Solid Liquid Incinerator and Conveyor System

Industry

Pharmaceutical

Business Issue

The client was faced with new mandated MACT requirements to improve air quality and a need for an incinerator with monitoring and characteristics capable of burning certain types of hazardous waste.

Project Summary

The project involved the use of DeltaV to control the Combustion Control, Container Handling System, Repack Area, and Repack HVAC, all components of the new incinerator.  Cornerstone Controls' project group coordinated their efforts with the client and the electrical and mechanical design firm.

Scope Responsibility

Cornerstone Controls’ responsibility included the following areas:

  • Provide two functional requirements documents based on all suppliers’ functional descriptions.  One document covers the Repack area and Container Handling System, and a second document covered the Combustion Control and Repack HVAC (as well as the CEMS interface from DeltaV).
  • Provide two design documents.  One document covers the Repack area and Container Handling System, and a second document covers the Combustion Control and Repack HVAC (as well as the CEMS interface from DeltaV).
  • Provide changes to the design and programming standards document as required by this project.
  • Provide control panel drawings.
  • Provide system architecture drawing.
  • Provide Power and Ground drawings.
  • Provide feedback on I/O lists and instrument database information (furnished by others).
  • Assign card/channels to I/O.
  • Assist in source code review.
  • Provide DeltaV software configuration for the Repack area, Container Handling System, Combustion Control, and Repack HVAC.
  • Provide interface tool between the Container Handling Management System and the DeltaV control system.
  • Provide DeltaV software configuration to communicate to the CEMS.
  • Create a MIMIC simulation.
  • Provide custom reports for the control system.
  • Provide a software test plan for the DeltaV configurations and the Container Handling Management System interface tool.
  • Provide software test cases for the DeltaV configurations and the Container Handling Management System interface tool.
  • Execute software test cases for the DeltaV configurations and the Container Handling Management System interface tool.
  • Lead FAT for the DeltaV configurations and the Container Handling Management System interface tool.
  • Provide a test summary report.
  • Provide hardware qualification document.
  • Execute hardware qualification.
  • Provide support for the IQ and OQ.
  • Provide support for CEMS testing and integration.
  • Update training material.
  • Setup MIMIC system.
  • Provide operator training instruction.
  • Provide project management of the Cornerstone and subcontractor efforts.
  • Develop and maintain the project schedule of associated Cornerstone and subcontractor efforts.
  • Develop Cornerstone’s project management plan.
  • Lead project review meetings.
  • Provide project status reports.
  • Provide cost estimate data for Cornerstone and subcontractor activities.
  • Provide the DeltaV system BOM.
  • Procure the DeltaV components and associated control panels.
  • Work with the client and their electrical design firm to ensure the power and grounding is correct.
  • Establish Data Historian and Reporting needs with the customer.
  • Create a recommended spare parts list.
  • Provide loop tuning.
  • Install DeltaV workstations and computer equipment for the control systems.
  • Terminate communication cable and test the control system network.
  • Fabricate all DeltaV control panels.

Results

Incinerator meets the client’s functional requirements and passes environmental agency testing requirements.