Virtualized PlantPAx System adds Process Flexibility

Transcription

1 Virtualized PlantPAx System adds Process Flexibility Jeff Moore Sr. Electrical Engineer Gallus BioPharmaceuticals Steven Schneebeli Lead Systems Engineer Malisko Engineering, Inc. Copyright 2012 Rockwell Automation, Inc. All rights reserved.

2 2 Agenda Company Introductions Project overview and expectations Design Overview and Details Benefits and Results Questions?

3 3 Gallus BioPharmaceuticals Company Overview Gallus BioPharmaceuticals is a world-class CMO, operating a commercially licensed manufacturing site in St. Louis. Profile More than 25 years of experience in process development. Over a decade of commercial manufacturing experience. The company s facilities are designed to support: Development of early-phase processes Scale-up (50L to 2000L) reactors Clinical manufacturing Commercial production

4 4 Gallus BioPharmaceuticals Company Overview Conversion to Contract Manufacturing & Development Organization from a spin-out of a commercial biopharmaceutical site: every major H.A. approval 5/2011 Supply agreement for 2 licensed: Remicade and Stelara 15 acre site, 200K ft2 facilities: transfer of 160 staff now over 210 Mammalian cell-culture, perfusion/fed-batch development & manufacturing Completion of Clinical Services Suite with Xcellerex Flexfactory 5/2012 (50L 2000L) Unique SuiteSPACE TM virtual-ownership business model and pay-per-run model mammalian cell-culture development products CONFIDENTIAL 3 commercial products (~200 lots)

5 5 Gallus BioPharmaceuticals St. Louis, MO Site Layout Clinical Services Suite (S5) Potential SuiteSPACE Commercial Core (S1-4) Expansion Space Quality Control B1 Process Development B2 B3 Administration Offices 15 acre site, adjacent to St. Louis International Airport 3 buildings - 200,000 ft 2, Expansion space - 100,000 ft 2 CONFIDENTIAL

6 Malisko Engineering Company Overview Experts in Manufacturing Automation and Validation Founded in 1994 Headquartered in St. Louis, Missouri USA Historic Laclede s Landing on the Mississippi Riverfront Regional Office in Denver, Colorado USA Serving the Rocky Mountain Region, the Western United States, Canada and Mexico Rockwell Solution Partner for Control, Process, and Information Systems. CSIA Certified Member Historic Laclede s Landing St. Louis, MO Denver, CO Malisko Western Regional Office Copyright 2012 Rockwell Automation, Inc. All rights reserved. 6

7 7 Project Overview and Expectations Project Justification: Change form fixed Large Pharma to flexible/nimble CMO Develop a portable dual bioreactor (Brx) control station. Expand existing Brx control flexibility in manufacturing. Replace the existing end-of-life Windows NT Control platform. Project Requirements: High availability control platform. Redundant HMI Servers Redundant ControlLogix PACs Redundant Device Level Ring (DLR) IO Network Framework for adding new Brx controllers as business plans change. Leverage existing Manufacturing Process Network (MPN) services for communication, security and data collection.

8 8 System Requirements System Design Requirements Multiple manufacturing suites supporting various customers Development flexibility Defined Batch recipes for manufacturing S88 model driven Utilization of standards-based Device Control Modules Server Virtualization System and Network Redundancy Use of Thin Clients Process Data archived to existing Site Historian Batch Reporting using SQL Server Reporting Services Validation of modules to reduce overall validation time

9 9 System Overview Virtualized PlantPAx system: Provides cost savings by reducing server count from 6 to 2 System Redundancy through: Primary and Secondary FactoryTalk View SE HMI/Data Servers Primary and Secondary Terminal Servers for Thin Clients Primary and Backup FactoryTalk Batch Servers Windows Terminal Server used for HMI Thin Clients ACP ThinManager Xli V6 provides redundancy between servers Low cost Arista Thin Client hardware with ACP Enabled firmware No moving parts, such as fans or hard drives, increase reliability

10 10 System Diagram Existing Active Directory Servers Existing SQL Server Existing Plant Historian VM Image 1: Primary FT View SE HMI/Data Server VM Image 2: Primary Thinmanager / Terminal Server VM Image 3: Primary Batch Server FTViewSE Thin Client MPN Ethernet Network B3 Data Center Switch Fiber Link B2 Distribution Switch Primary ControlLogix PAC Secondary ControlLogix PAC Redundancy Fiber Link VM Image 1: Secondary FT View SE HMI/Data Server VM Image 2: Secondary Thinmanager / Terminal Server VM Image 3: Backup Batch Server Brx I/O Panel (typ.) Device Level Ring Network ATF Panel DH Filter Panel

11 11 Project Design Functional Requirements Specifications was generated based off of the User Requirements Specification document. Malisko s enhanced PlantPAx process objects were used. Utilized controller-based Phase Manager to execute phase logic, tied to a FactoryTalk Batch Server. Program organized for modularity and addition of future Bioreactor carts Virtualization and Terminal server implementation followed Rockwell guidelines available on the Knowledgebase

12 12 Virtualization Overview Hardware virtualized servers remove the dependency of the hardware from the operating system, and allow multiple separate operating systems to share common hardware.

13 13 Virtualization Overview Interfacing between operating systems and the physical server hardware is handled through the Hypervisor, in this case, the free version of VMWare ESXi.

14 14 Thin Client Technology Overview Microsoft Windows Terminal Services, now known Remote Desktop Services (RDS) provides the ability to host multiple, simultaneous FactoryTalk View SE client sessions Automation Control Products (ACP) ThinManager Xli manages Thin Client hardware and provides redundancy capability between two physical RDS Servers Utilizes Remote Desktop Protocol (RDP) for connectivity Thin Client Hardware requires minimal configuration

15 15 Remote Desktop Services Architecture FT View SE Client ACP ThinManager XLi Windows Server 2008 R2 / Remote Desktop Services RDP ACP Firmware Enabled Thin Clients

16 16 16 Virtualization & Thin Client Cost Savings A traditional installation for this system would require six servers, and two thick clients with FT View SE installed on each client. Using Virtualization, server count was reduced to two servers Server cost savings: 66% Remote Desktop Services allowed the use Thin Client hardware. Client PC cost savings: 33% Reducing the number of servers and Thin Client PC s realizes a power savings of approximately: 55%

17 17 HMI Layout Top Banner Screen Nav. Menu Main Screen Alarm Banner

18 18 Pump Selection Six Peristaltic Pumps with up to eight possible pump types.

19 19 Malisko-Enhanced PlantPAX Process Objects Device control modules based on Rockwell PlantPAx process objects for Variable SpeedDrive, Solenoid Valve, Control Valve, Analog Input, PIDE VSD Motor Control Home Screen VSD Motor Control Engineering Screen Typical Interlock Screen Solenoid Valve Home Screen

20 20 Malisko-Enhanced PlantPAX Process Objects Typical Help Screen PIDE Home Screen PIDE Engineering Screen

21 21 FactoryTalk Batch Implementation FactoryTalk Batch Server used to create and run batches on individual Bioreactors. R&D Bioreactor cart runs a Manual Batch phase to track Batch start and end times, along with a Customer ID number. After Manual R&D Batch is ran, development of an automatic batch using the Recipe Editor to create SFCs is then created. Finally, after running the automated R&D Batch, the recipe is released to production. Utilized Class-based units and phases for ease of validation and expansion.

22 22 FactoryTalk Batch Implementation First phase used built-in FactoryTalk Batch ActiveX controls to select and schedule batches. Second phase (in progress) will use a custom FT View SE screen to select and schedule batches, utilizing FT Batch API calls. Allows for limiting available recipes for specific customers. More flexibility to customize Batch selection and status screen. Batch status is displayed on the HMI using the FT Batch System Status application. Collects batch system status from the batch server and stores it in predefined Logix controller structures Available on Rockwell Automation s Knowledgebase KB67642

23 23 ControlLogix PhaseManager PhaseManager Phases are synchronized with the FT Batch Area Model using a Logix5000 CIP data server, configured inside the FT Batch Equipment Editor.

24 24 Remote Alarm Notification / Historical Data Collection An existing Specter Instruments WIN-911 installation is used for Alarm Notification via messaging Critical process data is archived to an existing plant-wide data historian Local data log models are used to display trend data on each Bioreactor HMI client. Data log trends can be exported to a CSV is done through the trend window within FT View SE, allowing further offline analysis of process data.

25 25 Project Benefits and Results Cost savings realized through Virtualization and Thin Client technology. Ability to store server images and restore to upgraded hardware without rebuilding the software installation System flexibility in Bioreactor I/O cart design allows for easy relocation Design flexibility to add additional Bioreactor I/O panels without changes to automation. Reduces validation cost by leveraging modular design.

26 26 Project Benefits and Results Reduced controller foot print in manufacturing space by 50% Reduced PLC control hardware cost by up to $40,000 Server Hardware costs savings of approximately $20,000 Estimated Reduced Validation cost for extra panels by 75% DR time reduced by 6 hours

27 Questions Jeff Moore Sr. Electrical Engineer Gallus BioPharmaceuticals Steven Schneebeli Lead Systems Engineer Malisko Engineering, Inc. Copyright 2012 Rockwell Automation, Inc. All rights reserved.