Objectives / Goals
The project objective was to provide a new regenerative carbon bed system to replace the two existing single use bed's, this was part of an on-site initiative to meet current environmental regulations.
Project deliverables included re-engineering of the existing control system and data transfers between North and South Factory PLC's to control process using the carbon bed system. As the system is part of pharmaceutical production facility the project was to be designed and tested following the GAMP guidelines, to provide traceability of modifications and to ensure other operations controlled by the PLC system remained unaffected by the modifications.
System Overview
The system is design is based on two individual Rockwell Control Logics PLC's and RSView32 SCADA Systems.
An addition 200 I/O points were added to the system from a mixture of Standard and Intrinsically Safe (IS) areas. This required extension of the existing PLC backplane to house additional I/O requirements and provide space for future development of the system.
System Philosophy
The system implemented provides control of the regenerative carbon beds. The North PLC and South PLC Systems pass limited data from one system to another by way of hardwired links.
The SCADA system provides indication of both the North and South sides of the plants operation, however it is not possible for operators to interact with the operation of the South side from the North and visa versa.
Conclusion
Applied Integration UK Ltd successfully installed and commissioned via a phased approach, ensuring the minimum disruption to plant operations, meeting with the client original project requirements.