GAMP - Process Control SIG

GAMP 4 + Beyond
Tony de Claire

GAMP - Process Control SIG

SIG Background

Evolved from impromptu lunchtime meeting at the launch of initial GAMP (PICSVF) draft release in Westminster Two control engineering representatives given a mission at a meeting hosted by Wellcome, Dartford soon after Initial Group set up, with recruitment at a hotel bar in Basle (May96) Groups basic aim is to voice control system issues Well attended group with members of user background Active with / instigating a variety of contributor panels

GAMP - Process Control SIG

Purpose:

Address the considerations in applying GAMP Principles to Process Control System applications
Process Control Systems Section in GAMP 4 * Forthcoming GAMP Good Practice Guide Input to Calibration panel, Audit, GEP revisions Liaison with NAMUR and JETT ( * copies of pre-edited Draft available)

Work focus:

GAMP 4 - Process Control Systems

Used to automate manufacturing processes

Dynamic real-time I/O Collect data Control and manage the process Link to higher level data handling functionality or systems in Computer Integrated Manufacturing (CIM)

GAMP 4 - Process Control Systems

Covers a wide range of systems

Small control systems, e.g. in manufacturing equipment Large control systems, e.g. operating bulk product plants
Embedded Standalone (Integrated)

Two Main Categories

Embedded Systems

Microprocessor, PLC, or PC with sole purpose of controlling / monitoring manufacturing equipment. Usually delivered embedded in a unit or machine Multi-discipline engineering effort required to produce Much of the lifecycle documentation produced by supplier

Standalone Systems

Self contained systems, usually delivered separately & connected to field devices May be linked to / provide higher level functionality

Supervisory Control and Data Acquisition (SCADA) Distributed Control Systems (DCS) Controller or PLC controlling part of a process

Project engineering and co-ordination required

GAMP Validation Principles

Lifecycle (ref. Draft Figs 3.3, 3.4, 3.5) Planning, Supplier and Compliance Risk Assessments User and Supplier Partnership Specifications Traceability Formal Testing and Verification Documented Evidence

Lifecycle Phases

Planning & Requirement Definition Design Specification, System Development, & Build Design Review and Acceptance Testing Qualification & GEP Commissioning * Operation and Maintenance Decommissioning and Retirement
( * Aligns with ISPE Baseline Guide for Commissioning & Qualification )

Planning & Definition

Define Scope

Software Hardware Instrumentation Electrical Mechanical

Planning (continued)

Supplier Assessment

Quality System Capability Audits

Define structure of lifecycle documents

Quality and Project Plan

GxP Criticality and Compliance Risk Assessment

Importance of Specifications

Provide a structured definition of system requirements Enable requirement traceability matrix Allow complimentary lifecycle documents to be developed Support focused and auditable system development Establish test acceptance criteria Support maintenance of the system

User Requirements Specification

For small embedded applications, could be part of equipment specification For large standalone applications, e.g. DCS or SCADA, a separate URS is normal

User Requirements Specification

URS to clearly identify:

Parameters to be controlled and monitored Data to be generated, manipulated, or stored Functions to be performed Process sequence, interlocks, alarms Quality-related critical parameters, data & functions Safety and Environmental requirements Levels of testing required

Functional Specification

Embedded System FS may be part of overall

equipment specifications, including instrument, electrical, and mechanical elements

Standalone System FS typically one document,

identifying the functions, features and the design intentions for the system hardware and software

Functional Specification

Establishes how the requirements of the URS will be implemented

Functions to be performed Facilities to be provided Detailed process sequence logic and interlocks Interfaces to instruments, equipment, and other systems

Normally produced by supplier in response to the URS

Functional Specification

Basis of subsequent testing and verification, e.g. System Acceptance Testing Divergence with the URS to be identified Should identify any software functions that are not being utilised Often a contractual document subject to Change Control by Supplier

Design Specifications
Specifications for system design: Software Hardware Instrumentation
may include mechanical and electrical general arrangement drawings

Detailed Design Documentation

Process and Instrument Diagrams (P&IDs)

Showing process flow Identification and location of associated control and monitoring loops
Identification and location of major items

Plant Equipment Layout

Detailed Design Documentation

Loop and Instrument Schedule

Identify items in the loops Measurement ranges and tolerances Inputs and output signals Identifies Critical Parameters Alarm trip points and actions Sequence Logic & Interlock details

Detailed Design Documentation

Interconnection Drawings

Connections to field instrumentation Wiring termination, identification, rating, and polarity Sufficient detail to enable assembly, installation, and fault diagnosis

Hardware Design Specification

Defines architecture and configuration of the hardware, including:

Controllers PCs Input / Output types & allocation System Interfaces

Software Design Specification

Defines how the software is to implement the Functions Specification Defines the software and data structure, architecture, the software modules, their interactions, and interfaces. Structural modular programming language / techniques

Software Design Specification

Should identify programming standards where coding is involved, and naming conventions in all cases Ensure annotated hardcopy of software software provides clear understanding and can be used testing aid All non-standard software to be identified

System Software Development

Against pre-defined design intentions In accordance with suitable structured programming standards Author fully conversant with programming language / techniques Author experienced in similar design intentions

System Build

Embedded System - usually final assembly into

automated equipment precedes installation at usersite Standalone System the computer system & instrumentation are shipped to site, inspected and installed in conjunction with the manufacturing / process equipment
(All system build carried out according to approved manufacturer design/assembly documentation)

Software Review

Software to be reviewed (inspection, walkthrough etc) by independent developer(s) Examined against formal procedures prior to testing Ensure written / configured against predefined intentions and in accordance with programming standards

Design (& Development) Review

Formal and systematic verification that specified requirements are covered by the design and development activities

Supported by a structured set of lifecycle documentation May be a series of reviews throughout system design and development To verify adherence to Requirements Traceability Matrix Can encompass elements of acceptance testing Requirements and Design intentions should be agreed before significant code development Findings to be documented in a Design Review Report

Acceptance Testing

Proving the correct operation of software, hardware, and instrumentation, as defined by the URS and FS Based on approved Test Specifications, and formally reported Test specifications to include objectives, procedures and acceptance criteria To focus on GxP and other critical functions and data Determine level of testing to support Lifecycle Qualifications

Acceptance Testing

Depending on circumstances can encompass system development / build testing:

Software development tests Hardware manufacturing tests System integration tests Instrument manufacturing / calibration tests SAT (and FAT)

Tests during & on completion of manufacture to be to pre-defined procedures and documented

Acceptance Testing

Factory Acceptance Testing (FAT)

Pre-delivery Normally a contractual milestone For standalone systems - without connection to field instrumentation, with an agreed level of process simulation Testing constraints to be documented Opportunity to identify problems best resolved in Supplier environment

Acceptance Testing

Site Acceptance Testing

To determine that the system and any associated equipment has not been damaged, and functions correctly in the operating environment Normally a repeat of the FAT plus tests possible with process, instrumentation, interfaces, and service connections in place With adequate level of test procedures may be combined with engineering commissioning to provide necessary test data for IQ and OQ

Calibration of Instrumentation

Pre- and post-delivery, to defined, approved procedures Test equipment documented, and traceable back to acceptable standards Calibration test results retained Establish calibration interval depending on criticality, robustness, sensitivity, and operational experience

Qualification

Installation Qualification (IQ) confirms:

Hardware, electrical connections, data highways, field instrumentation, field cabling (and associated electrical & pneumatic equipment) is installed to documented design / standards Software loaded correctly Basic system functions operate satisfactorily on power-up System configuration / calibration Field instrumentation calibrated Lifecycle and associated support documentation approved and available

Qualification

Operational Qualification (OQ) - confirms that

operation of system hardware, software, I/O devices and field instrumentation will function satisfactorily under normal operating conditions and, where appropriate, under realistic stress conditions Performance Qualification (PQ) - normally carried out in conjunction with process qualification to confirm the correct operation of all system components, associated equipment, people and procedures that combine to run the manufacturing process

Validation

Qualification / Validation Reports on

successful completion of qualification testing and approved summary reports, a Validation Report will confirm that the system is ready for use in the manufacturing process for which it was designed

Operation & Maintenance To ensure validation status is maintained: Quality, Maintenance and Calibration regime Configuration Management Change Control

Reference to critical process parameters / data and Requirements Traceability Matrix

System reliability, repeatability, performance & diagnostic data Approved Lifecycle document status and accuracy SOP status and use

Periodic Reviews and Internal Audits

System Retirement

Decommissioning to include archiving data and software Archive Report to describe approach, list documents, raw data, and electronic records Verification of critical instrument calibration Special care with preservation and availability of GxP records throughout their retention period, as required by of 21 CFR Part 11, and associated predicate rules

Conclusions

GAMP Principles - can be applied effectively to process control systems, both embedded and standalone Good Engineering Practice - normal engineering commissioning activities can support the requirements of Qualification testing

GAMP Process Control SIG

Q. Whats next? A. Produce a Good Practice Guide Work underway to expand on the work done for the new GAMP 4 publication and produce a supplementary Good Practice Guide for Validation of Process Control Systems

Validation of Process Control Systems Guide

Proposed Contents

Introduction, Background, Definitions Regulatory Considerations Supplier Assessments Standalone and Embedded Systems Importance of Good Specifications Manufacturing Parameters & Quality Data Lifecycle of Process Control Systems Criticality Assessment Systems Specification, Design, Development and Review

Validation of Process Control Systems Guide

Proposed Contents (continued)

Factory Acceptance Tests Installation Qualification Operational Qualification Maintenance Calibration Change Management Review of Existing Systems Retirement / De-commissioning New Technologies

Validation of Process Control Systems Guide

Proposed Contents (continued)

Appendices Critical Parameters & Data Software Categories for Control Systems Postal Audit of Suppliers NAMUR guidance documents

GAMP Liaison Thanks to Sion Wyn & John Andrews

Any Questions?

Tony de Claire Process Control SIG