Project: Biopharmaceutical filtration automation (January 11, 2006)


Project Status Summary:
1. Control software development code complete 100%
2. HMI software code complete 100%
3. HMI external application configuration 100%
4. MF beta testing 100%
5. UF beta testing 100%

Customer Acceptance Testing
We completed the customer acceptance testing just before the holidays and have now packed up the system for the factory acceptance test (FAT). For the final piece of testing at our office, the customer’s automation engineer reviewed the code structure, documentation and the testing procedure we employed. The data format was also reviewed for incorporation into their plant wide system. Since the customer visit, we have updated the documents and the code per the punch list items. In total, we had 24 punch list items to address: 60 % were graphics related and 40 % were sequence or code modifications. Upon completion of these items, we shipped all of the relevant hardware to the skid vendor for incorporation into the electrical panels. These panels need to be completed prior to the equipment FAT, so we can properly and safely perform wet testing. When finished, each skid will have its own PLC and operator workstation, complete with full keyboard and pointing device for ease of use.

Factory Acceptance Testing
The factory acceptance test at the skid vendor’s shop is scheduled to begin January 18th. The first two days of the FAT are slated for I/O check out on the skids. This is an obligatory, yet often overlooked task during FAT scheduling discussions. In most cases, the FAT is scheduled as a one-week activity, but depending on the amount of I/O, it may take 2 full days to finalize the I/O check out. For this project, we will begin the I/O testing on the 18th, prior to the customer arriving. This will allow us time to properly document and test the I/O and prep the system for subsequent wet testing, which may include initial loop tuning and safety checks. The customer will arrive on the following Monday and will then have a full week of testing time. The testing will include both mechanical and operation tests on the skids. The mechanical tests will include a drawing walk down, slope verification, surface finish verification, dimensional check, and spray ball coverage test of the tanks. The operational testing will use the software to test equipment module functionality and alarms. If time permits, we will also begin running recipes, but recipes are not normally tested at an FAT.

What's Next?
The factory acceptance test at the equipment vendor’s shop is scheduled to begin next week.

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