Veterinary medicine process control programming

Project profile: Optimation was contacted by another system integrator to provide programming services for a client in the pharmaceutical industry. The client had a new process involving the manufacture of veterinary medicine.

11/06/2013


Optimation was contacted by another system integrator to provide programming services for a client in the pharmaceutical industry. The client had a new process involving the manufacture of veterinary medicine. Courtesy: OptimationProject name: Support for Emerson Process Management’s DeltaV for the manufacture of veterinary medicine.

Client: Confidential, subcontracted by another system integrator

Value: Approximately $160,000 total

Schedule: Approximately 1.5 years

Project objective: Implement the new system on schedule to allow the customer to meet an increased demand in the market, while leveraging the company’s rigorous process and product standards.

Qualifications: Optimation’s experience with project management, continuous and batch control, S88, Title 21 CFR Part 11, and the DeltaV control system made for a good fit as a solution provider for the project.

Benefits/results: Since installation, the system is up and running and the DeltaV controls have been successfully integrated with the vendor package controls on the skid equipment. The customer was able to bring the medicine to market on time, and realize the corporate production goals.

Programming details

For the control programming project for veterinary medicine manufacturing, Optimation initially provided input for the functional specification; detailed design specification; and software specification test, factory acceptance test, and site acceptance test (FAT/SAT) plans; and reviewed the various skids’ control system programs. Three Optimation software engineers were assigned to provide programming for the overall controls for the new pharmaceutical process using DeltaV software from Emerson Process Management. The required programming needed to comply with stringent customer software development standards. The programming included software and hardware configuration, continuous control, alarming, interlocks, batch control with recipe generation, graphics, and skid integration.

This was the first DeltaV system to be installed at this particular plant site, even though DeltaV is the standard controls system platform in many other locations for this client.

In addition to providing programming for direct DeltaV control of some of the equipment, Optimation also provided the programming associated with integrating the DeltaV system with different equipment skids, each containing vendor package controls. The physical interface to these package units was done via a combination of a DeltaV Virtual Interface Module (VIM card) over Ethernet along with DeltaV serial cards. These package controls were mostly programmable logic controllers (PLCs) but also included some custom controls (VAX-based). The package equipment included one bioreactor, two fermenters, three utilities TCUs (temperature control units), one WFI (water for injection) system, seven autoclaves, one centrifuge, one waste neutralization system, and one CIP system. Optimation aided the client with skid PLC programming along with some engineering assistance associated with I/O wiring.

Bob Sullivan is senior controls engineer, Optimation. Courtesy: OptimationFAT and SAT reviews were conducted as part of the project process. Additionally, Optimation created a detailed design specification with flow charts to document the details of the programming. After the design and implementation were complete, the Optimation team assisted in the testing, installation, debug, start-up, and commissioning of the system, and provided training for operators.

- Profile author: Bob Sullivan is senior controls engineer, Optimation.

www.optimation.us 

Optimation is among System Integrator Giants for 2012 and 2013 and a Control Engineering System Integrator of the year winner.



No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Learn how to create value with re-use; gain productivity with lean automation and connectivity, and optimize panel design and construction.
Go deep: Automation tackles offshore oil challenges; Ethernet advice; Wireless robotics; Product exclusives; Digital edition exclusives
Lost in the gray scale? How to get effective HMIs; Best practices: Integrate old and new wireless systems; Smart software, networks; Service provider certifications
Fixing PID: Part 2: Tweaking controller strategy; Machine safety networks; Salary survey and career advice; Smart I/O architecture; Product exclusives
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Look at the basics of industrial wireless technologies, wireless concepts, wireless standards, and wireless best practices with Daniel E. Capano of Diversified Technical Services Inc.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.