SIMPLIFYING SAFETY AND SECURITY AT PHILIPS SEMICONDUCTORS

Dec 1, 2001 12:00 PM

Inside mobile telephones, color televisions and countless computer peripherals and cars, there resides a Philips Semiconductors integrated circuit. Most people rarely think of the design technology required for these chips, much less the safety challenges of their manufacture.

It all happens at the Philips Semiconductors Albuquerque facility — approximately 500,000 square-feet, comprised of four clean room manufacturing areas (FABs) and their adjoining materials storage and office spaces. The facility produces semiconductors used all over the world.

A variety of manufacturing processes take place at the plant, but all have common steps. Philips Semiconductors purchases raw silicon wafers and applies 28 to 52 process layers, each made up of thousands of resistors and transistors. This manufacturing process demands a high level of attention and control. So does ensuring safety and security in the workplace, which is an important priority for Philips.

NO ROOM FOR ERROR

Philips Semiconductors' goal is to maintain non-stop production capability in a secure work environment, says Bob Sanders, security manager at the plant. “Our worker safety is taken very seriously. We have fire, security, card access, and toxic gas monitoring systems.”

Industry-wide, the semiconductor manufacturing process uses several toxic gases and chemicals (diborane, arsine, phosphine, and silane are a standard part of the creation of semiconductors). They are stored in special compressed gas cylinder cabinets and are piped to equipment in the manufacturing areas. Besides the toxic nature of the gases, some are also flammable and could cause an explosion.

MEETING THE SYSTEMS CHALLENGE

Philips Semiconductors always had extensive safety and security monitoring. However, there were complications due to disparate systems. “We had a multitude of different monitoring systems,” Sanders says. “We had various pieces of equipment that reported back to the security control center where we have one security officer who was responsible for monitoring all these points on multiple pieces of equipment and screens.”

Besides the complexity issue, there was a functionality problem. Whenever a warning system was activated, the security staff would manually gather information to initiate a response. “But what we had to do was not only to look up procedures and instructions manually, but then to send somebody down to the alarm unit to get the value and relate it to that alarm,” Sanders says. “We knew what type of event, as in the case of a toxic gas alarm, but somebody from the response team would have to stay by the monitoring equipment and relay the readings to the emergency response team.

“In 1996 I began looking for something to make our responses more efficient,” Sanders continues. “I wanted a unit that would integrate these different systems into one head-end.”

Entech Sales and Service Inc. designed and installed an Infinity building controls network by Andover Controls that would dramatically affect operations at the Albuquerque plant. The solution not only eliminated the complications of the old system, but also delivered new operational capabilities. Since then, Entech has continued to assist Philips Semiconductors with an upgrade to Andover's Continuum product as part of the facilitation of two new FAB modules, and also with their special needs for programming and expanding monitoring capabilities.

The security control center now relies on one interface — Continuum CyberStation — resulting in improved safety and efficiency. It controls and monitors every critical system: toxic gas monitoring, fire alarm system monitoring and security. From open doors to air-quality monitoring, from the lobby to the parking lot, the system creates a controlled universe in one interface that monitors more than 2,000 alarm points.

AIR-QUALITY MONITORING

With toxic and hazardous production materials used in the semiconductor manufacturing process, gas monitoring is a critical system in the building. There are numerous gas cabinets placed in the Sub FABs and gas bunkers located away from the production area for safety and maintenance. From here, compressed gases and chemicals are dispensed to the manufacturing process equipment. The gas monitoring system not only samples air quality, but also the process equipment in the FABs. It is also able to detect a chemical leak or spill.

Should there be a toxic gas alarm, Continuum CyberStation would provide an on-screen alarm, display the incident location on a building layout and deliver response instructions. The control center security officer then sends an officer to investigate and notify that FAB's emergency response team (ERT) via pager.

“The nice thing about the Andover system and the interface we've created is that we get real-time analog values,” Sanders says. “We actually see the level of gas and the readings. After a response has been sent and the problem is being investigated, we can see the real-time results of our response efforts.” Additionally, security and safety personnel can shut down any point in the gas system, from cabinets to machines.

If an event might affect an entire FAB, Continuum would automatically sound multiple audible evacuation alarms, shut down affected gas sources, and send out a page to the emergency response and security team. Upon arriving to the suspected leak or spill area, the ERT would use one of four Continuum Limelight workstations to view the exact alarm event and the OSHA hazard information for detected gases or chemicals. Based on the materials identified, the Continuum system can actually provide the correct information. Continuum Limelight is Andover's “Thin Client” user interface that allows users to control and monitor their building from a standard PC. As a result of the system, Philips Semiconductors is able to help ensure the safety and security of the work environment, Sanders explains.

SECURITY AND FIRE SYSTEMS

Safety and security have always been high priorities at the Philips Semiconductors Albuquerque plant. Entry to more than 62 doors, including the main lobby, the visitor lobby and the parking lot are controlled by card access. Four Continuum CyberStations, two Episuite photo badging stations (by ImageWare Systems ID Group), and HID proximity readers deliver security and access for more than 1,500 employees and contractors, and a comprehensive interface for officers.

Continuum CyberStation enables the security officer to view critical access points from multiple cameras. Digital video recording is accomplished through Intellex 16-channel recording units by Sensormatic, currently being integrated with the Andover system. As an individual uses an access card, all information from the card is displayed along with live video from the access point and the photo on the card.

“[The CyberStation provides us with] remote video monitoring, which allows us to monitor and review video from any of our properly configured workstations in the facility, not just at the control center,” Sanders notes. “Instead of interrupting security officers who might be in the middle of a situation, I can go to another workstation and bring up the video.”

A fire alarm system by Edward Systems Technology is integrated with Continuum. Prior to installing the Andover system, Sanders and his team used a complex collection of equipment to monitor these alarms. “The Andover system allows us to not only monitor those alarms, but to initiate a response by clicking a button on the screen,” he says. “We can evacuate one or more areas, a floor, or the entire facility.” Continuum provides control and backup monitoring of all security and fire/life safety systems from not only the security control center, but from any properly configured PC or any one of four Limelight workstations on the secure network.

THE BENEFITS OF ANDOVER INTEGRATION

“The Andover system is an upgrade to maintaining a safe and secure workplace,” Sanders says. “We're taking actions based on real events and eliminating many opportunities for false alarms,” he continues. “The system works exactly as planned. Our security folks love it because it's easy to use. Our emergency response team is very happy with it because it gives them real-time information. It makes their job a lot easier.”

FOR THE RECORD

ABOUT THE COMPANIES

For information, please circle the Reader Service numbers (listed below) on one of the Reader Service cards in the issue or visit infoLINK at www.securitysolutions.com.

Andover Controls	17
Edward Systems Technology	18
Entech Sales and Service Inc.	19
ImageWare Systems ID Group	20
Sensormatic	21

Want to use this article? Click here for options!
© 2008 Penton Media Inc.

This month in Access Control

• Opening Up About Door Closers
• An Enterprise Approach
• The Framework For Open Systems
• On A Higher Plane
• More from April's issue