Vieille, Vitté AkdenizSlide 1 Flow Analysis applied to S88 equipment control WBF Working Group...

Vieille, Vitté Akdeniz Slide 1

Flow Analysis applied to S88 equipment controlWBF Working Group Update

Flow Analysis applied to S88 equipment controlWBF Working Group Update

Jean Vieille – Eric Vitté – Omer Akdeniz

presented at the

World Batch Forum –2002 European Conference


FBF activitiesFBF activities

• New president elected in 2001– Jean-Pierre Bovée from AVENTIS

• 2 conferences in 2000, nothing else to date– Good success (80 – 90 people)

– We stopped because of the relative lack of users’ attendance

• 4 WGs Traceability / S88-FDA / PCF / FA– Only FA goes well because of sponsorship

• SCHNEIDER, ROCKWELL,

• Further help needed


Flow Analysis Working GroupFlow Analysis Working Group

• Joined group WBF – FBF launched in 2000– WBF FA Chair : Jean Vieille

– FBF WG4 Chair : Omer Akdeniz (Sinfor Automation)

• 48 members– 2 au 2 de 21 fr 1 ie 1 is 3 nl 1 sa 1 tu 5 uk 3 us 8 unknown

• Meetings held in Paris– Every 2 months

– Only participants from France to date

– Few comments received from others


Background : Previous workBackground : Previous work

• Astrid / Delta Nodes (FR)– Since 1986 :

• Rhone Poulenc Health, Safety, environment department setup a WG for multi-products process cells operational safety

• Issued an implementation guide for control systems

– JM RAYON set the basics and participated in ASTRID development. He owns the DeltaNodes® trademark • XNODES Case tool, PCNODES HMI http://www.jmrconseils.fr

– Proposed formal modeling rules, restricted applicability

• Flow based batch methodology (AU)– presented in “The Missing Link – A generic process control

model” By Spiro Georgakopoulos and Robert Price (Quemm Associates Pty Ltd)

– Proposed a more generalized approach, less formal rules


Benefits (1)Benefits (1)

A low level protective layer

• Prevent wrong operation at the device level– A valve checks itself if it can operate regarding the

upstream/downstream conditions

– Wrong manual operation, phase code mistakes, valve breakdown, safety preemption are inherently detected and protective action is processed without explicit coding

• Dramatically simplifies exception handling– Reduces implementation overhead, validation effort

– Adding new equipment is much simpler


Benefits –(2)Benefits –(2)

• Consistent set of equipment breakdown rules – Standardized modularization

• Higher level of re-usability– Because of modularization consistency

• Improved operation safety– Do not rely on extensive coding

• Easier exception handling, – Detects automatically most of abnormal situations

• Used as a tool to verify the flow integrity– Cross contamination risk assessment

• Reduced qualification / validation effort


Hard factsHard facts

• Multipurpose, 3 lines pharmaceutical plant– 34 units / shared EMs

– 600 instruments

– 200 phases

• FA replaced 1700 interlocks among 13000 combinations


Flow Analysis WG objectivesFlow Analysis WG objectives

• Improve the method– Solve the current drawbacks

– Take benefit of all inputs form WBF members

• Bring the method to the batch community– Complement ISA88 with critical elements for physical

modeling

– Write a comprehensive guideline as a basis for:• Implementation from both Automation and Process point of view

• Control systems dedicated function blocs development


Vision (1)Vision (1)

• Automation– Help to think Process first

– Clarify ISA88 shaded areas

– Consistent object design to help validation

• Control system design– Provide clear requirements for vendors to support FA

mechanisms

• Process design– Natural approach for matching control to actual equipment

and functionalities


Vision (2)Vision (2)

• Operation– Practical approach making easier operational personnel

involvement in spec and qualification

• Business: Reduces Total Cost of Ownership– Better modularization implies

• Better re-usability

• Better knowledge management

– Dramatic exception handling simplification

– Clear specifications for all lifecycle


ScopeScope

• Flow Analysis addresses (directly or partially)– Control Modules breakdown

– Equipment modules as Units sub-level or shared resource

– Equipment Coordination, Basic and Procedural Control design

– Exception handling within equipment domain

• Flow Analysis doesn’t address: Everything else!– Other Equipment modeling levels (Units, Process cells,

shared Ems)

– Recipes management and execution

– Process management

– Unit supervision

– Production Planning & Scheduling, Production information management


FA Background : Operational safetyFA Background : Operational safety

T1 T2

P1

T3 T4

P2

T5 T6 T7 T8


Who controls actuators?Who controls actuators?

Breakdown?

Safety System?

Control System?

Operator?


Control modulesControl modules

• ISA88 doesn’t say much about CMs• The basic equipment entities building block

• Upper level are only hierarchical virtual equipment starting from actual physical CMs

– Modularization guidance is explicitly excluded in the standard

• Most people understand CM as a single actuating instrument

• Many implementations liken device control to CMs


FA helps for CM / EM definitionFA helps for CM / EM definition

• CM is definitely equipment based– CM is the actual, mandatory physical building block

– CM without any instrument may exist

• Distinguish CM and « Device CM » DM as:– Basic control of a single instrument (actuator)

• Flow Breaking Device Module (FBDM) : – a particular DM which acts as a flow breaker between 2 or

more CMs holding

– includes the FA-based protective layer

• EMs (as sub-units) : – the collection of CMs dynamically assembled at run-time by

an EPE.


Possible S88 physical topologyPossible S88 physical topology

Process Cell

Unit Unit

EMEM EM

CM

EM

CM

CMCM CM CMCM CM


Typical S88 physical topologyTypical S88 physical topology

Process Cell

Unit1 Unit2EM3

EM1 EM2

CM7CM4CM1 CM3 CM8CM2 CM10CM6CM5 CM9


Common S88 physical topologyCommon S88 physical topology

Process Cell

Unit1 Unit2EM1

CM7CM4CM1 CM3 CM8CM2 CM10CM6CM5 CM9


FA – S88 physical topologyFA – S88 physical topology

Process Cell

Unit1 Unit2EM3

EM1 EM2

DM7DM4DM1 DM3DM2 DM10DM6DM5

CM1 CM2 CM3

EM3’

DM9DM8

CM4

Phase Y needs

these CMs

Phase X needs

these CMs


CMs Modelling rulesCMs Modelling rules

• CMs types– Material

– Energy

– Sky (=atmosphere!)

– Utility

– User defined

• Rules– Flow isolation (Nodes notion)

– Closed section (may need imagination)

– Aggregation taking care of:• Flexibility

• Re-usability

• Inter-CMs constraints


M

FromStorage

Inert Gas

Vacuum

Waste Air

Cold Out

Cold In

Hot In

Hot Out

Next Unit

FBDM

FBDM

FBDM

FBDM

FBDM

FBDM

FBDM

FB

DM

FBDM

FBDM

FB

DM

FB

DM

FB

DM

Material

Material

Material Material

Energy

Energy

Sky

Energy

Energy

Utility

Utility

Utility

Utility

Breackdown exampleBreackdown example


FA answer: Secured flowsFA answer: Secured flows

Phase 1 « Fill tank from CM2 » allocates CM2 & CM3

CM1 & CM4 are not allocated (or allocated by another phase)

CM4

CM1

CM2

CM3Tank

V2

V1

V3


FA modellingFA modelling

CM 3

CM4

FBDM2

FBDM3

CM3

CM4

CM2

CM1 FBDM1

FBDM6

FBDM5

FBDM4CM5

CM6

CM1CM2

CM6CM5FEED A from S1

FBDM1FBDM2 FBDM3

FBDM4 FBDM6 FBDM5


Multi-flow Control ModuleMulti-flow Control Module

FBDM1

FBDM2

FBDM3

FBDM4

FBDM5

FBDM6

ControlModule

Node1

Node2

Gate1

Gate2

Gate3

Gate4

Gate5

Gate6


CM data modelCM data model

Control Module Element

Control Module Property

Flow Breaking Device

Control ModuleControl Module

Class

Material Property

0..1

Gates0..n0..n

1..1

0..n

0..n

0..nMay inherit the properties and gates of

Control Module Node

0..n

0..n


Progress - HelpProgress - Help

• The 3rd draft should be published at the conference time– Hope to publish the report early 2003

• We need your help!

– Go to:

www.frenchbatchforum.org/Francais/wg4_fr.htm

– Subscribe to our mailing list

[email protected]

[email protected]

– Download the current draft

– Send your comments or your encouragement

It’s all in ENGLISH!


Thank you

Vieille, Vitté AkdenizSlide 1 Flow Analysis applied to S88 equipment control WBF Working Group...

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