Chemical & Pharmaceutical

Both the chemical and the pharmaceutical sectors are currently faced with new challenges to overcome. Factors such as regulations, quality and increased price sensitivity play a critical role for the success of big multinational companies in both industries. Improving manufacturing processes allows meeting the demands of a changing competitive environment.

The pharmaceutical sector has stringent design constraints employing GAMP design and verification standards. We have engineered numerous control systems compliant with GAMP standards, again to some household names in the pharmaceutical sector. Meeting and exceeding safety and quality regulations is always at the heart of what we do.

The primary focus of the chemical industry has always been safety and productivity. Hazardous areas and ATEX regulations need to be accounted for in many of the system designs for chemical applications. Appropriate ATEX-compliant systems, where required, are an inherent part of the solutions we provide to this sector.

Scope of Supply:

  • Conduct a detailed site survey.
  • Produce a detailed specification document. (FDS)
  • Produce electrical circuit schematic diagrams.
  • Produce electrical cable schedules.
  • PLC, HMI software engineering.
  • Provide Factory Acceptance Test documentation. (FAT)
  • Shipment of equipment.
  • Provide Site Acceptance Test documentation. (SAT)
  • Electrical Installation – control panel and interface wiring
  • Mechanical Installation (if required by the customer)
  • Commissioning – testing of new control system
  • Validation – Validating the control system to conform to GAMP standards

 Previous projects:

3M

Indexing Table Control System

Main control build using Allen Bradley and Schmersal equipment

Pilz emergency stop relays employed for safety.

Software engineering

Panel testing

Commissioning

Unwind/Rewind Safety System

Emergency stop system engineering to suit an assumed risk level category

PL .D. as defined in ISO EN 13849 for the apparatus supplied. Equipment used: SICK, Pilz

Electrical installation – Termination of the power and control cables in the existing and new control panels. Installation of auxiliary components in the existing control panels, DC drive contactors and safety relays.

Commissioning

Cold Fill Line Control System

Upgrade of filling table and consolidation of controls using Allen Bradley and Pilz equipment.

Manufacture and supply of bespoke electrical and pneumatic panel.

Software validation to conform to GAMP standards

Electrical installation

Commissioning

Aeromatic Fluid Bed Clean In Place (CIP) Control System

Control system upgrade using Rockwell equipment.

Emergency stop system engineering using Pilz safety relays

Equipment testing and commissioning

Laser Marking System Integration

Main control build using Rockwell and Parker SSD equipment.

Safety control system engineering using Pilz relays

Design, build and commission

 

Crown Paints

Paint Line Feed System

Control system engineering using Siemens S7 equipment. Scope of supply includes producing circuit schematic diagrams to EN60204-1, engineering of PLC and HMI resident functional software and manufacturing of control cubicles.

Commissioning

Palletising Line PLC Upgrade

Replacement of the existing control desk and its TI PLC with new control desk and including Siemens S7-300 PLCs.

Installation and Commissioning

Palletiser Guarding System

Safety system engineering including PLC software and new control cubicle. Equipment used: Fortress Interlocks

Electrical Installation including new E-stop buttons, E-stop guard actuators and E-stop control panel.

Mechanical Installation including panel guards and door panels.

Commissioning

 

Barony Universal Products

Deluge Pump Control System

Control system engineering using Siemens S7 equipment. Scope of supply includes producing circuit schematic diagrams, writing PLC and HMI software and providing Factory Acceptance Test/ Site Acceptance Test documentation.

Emergency stop system engineering to suit an assumed SIL1.

Installation and Commissioning

Tank Farm Control System

The Tank Farm consists of freestanding storage vessels containing LPG and Ethanol.

Main panel build using Siemens PLC, HMI and associated control equipment.

Safety control system engineered to suit an assumed SIL1 or performance level ‘c’ equivalent to CAT2.

Electrical Installation

Commissioning

 

Pipeline Induction Heat

Heater Control System

Control panel build using Siemens S7 PLC, Eurotherm temperature and heater power controllers, Omron relays and Merlin Gerin overloads.

Recent Posts

Sustainable and Eco-Friendly Drive Technology from Optima

The innovative sinamics G220 variable frequency drive from Siemens not only helps reduce harmonics (Gary Wilcock) but is also a more sustainable drive choice. Let us explain.

The animation below shows the draft panel layouts for 8 drives using the G120 drives along with the required input and output reactors due to the long cable lengths involved for this installation. 

Shown on the right of the animation is the draft layout using the new G220 drives.

The new G220 drives, allow us to accommodate double the number of drives in one cabinet as no chokes are required.

SINAMICS G220 – the variable frequency drive for all industries

It has helped Optima Control Solutions Ltd make this a more sustainable design. 

Not only have we have reduced CO2 emissions in transit as the cabinet is lighter, we have also reduced the amount of minerals required to build by avoiding additional copper in the line chokes and steel in the chokes and cabinets.

The fusing for the other 8 drives has been moved to an adjacent cabinet where there are other drive sizes located. The control panel build is now underway. 

A big thanks to Ben Poole, too for his timely demonstration of these excellent drives. Sustainability CleanTech

 

  1. Continued Upgrade of Batch Plant Leave a Reply
  2. SINAMICS G Smart Access Module Leave a Reply
  3. Scalable motion control systems from Siemens and Optima Leave a Reply
  4. Efficient Motion Control ATEX Coating Leave a Reply
  5. Digital cloud-based asset monitoring is offered worldwide Leave a Reply
  6. Full Project Turnkey Solutions Leave a Reply
  7. Safety Scanner Issues and EN999 Leave a Reply
  8. Parker SSD Microtach Replacements Leave a Reply
  9. Accelerate your digital and sustainability transformation at Siemens Transform 2024 Leave a Reply