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