ : good general HVAC knowledge, if you can DDC provider+ : good general HVAC knowledge, if you can use their standards ituse their standards it’’s OK s OK ……DDC provider DDC provider ‐‐ : : …… but if you want to change itbut if you want to change it’’s difficult.s difficult.DDC provider DDC provider ‐‐ : Qualification: Qualification

‐‐‐‐> Siemens PLC is still the best choice for us but we have to > Siemens PLC is still the best choice for us but we have to do something about the HVAC knowledge.do something about the HVAC knowledge.


Why a change was neededWhy a change was needed……

In the past the quality and integrity of a system (specifically In the past the quality and integrity of a system (specifically the software) was depending on the contractor. Many the software) was depending on the contractor. Many surprises occurred and many changes were needed during surprises occurred and many changes were needed during development, construction and start updevelopment, construction and start up

Time schedule and / or lack of detailed information during Time schedule and / or lack of detailed information during detailed design versus lack of HVAC knowledge by detailed design versus lack of HVAC knowledge by software integrator. software integrator.

> Gaps in transfer of information between HVAC main > Gaps in transfer of information between HVAC main contractor and software integratorcontractor and software integrator

HVAC standardisation HVAC standardisation Siemens PLC S7 (JPH anno 2003)

Complete integrated mechanical design, functional Complete integrated mechanical design, functional description, software and testingdescription, software and testing

Goal : make a standard design that is flexible and easy in Goal : make a standard design that is flexible and easy in use and the performance is (almost) independent from use and the performance is (almost) independent from project team.project team.

(generic) PID (generic) PID ‐‐‐‐> standard construction > standard construction (example see page 19)(example see page 19)PID based on standard components with fixed tags (to prevent as PID based on standard components with fixed tags (to prevent as much as much as possible changes in software)possible changes in software)

(generic) System and functional description (generic) System and functional description ‐‐‐‐> standard > standard functionalities functionalities 80% of all possible needed options are 80% of all possible needed options are already foreseenalready foreseen


DRC / DSEC and CSU projects DRC / DSEC and CSU projects ‐‐ the ideal innovation the ideal innovation environmentenvironment


DRC / DSEC and CSU projects DRC / DSEC and CSU projects ‐‐ the ideal innovation the ideal innovation environmentenvironment

Total HVAC budget : +/Total HVAC budget : +/‐‐ 23 million $23 million $

3 of 3 HVAC contractors involved3 of 3 HVAC contractors involved

2 of 3 Software Integrators involved2 of 3 Software Integrators involved

3 of 3 Internal Customers Involved3 of 3 Internal Customers Involved

‐‐‐‐> Interdepartmental, > Interdepartmental, ““IntercontractoralIntercontractoral”” teams. teams. The experience of the past meets the state of the art of The experience of the past meets the state of the art of today and the requirements of the future. today and the requirements of the future.


An example : Recovery CoilsAn example : Recovery Coils

PIDPID

DSDDSD

Software = DSDSoftware = DSD

Testing Testing ‐‐> based on certificates and integration testing> based on certificates and integration testing

HVAC standardisation

Requirements for functional specs and verification

HVAC standardisation J&J anno 2009

HVAC standardisation HVAC standardisation J&J anno 2009

o HVAC typicals – Done

o HVAC controls related to the typicals – Draft available

o Test matrix development for HVAC - Done

o Test script develop for HVAC, BMS, Chiller – under construction

--> Example of test template ( non QBMS system JPH Belgium”)

--> Example of test template J&J

HVAC standardisation HVAC standardisation J&J anno 2009 (testing and verification)

(extra) INPUT

green tag / blue tag (buckets) alligned with SD&V / SDP cleanroom and integrated in list

– Construction testing / Pre - functional testing / Green Tag /Functional testing / Blue tag…

Splitt Controller / HVAC system / Clean roomFIG. 1: HVAC/CLEAN ROOM/BMS SYSTEM TEST BOUNDARIES

CLEAN ROOM

TERMINAL HEPA

HC

TT

TV

REHEAT COIL

HVACTESTING

BMS PRE-FUNCTIONALTESTING

UTILITIESTESTING

CLEAN ROOM TESTING

PIPINGPRESSURETESTING WITHUTILITIES

RECEIPT,INSTALLATION,

CALIBRATION WITHHVAC

I/O TESTING WITH BMS,FROM DISPLAY TO FIELDDEVICE, INCLUDINGPROPER CONNECTION TODEVICE AND CORRECTVALVE OR DAMPERSTROKE LENGTH ANDDIRECTION

APPLICATION SOFTWARE

TC AOAI

FIELDPANEL

BMS FAT

SERVER INSTALLATION WITH HVAC

I/O TESTING WITH BMS,FROM DISPLAY TO

FIELD DEVICE,INCLUDING PROPER

CONNECTION TODEVICE

TT

PDITI

AI AI

PDT

RECEIPT,INSTALLATION,

CALIBRATION WITHCLEAN ROOM

HVAC standardisation HVAC standardisation J&J anno 2009 SDP cleanroom SDP cleanroom

General : Goal is to create ready for use (= ready for copy/paste + small project specific modifications) PID & DSD in compliance with SDP cleanroom guideline “Air Handling PIDs”

Advantages : – standard practice - proven technology– Reuse of documents / test templates / test reports (module testing) /

program– High speed development of documents / short review periods– High predictability of quality level

Disadvantages– “Reduced creativity/innovation” level for (automation) contractor -

motivational aspectssolution can be - dedicated “expert team”

HVAC standardisation HVAC standardisation J&J anno 2009 SDP cleanroom SDP cleanroom

Existing : generic PID and DSD for PLC - controllers(Siemens PLC S7 with CFC HVAC library)

since 2002 more than 30 HVAC systems are programmed with “the same Siemens PLC S7 software” (in vitro and in vivo labs, pharma inlc. Sterile manufacturing, offices, chemical production, )reference (PJRC, DSEC, CDPP (head block), Visine, Hydrogenation plant,CSU, …)What’s New : generic PID & DSD for DDC -controllers (see recommendation SDP automation)(Siemens Desigo PX with CFC HVAC library)reference project (CDPP process building )planning :

– Q4 2008 generic documents + program ready for use– Q3 2009 HVAC running for CDPP

Future (dream?) : same WW approach including “other preferred (*1) software contractors”

(*1) based upon location (US-EU-Asia), corporate frame work agreements..

HVAC and SDP cleanroom HVAC and SDP cleanroom PID (SDP cleanroom)PID (SDP cleanroom)

HVAC and SDP cleanroom HVAC and SDP cleanroom PID Siemens PLC = PID Siemens DesigoPID Siemens PLC = PID Siemens Desigo

HVAC and SDP cleanroom HVAC and SDP cleanroom PID PID (Siemens PLC / Siemens Desigo) (Siemens PLC / Siemens Desigo) functions/option 1,2,3,4functions/option 1,2,3,4

HVAC and SDP cleanroom HVAC and SDP cleanroom PIDPID (Siemens PLC) (Siemens PLC) functions/option 1,2,3,4functions/option 1,2,3,4

HVAC and SDP cleanroom HVAC and SDP cleanroom PID PID (Siemens Desigo) (Siemens Desigo) functions/option 1,2,3,4functions/option 1,2,3,4

HVAC standardisation HVAC standardisation Case study 2

Chemical Development Pilot PlantChemical Development Pilot Plant

Total project cost = 130 million EuroTotal project cost = 130 million Euro

NON gmp critical BMS with on top a independent QBMSNON gmp critical BMS with on top a independent QBMS

3 + 1 AHU : in total +/3 + 1 AHU : in total +/‐‐ 220.000 m3/h (210.000 single pass)220.000 m3/h (210.000 single pass)

‐‐ Question from SDP (2006)Question from SDP (2006)““How can we defend the cost for PLC controllers to our customers How can we defend the cost for PLC controllers to our customers ??””Are we still doing the right thing ?Are we still doing the right thing ?

3 Desigo PX controllers / 1 Siemens S7 plc3 Desigo PX controllers / 1 Siemens S7 plc

connecting Desigo with the existing BMS for alarming and reportconnecting Desigo with the existing BMS for alarming and reporting ing was challenging was challenging

HVAC standardisation HVAC standardisation Lessons Learned : Projects

only if you have multiple projects (>5) it is beneficial to creaonly if you have multiple projects (>5) it is beneficial to create te your own standardyour own standard

only if you have multiple projects (>2) it is beneficial to the only if you have multiple projects (>2) it is beneficial to the user user to implement an existing standard approachto implement an existing standard approach

standard can be reused for +/standard can be reused for +/‐‐80% in pharma 80% in pharma ‐‐ lab buildings lab buildings ––offices offices –– chemical plantschemical plants

once you have the standard, mechanical design, software design once you have the standard, mechanical design, software design and integration, start up and maintenance cost will be reduced and integration, start up and maintenance cost will be reduced by factor 0.5 to 10 (depending on team !!!)by factor 0.5 to 10 (depending on team !!!)

HVAC standardisation HVAC standardisation Lessons Learned : Team

Keep a core team available on both sides (user and software Keep a core team available on both sides (user and software integrator)integrator)

New user : results in additional (other) functionalities becauseNew user : results in additional (other) functionalities because‐‐ he isnhe isn’’t aware of the initial possibilities (changing functionality t aware of the initial possibilities (changing functionality with parameters) with parameters) ‐‐ he is referring to other projects/experiences of the pasthe is referring to other projects/experiences of the past

focus is lost focus is lost

New software integrator (can be @ the same company) New software integrator (can be @ the same company) ‐‐ misinterpretations : extra time needed to explain again the sitmisinterpretations : extra time needed to explain again the site e or plant specific requirementsor plant specific requirements‐‐ is spending more time to create documents, is making new is spending more time to create documents, is making new documents, documents, ……..

routine is lostroutine is lost

you need more time and get lower qualityyou need more time and get lower quality

HVAC standardisation HVAC standardisation Lessons Learned : WWE

Keep a core team available on both sides (user and software Keep a core team available on both sides (user and software integrator)integrator)

Compose user requirements based upon standard PID, Compose user requirements based upon standard PID, functional description (user, SDPfunctional description (user, SDP‐‐representative, representative representative, representative software integrator)software integrator)

Software can be developed and preFAT tested at home office of Software can be developed and preFAT tested at home office of software integratorsoftware integrator

Small affiliates can benefitSmall affiliates can benefitfrom the knowledge from the knowledge and lessons learnedand lessons learned

HVAC standardisation HVAC standardisation The future (anno 2003)

How others can benefit from our standardsHow others can benefit from our standards

J&J J&J is not a software company so we are not going to sell is not a software company so we are not going to sell the HVAC standards. But we are going to promote them.the HVAC standards. But we are going to promote them.

There is an interest of companies who have already There is an interest of companies who have already Siemens PLCSiemens PLC’’s for water/HVAC systems or who need a high s for water/HVAC systems or who need a high degree of flexibility / accuracy / testing (validation)degree of flexibility / accuracy / testing (validation)(other pharmaceutical companies, nuclear industry, (other pharmaceutical companies, nuclear industry, ……))

HVAC standardisation HVAC standardisation The Fututre (anno 2003)

How can we have a benefit because of others having a benefit How can we have a benefit because of others having a benefit of our standardsof our standards

Because of this interest we will get more and better Because of this interest we will get more and better motivated contractors.motivated contractors.

> Leveraging knowledge and experience> Leveraging knowledge and experience

HVAC standardisationHVAC standardisationWe can make the differenceWe can make the difference

03-sep-08 : The Netherlands will invest 100 Billion Euro to prevent from flooding

03-sep-08: windrecord for cuba : hurricane Gustav 340 km/h

28-aug-08: the North Pole is melting "The sea ice cover this year has reached a new record low"

Climate change ?

Please try to reduce your

energy consumption

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