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A Flow Stream Approach for Process Cell Modularization
François Lebourgeois (Rhône Poulenc) Jean-Michel Rayon (Consultant) Jean Vieille (Consultant)
World Batch Forum 2000
Brussels, October 2000
Lebourgeois
Copyright © 2000
Slide 1
Summary
· Origin of ASTRID · Product Processing vs Equipment Control : no longer mixed-up · Safe Operation vs Flexibility: reducing the risk · Material & Energy Flow Analysis · Bottom-up Engineering · The 4 ASTRID objects · ASTRID vs S88: how do they fit together? · Successes and Issues · Future Lebourgeois Copyright © 2000 Slide 2
Origin of ASTRID
· · · · The Story begins in 1988 WG led by Health, Safety and Environment Management of Rhône-Poulenc Part of « Process Control Safety » program Focused on Safe Operation of Multipurpose process cell Operator
Actuators
Safety Interlock System
Control System
Lebourgeois
Copyright © 2000
Slide 3
Product Processing vs Equipment Control: no longer mixed-up
Describe Recipe Procedure Using Equipment Procedural Elements EPEs Granularity against Flexibility / Complexity Define Equipment Procedural Elements Assemble Process Elements in paths Detail Process Cell Elements
Product Processing Definition
Equipment Control Definition
Lebourgeois
Copyright © 2000
Slide 4
Safe Operation and Flexibility : Reducing the risk
Reactor #1 Allocated to batch A
Reactor #2 Allocated to batch B
V1 ?
Lebourgeois
Copyright © 2000
Slide 5
Material and Energy Flow analysis
Energy Sources
A
Material Sources
C
Material Sinks
D E
B F
Energy Sinks Lebourgeois Copyright © 2000 Slide 6
1. Identify Containers
A
Material Sources
C
Material Sinks
D E
B F
Lebourgeois
Copyright © 2000
Slide 7
2. Identify realistic Paths
A
Material Sources
C
Material Sinks
D E
B F
Lebourgeois
Copyright © 2000
Slide 8
3. Create / check Recipes: Sequence Paths
1 Material Sources
A
4
C
5
Material Sinks
3 2
D E
3
B F
Lebourgeois
Copyright © 2000
Slide 9
Bottom-Up Engineering
1. Identify, highlight & name Containers or RESOURCES on P&ID
Analytic Process Equipment check Straightforward, rule-based Process
1. Identify, highlight & name Paths or FUNCTIONS: Build all elementary flows/paths
Combine and attach resources to the path Check ability to execute Recipes
1. Attach DEVICES to Resources 2. Describe FUNCTIONS and RESOURCES behavior Lebourgeois Copyright © 2000 Slide 10
Work on P&ID
A
A
P1
A
A
Lebourgeois
Copyright © 2000
Slide 11
Highlight Resources
R1
R2
A
B R3
R4
P1
R5
C
R6
D
Lebourgeois
Copyright © 2000
Slide 12
Define paths : get functions
F2 F1
R1
R2
A
B
R3
R4
P1 F3
R5
C
R6
D
F1 : Fill A (R1, R2) F2 : Fill B (R1, R3) F3 : Transfer B -> C (R3, R4, R5) ... Lebourgeois Copyright © 2000
Slide 13
Attach Devices to Resources : manage interlocks
F2 F1 R1
V1 R2
F3
V2
A
B
R3
R4
F3 V3 F3 F3
V5 V4 P1
F3 R5
F3 F3
V6
R6
F3
C
D
Transfer from B to C: F3 is active, F1 and F2 are inactive: · V4 and V5 are controlled by F3 · V2,3,6 are locked; F2 is inhibited, F1 is available for use Lebourgeois Copyright © 2000 Slide 14
Other applications
· The Flow Stream analysis opens interesting domains of application:
Sanitary / cross contamination control
Resource 1 ·Product X ·Dirty ·Clean Resource 2 ·Product Y ·Dirty ·Clean
Capacity limitation
Resource 1 ·Maximum Capacity ·Committed Capacity
Resource 2,3, 4, 5 ·Required Capacity
Lebourgeois
Copyright © 2000
Slide 15
The 4 ASTRID Objects
R1: Recipe
F1: Fill A
F2: Fill B
F3: Transfer B-> C
R1: Feeding Line
R2: Tank A
R3: Tank B
R4: Transfer Line
R5: R6: Tank C Tank D
V1
V2
V3
V4
V5
V6
Lebourgeois
Copyright © 2000
Slide 16
ASTRID vs S88: How do they fit together
Procedural model (Functionality) PROCEDURE UNIT PROCEDURE OPERATION UNIT FUNCTION (Path) Equipment model PROCESS CELL Equipment model Procedural model (Functionality)
FUNCTION (Behavior, Chaining, Sequencing)
PHASE
EQUIPMENT MODULE CONTROL MODULE RESOURCE DEVICE
S88
CONTROL MODULE
ASTRID
Lebourgeois
Copyright © 2000
Slide 17
Successes & Issues · Successes
Used for over 10 years 20 plants, 40 Process Cells, 100 Controllers, 40000 I/O 's New Users since Rhône-Poulenc affiliation (AVENTIS, RODHIA, PASTEUR-MERIEUX):
· PFITZER, DANONE (LU, KRONENBOURG), SANOFI, (Chemical, F&B, Pharma)
Users are fans!
· Issues
Slow spread: education and promotion needed (as S88) Control System implementation : ASTRID resources availability, programming features
Lebourgeois
Copyright © 2000
Slide 18
Conclusion
· ASTRID as an S88 companion
for Equipment control: solidification of concepts
· ASTRID fans love:
Easy to understand, Equipment based Specifications Dynamic and optimized Resource Allocation / Safe Actuator Interlocks Easy Material transfers Information propagation and summarization Operational Qualification support for validation SO SIMPLE!
· Future
Improvement of ASTRID vs S88 compliance ASTRID vendor libraries in Control Systems Extensive documentation available at http://fbforg.homepage.com
Lebourgeois
Copyright © 2000
Slide 19
François Lebourgeois (Rhône Poulenc) Jean-Michel Rayon (Consultant) Jean Vieille (Consultant)
World Batch Forum 2000
Brussels, October 2000
Lebourgeois
Copyright © 2000
Slide 1
Summary
· Origin of ASTRID · Product Processing vs Equipment Control : no longer mixed-up · Safe Operation vs Flexibility: reducing the risk · Material & Energy Flow Analysis · Bottom-up Engineering · The 4 ASTRID objects · ASTRID vs S88: how do they fit together? · Successes and Issues · Future Lebourgeois Copyright © 2000 Slide 2
Origin of ASTRID
· · · · The Story begins in 1988 WG led by Health, Safety and Environment Management of Rhône-Poulenc Part of « Process Control Safety » program Focused on Safe Operation of Multipurpose process cell Operator
Actuators
Safety Interlock System
Control System
Lebourgeois
Copyright © 2000
Slide 3
Product Processing vs Equipment Control: no longer mixed-up
Describe Recipe Procedure Using Equipment Procedural Elements EPEs Granularity against Flexibility / Complexity Define Equipment Procedural Elements Assemble Process Elements in paths Detail Process Cell Elements
Product Processing Definition
Equipment Control Definition
Lebourgeois
Copyright © 2000
Slide 4
Safe Operation and Flexibility : Reducing the risk
Reactor #1 Allocated to batch A
Reactor #2 Allocated to batch B
V1 ?
Lebourgeois
Copyright © 2000
Slide 5
Material and Energy Flow analysis
Energy Sources
A
Material Sources
C
Material Sinks
D E
B F
Energy Sinks Lebourgeois Copyright © 2000 Slide 6
1. Identify Containers
A
Material Sources
C
Material Sinks
D E
B F
Lebourgeois
Copyright © 2000
Slide 7
2. Identify realistic Paths
A
Material Sources
C
Material Sinks
D E
B F
Lebourgeois
Copyright © 2000
Slide 8
3. Create / check Recipes: Sequence Paths
1 Material Sources
A
4
C
5
Material Sinks
3 2
D E
3
B F
Lebourgeois
Copyright © 2000
Slide 9
Bottom-Up Engineering
1. Identify, highlight & name Containers or RESOURCES on P&ID
Analytic Process Equipment check Straightforward, rule-based Process
1. Identify, highlight & name Paths or FUNCTIONS: Build all elementary flows/paths
Combine and attach resources to the path Check ability to execute Recipes
1. Attach DEVICES to Resources 2. Describe FUNCTIONS and RESOURCES behavior Lebourgeois Copyright © 2000 Slide 10
Work on P&ID
A
A
P1
A
A
Lebourgeois
Copyright © 2000
Slide 11
Highlight Resources
R1
R2
A
B R3
R4
P1
R5
C
R6
D
Lebourgeois
Copyright © 2000
Slide 12
Define paths : get functions
F2 F1
R1
R2
A
B
R3
R4
P1 F3
R5
C
R6
D
F1 : Fill A (R1, R2) F2 : Fill B (R1, R3) F3 : Transfer B -> C (R3, R4, R5) ... Lebourgeois Copyright © 2000
Slide 13
Attach Devices to Resources : manage interlocks
F2 F1 R1
V1 R2
F3
V2
A
B
R3
R4
F3 V3 F3 F3
V5 V4 P1
F3 R5
F3 F3
V6
R6
F3
C
D
Transfer from B to C: F3 is active, F1 and F2 are inactive: · V4 and V5 are controlled by F3 · V2,3,6 are locked; F2 is inhibited, F1 is available for use Lebourgeois Copyright © 2000 Slide 14
Other applications
· The Flow Stream analysis opens interesting domains of application:
Sanitary / cross contamination control
Resource 1 ·Product X ·Dirty ·Clean Resource 2 ·Product Y ·Dirty ·Clean
Capacity limitation
Resource 1 ·Maximum Capacity ·Committed Capacity
Resource 2,3, 4, 5 ·Required Capacity
Lebourgeois
Copyright © 2000
Slide 15
The 4 ASTRID Objects
R1: Recipe
F1: Fill A
F2: Fill B
F3: Transfer B-> C
R1: Feeding Line
R2: Tank A
R3: Tank B
R4: Transfer Line
R5: R6: Tank C Tank D
V1
V2
V3
V4
V5
V6
Lebourgeois
Copyright © 2000
Slide 16
ASTRID vs S88: How do they fit together
Procedural model (Functionality) PROCEDURE UNIT PROCEDURE OPERATION UNIT FUNCTION (Path) Equipment model PROCESS CELL Equipment model Procedural model (Functionality)
FUNCTION (Behavior, Chaining, Sequencing)
PHASE
EQUIPMENT MODULE CONTROL MODULE RESOURCE DEVICE
S88
CONTROL MODULE
ASTRID
Lebourgeois
Copyright © 2000
Slide 17
Successes & Issues · Successes
Used for over 10 years 20 plants, 40 Process Cells, 100 Controllers, 40000 I/O 's New Users since Rhône-Poulenc affiliation (AVENTIS, RODHIA, PASTEUR-MERIEUX):
· PFITZER, DANONE (LU, KRONENBOURG), SANOFI, (Chemical, F&B, Pharma)
Users are fans!
· Issues
Slow spread: education and promotion needed (as S88) Control System implementation : ASTRID resources availability, programming features
Lebourgeois
Copyright © 2000
Slide 18
Conclusion
· ASTRID as an S88 companion
for Equipment control: solidification of concepts
· ASTRID fans love:
Easy to understand, Equipment based Specifications Dynamic and optimized Resource Allocation / Safe Actuator Interlocks Easy Material transfers Information propagation and summarization Operational Qualification support for validation SO SIMPLE!
· Future
Improvement of ASTRID vs S88 compliance ASTRID vendor libraries in Control Systems Extensive documentation available at http://fbforg.homepage.com
Lebourgeois
Copyright © 2000
Slide 19
Johann Sebastian Bach. the music closest to silence, closest, in spite of its being so highly organized, to pure, one-hundred-degree proof Spirit" (Aldous Huxley, Island)