Transcript Flow Analysis applied to S88 equipment control

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 Akdeniz
Slide 1
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 Akdeniz
Slide 2
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 Akdeniz
Slide 3
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 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
Vieille, Vitté Akdeniz
Slide 4
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 Akdeniz
Slide 5
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 Akdeniz
Slide 6
Hard facts
• Multipurpose, 3 lines pharmaceutical plant
– 34 units / shared EMs
– 600 instruments
– 200 phases
• FA replaced 1700 interlocks among 13000
combinations
Vieille, Vitté Akdeniz
Slide 7
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 Akdeniz
Slide 8
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 Akdeniz
Slide 9
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 Akdeniz
Slide 10
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 Akdeniz
Slide 11
FA Background : Operational safety
T1
T2
T3
T4
P1
P2
T5
Vieille, Vitté Akdeniz
T6
T7
T8
Slide 12
Who controls actuators?
Operator?
Control
System?
Safety
System?
Breakdown?
Vieille, Vitté Akdeniz
Slide 13
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 Akdeniz
Slide 14
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 Akdeniz
Slide 15
Possible S88 physical topology
Process Cell
Unit
EM
Unit
EM
EM
EM
CM
CM
CM
Vieille, Vitté Akdeniz
CM
CM
CM
CM
CM
Slide 16
Typical S88 physical topology
Process Cell
Unit1
EM1
EM3
Unit2
EM2
CM1 CM2 CM3 CM4 CM5 CM6 CM7 CM8 CM9 CM10
Vieille, Vitté Akdeniz
Slide 17
Common S88 physical topology
Process Cell
Unit1
EM1
Unit2
CM1 CM2 CM3 CM4 CM5 CM6 CM7 CM8 CM9 CM10
Vieille, Vitté Akdeniz
Slide 18
FA – S88 physical topology
Process Cell
Unit1
EM1
CM1
Phase X
needs
these CMs
CM2
EM3
Phase Y
needs
EM2 these CMs
EM3’
CM3
CM4
Unit2
DM1 DM2 DM3 DM4 DM5 DM6 DM7 DM8 DM9 DM10
Vieille, Vitté Akdeniz
Slide 19
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 Akdeniz
Slide 20
Utility
Inert Gas
Utility
FBDM
Breackdown example
M
From
Storage
Sky
Utility
Material
FBDM
FBDM
FBDM
FBDM
Vacuum
FBDM
Energy
Energy
Hot In
Utility
Material
FBDM
Waste Air
FBDM
FBDM
Cold In
FBDM
Energy
FBDM
Energy
Material
FBDM
Cold Out
FBDM
Hot Out
Material
Next Unit
Vieille, Vitté Akdeniz
Slide 21
FA answer: Secured flows
CM1 & CM4 are not allocated (or allocated by another phase)
Tank
CM1
CM3
V1
CM4
V3
CM2
V2
Phase 1 « Fill tank from CM2 » allocates CM2 & CM3
Vieille, Vitté Akdeniz
Slide 22
FA modelling
CM1
CM2
FBDM2
CM
3
FBDM4
FBDM1
FBDM3
CM
4
FBDM6
CM6
CM5
FEED A from S1
CM
1 FBDM1
CM
FBDM2
2
FBDM3
Vieille, Vitté Akdeniz
FBDM5
CM
3
CM
4
FBDM4
FBDM6
FBDM5
CM
5
CM
6
Slide 23
Multi-flow Control Module
Control
Module
Gate1
FBDM1
FBDM2
Node1
Gate2
Gate3
FBDM4
Gate5
FBDM5
Node2
FBDM3
FBDM6
Gate4
Vieille, Vitté Akdeniz
Gate6
Slide 24
CM data model
Control Module
Element
0..n
Control Module May inherit
0..n Control Module
Class
the properties
and gates of 
0..n
Control Module
Node
0..n
0..n
Control Module
Property
0..n
Flow Breaking 1..1
Device
Vieille, Vitté Akdeniz
Gates
0..n
0..1
Material
Property
Slide 25
Progress - Help
• The 3rd draft should be published at the
conference time
– Hope to publish the report early 2003
• We need your help!
It’s all in ENGLISH!
– 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
Vieille, Vitté Akdeniz
Slide 26
Thank you
Vieille, Vitté Akdeniz
Slide 27