Vieille, Vitté AkdenizSlide 1 Flow Analysis applied to S88 equipment control WBF Working Group Update Jean Vieille – Eric Vitté – Omer Akdeniz presented at the World Batch Forum –2002 European Conference

Vieille, Vitté AkdenizSlide 2 FBF 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

Vieille, Vitté AkdenizSlide 3 Flow 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

Vieille, Vitté AkdenizSlide 4 Background : 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 –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

Vieille, Vitté AkdenizSlide 5 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

Vieille, Vitté AkdenizSlide 6 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

Vieille, Vitté AkdenizSlide 7 Hard facts Multipurpose, 3 lines pharmaceutical plant –34 units / shared EMs –600 instruments –200 phases FA replaced 1700 interlocks among combinations

Vieille, Vitté AkdenizSlide 8 Flow 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

Vieille, Vitté AkdenizSlide 9 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

Vieille, Vitté AkdenizSlide 10 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

Vieille, Vitté AkdenizSlide 11 Scope 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

Vieille, Vitté AkdenizSlide 12 FA Background : Operational safety T1 T2 P1 T3T4 P2 T5T6T7 T8

Vieille, Vitté AkdenizSlide 13 Who controls actuators? Breakdown? Safety System? Control System? Operator?

Vieille, Vitté AkdenizSlide 14 Control 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

Vieille, Vitté AkdenizSlide 15 FA 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.

Vieille, Vitté AkdenizSlide 16 Possible S88 physical topology Process Cell Unit EM CM EM CM

Vieille, Vitté AkdenizSlide 17 Typical S88 physical topology Process Cell Unit1Unit2EM3 EM1EM2 CM7CM4CM1CM3CM8CM2CM10CM6CM5CM9

Vieille, Vitté AkdenizSlide 18 Common S88 physical topology Process Cell Unit1Unit2EM1 CM7CM4CM1CM3CM8CM2CM10CM6CM5CM9

Vieille, Vitté AkdenizSlide 19 FA – S88 physical topology Process Cell Unit1Unit2EM3 EM1EM2 DM7DM4DM1DM3DM2DM10DM6DM5 CM1CM2CM3 EM3’ DM9DM8 CM4 Phase Y needs these CMs Phase X needs these CMs

Vieille, Vitté AkdenizSlide 20 CMs 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

Vieille, Vitté AkdenizSlide 21 M From Storage Inert Gas Vacuum Waste Air Cold Out Cold In Hot In Hot Out Next Unit FBDM Material Energy Sky Energy Utility Breackdown example

Vieille, Vitté AkdenizSlide 22 FA 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 CM3 Tank V2 V1 V3

Vieille, Vitté AkdenizSlide 23 FA modelling CM 3 CM 4 FBDM2 FBDM3 CM 3 CM 4 CM 2 CM 1 FBDM1 FBDM6 FBDM5 FBDM4 CM 5 CM 6 CM1 CM2 CM6 CM5 FEED A from S1 FBDM1 FBDM2 FBDM3 FBDM4 FBDM6 FBDM5

Vieille, Vitté AkdenizSlide 24 Multi-flow Control Module FBDM1 FBDM2 FBDM3 FBDM4 FBDM5 FBDM6 Control Module Node1 Node2 Gate1 Gate2 Gate3 Gate4 Gate5 Gate6

Vieille, Vitté AkdenizSlide 25 CM data model Control Module Element Control Module Property Flow Breaking Device Control Module Control Module Class Material Property 0..1 Gates 0..n n May inherit the properties and gates of  Control Module Node 0..n

Vieille, Vitté AkdenizSlide 26 Progress - Help The 3rd draft should be published at the conference time –Hope to publish the report early 2003 We need your help! –Go to: –Subscribe to our mailing list –Download the current draft –Send your comments or your encouragement It’s all in ENGLISH!

Vieille, Vitté AkdenizSlide 27 Thank you