Client Challenge
A pharmaceutical facility in North Carolina required continuous support and system upgrades for its complex process control infrastructure spanning two distinct production areas:
- Raw Material Production Area: Primarily controlled by Allen Bradley PLCs (ControlLogix, CompactLogix) and Delta V systems.
- Secondary Processing Area: Operated with a mix of legacy and modern systems, including Modicon Quantum Hot Standby PLCs (ProWORX 32 and Unity software), Allen Bradley MicroLogix, Allen Bradley ControlLogix , and Delta V systems.
Our client faced challenges integrating new equipment, while maintaining legacy systems, ensuring regulatory compliance and, minimizing operational disruptions. Our team was engaged to provide upgrades, enhancements, and validation support across systems.
Our Solution
Over multiple years, DSI Innovations executed targeted upgrades and additions to enhance the facility’s process control systems, including:
- Legacy Modicon I/O Upgrades (2012–2016):
- Upgraded Modicon 984 I/O to Quantum I/O using S908 Remote I/O.
- Performed hardware replacements, made necessary software modifications, and supported system re-validation.
- Ammonia System Upgrade (2014):
- Modified the Allen Bradley ControlLogix system to integrate new function blocks developed by the client’s engineering team.
- Added a new ammonia tank, valving, and safety systems.
- Updated the iFix SCADA system to support the new functionality and ensured regulatory validation.
- Cooling Tower Pump Upgrade (2015):
- Updated the CompactLogix system to include new function blocks and integrated Allen Bradley PowerFlex pumps over Ethernet.
- Modified the iFix SCADA system to align with the new controls and supported system validation.
- Unity Quantum Hot Standby System Additions (2015–2018):
- Modified PLC code to accommodate new communications with Eaton and Rockwell MCCs.
- Updated iFix SCADA to reflect system changes and ensured validation compliance.
- Boiler System Upgrade (2018):
- Converted the legacy Modicon 984 system to an Allen Bradley CompactLogix system using PlantPAX objects for modern programming and design.
- Migrated SCADA functionality to FactoryTalk View SE, providing a unified and updated interface.
The Results
The comprehensive upgrades and enhancements delivered by DSI Innovations provided significant benefits for the pharmaceutical facility:
- Improved System Reliability: Upgrading legacy systems to modern hardware and software reduced the risk of equipment failure and streamlined maintenance.
- Enhanced Integration: New communication capabilities and SCADA updates ensured seamless operation across diverse systems.
- Regulatory Compliance: DSI’s support for system validation ensured that all upgrades met industry standards and regulations.
- Operational Efficiency: The modernized control systems, including PlantPAX programming and enhanced SCADA interfaces, improved monitoring and control capabilities for operators.
- Minimized Downtime: By carefully planning and executing upgrades, DSI minimized disruptions to production, maintaining the facility’s operational continuity.
This multi-year partnership demonstrated DSI Innovations’ ability to support and modernize complex process control environments while adhering to stringent pharmaceutical industry requirements.
