Project Experience

Sample Projects

Project: API Production Facility Expansion Automation
Client: Multinational Pharmaceutical Company

Project Summary

This project encompassed the automation of a Spray Dryer, an Agitated Vacuum Cone Dryer and associated utilities for the API Production Facility Expansion.

ProsCon successfully designed, built, configured, tested, installed, networked commissioned and validated this system which comprised:

• Two Siemens S7-400 PLC’s housed in steel cabinets, I.S barriers, power supplies, relays, etc.
• InTouch SCADA: PC running Windows NT 4.0 with a standard 3Com 3C509-TPC card with Siemens Softnet S7 software for interfacing to the H1 PLC network.
• A Challenger 14i type IS PC for installation in a Zone 1 Group II B hazardous area connected to the safe area PC.

ProsCon produced the following system design documentation:

• Panel Layout Drawings, Panel Wiring Drawings, Termination Drawings, Power Distribution Drawings, System Architecture Drawings, Functional Design Specification, I/O listing and all Validation Documentation (Quality Plan / Control System Validation Plan, Control System Hardware and S/W FAT Protocol, Control System IQ and OQ Protocol.

The Hardware FAT tested all panels as per approved FAT protocol. All hardware components, 100% of I/O (including remote I/O) and Controllers were tested. The Software FAT included 100% testing of all sequences, procedural control, alarms, graphics, trends, security, interlocks, historical data collection and compliance tests.