vieille, vitté akdenizslide 1 flow analysis applied to s88 equipment control wbf working group...
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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
Vieille, Vitté Akdeniz Slide 2
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
Vieille, Vitté Akdeniz Slide 3
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
Vieille, Vitté Akdeniz Slide 4
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
Vieille, Vitté Akdeniz Slide 5
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
Vieille, Vitté Akdeniz Slide 6
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
Vieille, Vitté Akdeniz Slide 7
Hard factsHard 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 8
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
Vieille, Vitté Akdeniz Slide 9
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
Vieille, Vitté Akdeniz Slide 10
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
Vieille, Vitté Akdeniz Slide 11
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
Vieille, Vitté Akdeniz Slide 12
FA Background : Operational safetyFA Background : Operational safety
T1 T2
P1
T3 T4
P2
T5 T6 T7 T8
Vieille, Vitté Akdeniz Slide 13
Who controls actuators?Who controls actuators?
Breakdown?
Safety System?
Control System?
Operator?
Vieille, Vitté Akdeniz Slide 14
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
Vieille, Vitté Akdeniz Slide 15
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.
Vieille, Vitté Akdeniz Slide 16
Possible S88 physical topologyPossible S88 physical topology
Process Cell
Unit Unit
EMEM EM
CM
EM
CM
CMCM CM CMCM CM
Vieille, Vitté Akdeniz Slide 17
Typical S88 physical topologyTypical S88 physical topology
Process Cell
Unit1 Unit2EM3
EM1 EM2
CM7CM4CM1 CM3 CM8CM2 CM10CM6CM5 CM9
Vieille, Vitté Akdeniz Slide 18
Common S88 physical topologyCommon S88 physical topology
Process Cell
Unit1 Unit2EM1
CM7CM4CM1 CM3 CM8CM2 CM10CM6CM5 CM9
Vieille, Vitté Akdeniz Slide 19
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
Vieille, Vitté Akdeniz Slide 20
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
Vieille, Vitté Akdeniz Slide 21
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
Vieille, Vitté Akdeniz Slide 22
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
Vieille, Vitté Akdeniz Slide 23
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
Vieille, Vitté Akdeniz Slide 24
Multi-flow Control ModuleMulti-flow Control Module
FBDM1
FBDM2
FBDM3
FBDM4
FBDM5
FBDM6
ControlModule
Node1
Node2
Gate1
Gate2
Gate3
Gate4
Gate5
Gate6
Vieille, Vitté Akdeniz Slide 25
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
Vieille, Vitté Akdeniz Slide 26
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
– Download the current draft
– Send your comments or your encouragement
It’s all in ENGLISH!
Vieille, Vitté Akdeniz Slide 27
Thank you