Process automation and control project examples

Multi-column deionizer/drug production system

A Bailey Network 90 DCS installation was expanded to provide batch controls for a deionizer and drug production system. The 250-process I/O expansion required design, logic configuration, operator interface configuration and integrated testing. The design and configuration was performed using the Bailey batch language. The control logic considered process unit allocation issues. Extensive interlocking and the sharing of common process resources in this pharmaceutical application resulted in more than 9,000 lines of batch language code.

Drug incineration system

A large pharmaceutical firm had stockpiled a quantity of off-spec drugs which needed to be disposed of per FDA guidelines. RoviSys engineered a 250 I/O point expansion of an existing Rosemount RS3 drug production system to control an incinerator where the off-spec drugs are destroyed. Control and monitoring are accomplished using the DCS batch language and 13 custom process graphics. Ash handling, scrubber controls and wastewater treatment were incorporated as part of the system expansion. A software interface to a PLC within existing OEM equipment was also provided. Kickoff to full operation took less than 3 months.

Food production with clean-in-place

A major food processor modified their process to improve product quality and sanitizing of the production process. RoviSys provided NEMA 4X control and solenoid valve panels with instrumentation and configured 10 Bailey multi-loop controllers, seven sequence controllers and a HMI to provide a clean-in-place system for two complete cooking processes. Labor required to prepare the process for the next run of product was minimized. The graphics on the operator station provided a dynamic view of the CIP process and permitted interaction with the configured batch sequences. A PLC system was also configured to replace a physical patch panel to make room for the control expansion.

Cheese slurry batching system

RoviSys configured a system to control the charging, mixing, heating and discharging of a cheese slurry tank while providing full integration into a production kitchen for a large food processor. Operator interface was via a panel-mounted NEMATRON graphic screen and keyboard. A PLC that controlled the recipes and product routing was interfaced to a dedicated Satt temperature controller, which manipulated steam heat to the process.

Resin blending system

A manufacturer of food container resin coatings replaced their hard coded VAX based batch control system with a more flexible, reliable and maintainable PLC and PC system. RoviSys was selected over several integrators to supply a recipe driven system using Rockwell PLCs. The batch option was engineered for single "operation" batch recipes so the customer could easily edit recipes changing only the parameter file. Custom programs were developed to allow operators to use familiar raw material nomenclatures when modifying batches.

The process consisted of nine blend tanks, three common headers and two pre-weigh vessels. RoviSys interfaced to the two serial scale controllers via a multiplexer and the built-in RS-232 port on the PLC. Once started by an operator, the entire batch sequence is performed automatically. The operator may hold, prioritize or modify a batch, which increases flexibility to meet customer needs. After the common equipment is released by an active batch, multiple batches may be run in parallel.

Ascorbic acid plants

Bailey Controls INFI90 distributed control system and Batch90 software running on a MultiFunction Controller was engineered and commissioned by RoviSys to control ascorbic acid (Vitamin C) production and refinement for a major food producer. Food grade ascorbic acid was produced, stored and tracked for use in the adjacent facility. FDA validation and lot tracking were included in the scope of the project.

A similar plant at another site requested a new DCS to control its production. RoviSys updated the configurations and made modifications to adapt to different equipment. Startup was completed only three months after the decision to proceed. All documentation, testing and validation was completed on schedule by using standards developed by RoviSys.

Tomato sauce plant

A major food producer wanted to convert batch preparation of tomato sauce into a continuous process using heat exchangers. The control process needed to assure sufficient cooking time in one pass without burning. Automation of clean-in-place procedures for chemical sterilization was also required to end nightly equipment disassembly for cleaning.

RoviSys engineered panel mounted single loop controllers for the heat exchangers along with panel-mounted sequence controllers for the CIP algorithms. HMI development included graphics and trending for operators through factory MMI over a local area network.

Pharmaceutical freeze dryer automation

A pharmaceutical company needed recipe driven batch automation of eight custom freeze dryers over split data highways for performance and reliability. MMI and batch logging and reports to a host PC with interface to a mainframe was accomplished using custom designed C code, graphics screens and logs. Reporting to meet user and FDA requirements was included. The company runs small and custom test campaigns for its primary customer, thus requiring a flexible off-line recipe editor.

RoviSys designed this recipe editing and management system around a commercially available spreadsheet package. Each batch of product can be worth over $1 million so each freeze dryer has its own PLC and operator interface. The host is backed up by the local MMI's, which are configured in pairs for complimentary redundancy. RoviSys assisted with the FDA validation of this control system.

Small tablet batch tracking

A pharmaceutical manufacturer required batch tracking of 250 tablet recipes produced using PLC control with integration of nearly three dozen barcode and label printers. The solution architecture needed to allow for network to plant maintenance, expert, laboratory information management and ERP systems over a network. RoviSys engineered and commissioned the system to client requirements and assisted with meeting FDA validation requirements.