(233n) Fault-Tolerant Control Design and Risk MAP Based Resiliency Analysis of Continuous Solid Dose Manufacturing
- Conference: AIChE Annual Meeting
- Year: 2016
- Proceeding: 2016 AIChE Annual Meeting
- Group: Pharmaceutical Discovery, Development and Manufacturing Forum
Monday, November 14, 2016 - 3:15pm-5:45pm
First, a risk mapping was designed to characterize the frequency and severity of the potential faults during the design and operation stages, e.g., model-plant mismatch, calibration errors, failing/missing sensors, process disturbances, etc. The three levels of hierarchical control strategies design, which ranges from single proportional-integral-derivate (PID) control loop to plant-wide advanced model predictive control (MPC), were then assessed subject to the potential faults by using control key performance indices (KPIs), such as, time to product (T2P), magnitude to product (M2P), and other control measures, such as Morariâ??s resiliency index (MRI).10 Mitigation planning for severe faults were also suggested, e.g., to activate or decommission a specific control level, or to divert the off-spec products.
The proposed systematic framework for fault-tolerant control design was demonstrated in a pilot plant for continuous dry granulation process11 and was shown to be efficient and robust in handling potential faults and achieving a robust processing line for solid dose.
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