Control System Upgrade

Industry

Pharmaceutical

Business Issue

The current fermentation process was controlled by an obsolete Moore control system approaching the end of its useful life. Obtaining parts and support for the equipment was difficult and resources were being consumed by the increasing challenges of the aging systems.

Project Summary

The resulting process is a batch operation including tank control, pH control, and an extraction process.

The existing system consisted of 5 separate systems and included some independent PLC controlled equipment (Rockwell and Modicon) and independent single loop Moore controllers.  A new DeltaV system was purchased to replace the 5 existing systems and interface to the existing PLCs.   The system also interfaced through OPC to an existing plant data historian.

A demanding production schedule required that the switchover occur with minimum downtime.  Due to limited space in the control room, the hardware design also required using existing panels to house the new equipment and staggered installation to allow old panels to be removed as they were replaced to make room for the new panels.

Scope Responsibility

Project management activities including:

  • Scope Management
  • Budget Management
  • Project Scheduling
  • Installation management

Hardware design of the new DeltaV system including:

  • System Architecture Drawing
  • Panel layout and wiring design
  • Interfacing to existing PLCs

Fabrication of new control panels and control room furniture

Software design, development, and integration

Computer system validation

Installation / Integration of new DeltaV control panels

Onsite commisioning 

Results

The new DeltaV control system successfully replaced the obsolete Moore system with minimal impact to the production schedule.