Application of a Decentralized Process Control System in a Biotechnology Project

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DÜPERTHAL Sicherheitstechnik GmbH & Co. KG

Production data are centrally stored and evaluated. System operators also have access to current and historical process data, mobile call stations via WiFi are planned via view stations distributed within the building. The standardized interface of the logging system has proven to be very helpful in including the equipment groups from various suppliers. A Siemens control unit can also be connected via a Profibus coupling.

The autonomous solution approach also made it possible to operate several equipment groups simultaneously. Since every equipment group has its own power supply, control system and operation, a malfunction of a component will not jeopardize the entire production process.

Decentralised Control Systems – An Easy Solution?

The challenge of changing system inserts and changing processes could also be easily solved with the decentralized approach. “The system control is cost-effective and functional due to the modular structure. Control functions, such as ‘agitating’ are distributed into basic functions according to Namur recommendations and can be reused at another point. We were able to reduce the testing effort overall and the tests of individual modules by this copying effect,” reports Sütterle. From the view of the automation engineer, the easy and uniform operating concept also on various equipment groups has contributed essentially to the acceptance by the employees. The training effort was therefore kept at a minimum.

Additional Information

Background

Building Alarm System

The Wago-I/O-System was originally developed for the factory automation, for example, as reliable fault alarm system of production facilities. In the meantime, it also has proven itself as multi-purpose and scalable automation system in other application areas. Based on the Wago-IPCs (758-870) and the Wago controller (750-841), pac developed a building alarm system for reporting, logging and treating (work flow) of faults and a monitoring and logging system for infrastructure systems (storage rooms, purest steam generators, pure water, refrigerators). Both systems are successfully used at Novartis under GMP conditions (Good Manufacturing Practice). The treatment and logging of alarms are stored for each work flow (according to FDA).

Positive Experiences

“The use of a decentralized process control with the IPC is cost-effective, scalable and flexible. The competent and quick support has been proven to be positive in practice. To our surprise, we were always able to directly talk to an expert and receive a quick and competent reply,” summarized the managing director at pac his experiences. ●

* The author works as a technical journalist.

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