1. ASTRID TM
(Analyse STRucturée pour l'Industrialisation des procédés Discontinus)
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

2. JMR Conseil has participated to this WG as external consultant
ASTRID is the result of a working group founded by Health, Safety and Environnement Management of RHONE POULENC Group as part of the program "process control safety".
JMR Conseil has participated to this WG as external consultant
This program concerns the three components of the decision making system in process control.
the operator
safety interlock system
monitoring & control system
OPERATOR
man machine interface
monitoring &
control
control
safety interlock
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

3. OBJECTIVE : TO MASTER SAFE CONTROL OF OUR PLANTS.
TO BE SAFE IN:
control design (automatised or not)
safety interlocks design.
Operation of the process
SAFETY MASTERED ALONG THE LIFE CYCLE OF THE PROJECT:
Design -----> Construction -----> Operation > Maintenance.
OPERATOR
man machine interface
Monitoring &
control
safety
interlock
TOTAL QUALITY APPROACH
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

4. the answer of field people
An analysis method of the control tasks based on a PROCESS MODEL
INDEPENDANT OF THE CONTROL MODE (automatised, manual )
adapted to a mixed control (automatised and manual)
MODULAR, hierarchised objects
easily reconfigurable
WITH A STRONG FORMALISM (no ambiguity, no redondances)
to understand each other
to communicate
to validate
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

5. GENERAL PRINCIPLES: FOUR CLASSES OF HIERARCHISED OBJECTS.
Functional objects :
RECIPES :
production procedure management.
(serial and/or parallel set of phases)
PHASES :
elementary phasis of chemical engineering
Material objects:
EQUIPMENT MODULES :
group of control modules «statically»
interdependant .
CONTROL MODULES :
images of inputs outputs.
plant scheduling
RECIPES
Functional
PHASES
equipment modules
EQUIPMENT MODULES
Matérial
CONTROL MODULES
software
hardware
SENSORS
ACTUATORS
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

6. COMPARISON WITH STANDARDS (ISA SP88 and IEC1512)
ASTRID
ISA/SP88
phasenel
Matériel
phasenel
Matériel
(Partial) RECIPE
RECIPES
OPERATION
UNIT
PHASES
PHASES
EQUIPMENT MODULE
EQUIPMENT MODULE
CONTROL MODULE
CONTROL MODULE
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

7. TRANSFER FROM A TO C
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

8. SPLIT THE PLANT INTO INDEPENDANT ENTITIES, THE EQUIPMENT MODULE: defining somes rules for splitting the P&ID
An equipment module start at the origin of the fluid and finishes before the isolating actuator
The size of elementary equipment module is lower as the flexibility and multipurpose need is high
Vacuum N2 F Q E T2
hot
cold A B C D
cold
hot P1
purge
purge
fluid field F
energy field P2
gas phase (event collector,vacuum...) field
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

9. CONTROL MODES: ADAPTED TO THE COMPLEX SITUATIONS OF THE MULTIPURPOSE BATCH PLANTS .
Commandes
Production control
Automatic mode:
Automatic sequencing of the
phases
Semi automatic mode :
Sequencing of the phases by
operator
Tele control mode:
Actuators are controlled indivi-
dually.
Recipe control is the prefered control mode
RECIPES
Automatic mode
Commandes
Production control
PHASES
Semi automatic mode
Commandes
(development, adjustment) .
EQUIPMENT MODULES
Commandes
telecontrol
CONTROL MODULE
Commandes
(incidents , tunings)
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

10. SINGLE COMMAND OF THE ACTUATORS : ACTUATOR (OR CONTROL MODULE) ALLOCATION TO A SINGLE EQUIPMENT MODULE
An actuator is commanded by only one
equipment module
Internal actuator: by the equipment module
Actuator at the border of two equipment modules:
command allocation to a single equipment module
the actuator command is allocated to the
upward equipment module (recommendation)
The actuator status can be read by the
adjacent equipment modules
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

11. SAFE TELECOMMAND MODE: THE LOCK.
In automatic or semi-automatic modes, we must be able to intervene in telecontrol modes. The lock concerns the actuators at the border of an occupied equipment module. The lock is set to prevent manual activation (by telecontrol) of an actuator).
A phase can occupy an equipment module with border actuators locked. Then, the equipment module can command its internal actuators but cannot command the actuators which are protected by a lock.
The unlock is done by the phase after the use of the equipment module or when a default has been detected (by the phase). In this case the unlock is done according to the sequence defined in the phase.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

12. IMPLEMENTATION MECHANISM
THE LOCK
IMPLEMENTATION MECHANISM
FUNCTIONNAL SAFETY (SPECIALLY ADAPTED TO FLEXIBLE PLANT)
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

13. IMPLEMENTATION MECHANISM OF THE LOCK : Tranfer phase from A to C.
isolating actuator (of a control module) mail boxes E V5
to Y
V14 T1
from X V6 V1 V3 T2 A B V7 V8
V10
V11 V4 V2 C D P1 P2 V9
V10
from F
V13
to Z
to Z
The control module is able to identify the phase occupying the contiguous equipment modules.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

14. IMPLEMENTATION MECHANISM OF THE LOCK : -F1 phase occupies the needed equipment modules. - Each equipment module put in the border actuators mail boxes the phase identifier (F1)
number identifying the phase which occupy the upper stream equipement module
number identifying the phase which occupy the down stream equipment module E F1
to Y V5
V14 F1 T1
from X V6 F1 F1 V1 V3 T2 F1 F1 F1 F1 F1
V10
V11 A B V7 V8 F1 V2 V4 C D F1 F1 P1 F1 P2 V9
V12
from F
V13
to Z
to Z
This mechanism occurs when the equipment module is occupied before any command.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

15. These identifiers determine which actuators can be controlled by the phase.
The phase F1 occupies the upstream equipment module F1
LOCK: The actuator does not accept any command
An other phase (or no phase) occupies the downstream equipment module
(F10)
The phase F1 occupies the upstream equipment module F1
Every command from the upstream equipment module is enabled.
Other commands (automatic, semi automatic or telecontrol)
are disabled.
AND the downstream equipment module F1
No phase occupies the upstream and downstream
equipment module
Telecommand enabled on this actuator
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

16. INSIDE THE PATH , ACTUATORS CONTROL IS POSSIBLE UNDER PHASE RESPONSABILITY
Lock E V5
to Y
V14 T1
from X V6 V1 V3 T2
V10
V11 A B V7 V8 V2 V4 C D P1 P2 V9
V12
from F
V13
to Z
to Z
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

17. THE OPERATOR CAN SEE THE ACTIVATED PATH
Lock E V5
to Y
V14 T1
from X V6 V1 V3 T2
V10 V7 V8
V11 A B V2 V4 C D P1 P2 V9
V12
from F
V13
to Z
to Z
the lock protects the path during the transfer
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

18. FUNCTIONNAL SAFETY, PARTICULARLY ADAPTED TO MULTIPURPOSE PLANTS :
A multipurpose plant must adapt quickly to new production campaign.
This new campaign implies new plant configuration
and new process rules.
Example : One operation allows parallel transfer, an other operation does not.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

19. Phase F1 : Transfer from A to C concurrently with Phase F11 : transfer from F to D :
Identication number of the phase occupying the upstream
equipment module
Identification number of the phase occupying the downstream
equipment module E F1
to Y
F11 V5
V14 F1 T1
from X V6 F1 F1 V1 V3 T2 F1 F1
F11 F1
F11 F1 F1
F11
F11
V10
V11 A B V7 V8 F1 V2 V4 C D F1 F1 P1 V9 F1
F11 P2
V12
from F
V13
to Z
to Z
The lock set on V8, and the lock set on V10 , inhibit the parallel transfer to equipment
modules B and C.
Explicit interlock is not needed.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

20. Phase F10 : simultaneous transfer from A and F to C.
Identication number of the phaseoccupying the upstream
equipment module
Identification number of the phase occupying the downstream
equipment module E
F10
to Y V5
V14
F10 T1
from X V6
F10
F10 V1 V3 T2
F10
F10
F10
F10
F10
F10
F10 V7 V8
V10
V11 A B
F10 V2 V4 C D
F10
F10 P1
F10 P2 V9
V12
from F
V13
to Z
to Z
In this case, parallel transfer is possible, if allowed by the phase.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

21. THIS ENCLOSED PATH INHERITS THE BEHAVIOR OF THE OBJECT CLASS «EQUIPMENT MODULE»
Lock E V5
to Y
V14 T1
from X V6 V1 V3 T2
V10
V11 A B V7 V8 V2 V4 C D P1 P2 V9
V12
from F
V13
to Z
to Z
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

22. THE PROGRESS OF THE COMMAND FROM THE RECIPE TO THE CONTROL MODULE
Product name
Header
Products, variables, etc...
Process parameters
Physical and chemical caracteristics, volume,
capacity...
Equipments parameters
OBJECT
«RECIPE»
Procédure
phases
Dynamic links
The manager send parameters to the phase to be activated
(Id) Loads
(Id) Agitates
(Id) End
Process parameters
Process parameters
Process parameters
Equipment parameters
Equipment parameters
Equipment parameters
OBJECT
«EQUIPMENT MODULE»
control description
(1131-3)
control
description
(1131-3)
control description
(1131-3)
Dynamic links
OBJECT
«CONTROL MODULE»
Equipment module1
Equipment module 2
Equipment module n
Static links (plant configuration)
Operator’s tele command brake this link
OBJECT
«CONTROL MODULE»
control module 1
control module 2
control module 3
control module n
ACTUATORS
SENSORS
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

23. LINKS AND INFORMATION EXCHANGES BETWEEN OBJECT CLASSES
PHASE
AGITATE
LOAD
Temporary Links
(dynamic)
RESSOURCE
AGITATOR
REACTOR C
PIPE T1
PUMP P1
TANK E
Permanent links
(static)
control module
LEGENDE :
Permanent link
Dynamic link (activated when equipment module is occupied by the phase)
Information
Information (activated when equipment module is occupied by the phase)
Lock
A phase can read information coming from other phases or equipment module
according to the description of the phase behaviour
Information related to lock
This is the single case of horizontal communication.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

24. ASTRID: conclusion
monitoring &
control
OPERATOR
man machine interface
monitoring &
control
safety interlock
Most of control equipment vendors refer to the model proposed by ISAS88/IEC The top down approach adopted by S88 working group is non ambiguous and based on a rigorous formalism for the upper functional layers, recipe, phase.
The lack of rigorous formalism for the lower layers «hardware oriented» let the instrumentation people free to implement, on his own way, the transfer to the actuators (control module) of the orders coming from the upper functional layers.
Therefore, the quality of the solution is higly dependent of the instrumentation people’s skill.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

25. OPERATOR
man machine interface
safety interlock
monitoring &
control
ASTRID: conclusion
To progress towards an «INTRINSEC» quality and safety solution, Rhône Poulenc has adopted a process model based on four hierarchised object classes.
Rhône Poulenc focused on the material object «equipment module» which is the single path for transfering orders from the phases to the actuators or control module. The equipment module is the result of splitting the batch process plant into simple elements. Rhone Poulenc has defined a generic behaviour imbedded in the objets phase, equipment module and control module guaranteeing a safe cooperation between these objects .
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

26. OPERATOR
man machine interface
safety interlock
monitoring &
control
the model brings:
a shared formal referential which makes validation easy:
operating procedure validation (WHAT)
monitoring &control system validation (HOW)
an help for mastering the complexity thanks to rigorous procedure for splitting the global system into simple and prevalidated elements able to cooperate safely.
a potential automation of the engineering, construction, capacity to automatise the engineering , programming and documentation activities:
better responsiveness with a better quality and safety level
lower cost
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

27. OPERATOR
man machine interface
monitoring &
control
safety interlock
ASTRID accept every existing descrition languages for specifiing the specific behaviour of the objects and particularly the languages. Up to you to choose the best fitting one.
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation

28. TRANSFER FROM A TO C
PRESENTATION_FBF-WBF_rev0_13/10/99/ F. Lebourgeois/ Rhône Poulenc Industrialisation