Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Mallinckrodt: Pharmaceutical Plant Save...
Agenda
Company Overview
Project Team
Our Challenge (2 phases)
Justification
What’s Out, What’s Left, What’s New
Virtualiza...
Company Overview
3
Pharmaceutical manufacturer
 Bulk Active Pharmaceutical Ingredients (API)
 Specialty Chemicals
 Imag...
Project Team
Mallinckrodt Pharmaceuticals
 Don Geers – Lead Controls Engineer
 Lead Process Engineer
 Various other Pro...
Our Challenge
Phase 1
 Develop a programming standard for all new PAC based
installations in our facility. Provides for a...
Justification
How did we justify this project.
 Cost avoidance.
 Process runs 24x7x364. Uptime is extremely important.
...
Phase 1 (programming standard)
Why develop a Programming Standard.
 There are basically two different control systems in ...
Phase 1 (programming standard)
No common programming
platform for the PAC based
systems.
 Develop a programming standard ...
Phase 1 (programming standard)
What was needed to develop this standard.
 Partnered with Rockwell Automation Systems and ...
Phase 2 (the upgrade)
Scope
 Partnered with Rockwell Automation Systems and Solutions
Business (SSB) to execute the proje...
Phase 2 (the upgrade)
 Scope – continued
 As-Built 64 Process Logic Descriptions (PLD’s) per existing PLC
code for accur...
Phase 2 (the upgrade)
12
Process Logic Description
Development Structure
Documentation Development:
• Each unit on Train 1...
Phase 2
13
Mail Merge Demonstration
What’s Out, What’s Left, What’s New
14
Out
1 - PLC3
2 - PLC/5’s
DOS based prog. terminal
4 - FactoryLink HMI operator
term...
What’s Out, What’s Left, What’s New
15
All Servers and Terminals
are virtualized.
Servers
FactoryTalk® Batch
FactoryTalk® ...
Virtualization
Built upon our existing VMware infrastructure.
Two identical systems in two separate buildings.
Automatic b...
Factory Acceptance Testing
Joint venture with Rockwell Automation and local Systems Integrators.
Accelerated schedule. Sta...
Qualification & Startup (IQ/OQ)
Installation Qualification (IQ)
 Old controls removed and new controls installed in 4 day...
Qualification & Startup (PQ)
Process Qualification (PQ)
 Introduction of actual product.
 Five batches were run initiall...
What went well
20
What went well
Programming Standard (HMI & controllers).
Excellent documentation for FAT testing and val...
Lessons learned
21
Lessons learned
You can’t have enough help.
Get involved earlier in the details of the program code to ...
Going Forward
22
Future State
 The Programming Standard has been used on 4 upgrade projects to
date, with another grass r...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Thank you for participating!
Please rem...
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Mallinckrodt: Pharmaceutical Plant Saves $100k with Virtualized PlantPAx Platform

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Mallinckrodt Pharmaceuticals was running its ingredient production facility on legacy 1980s PLC technology that was becoming difficult to maintain and update. The company upgraded to a PlantPAx process automation system built on an existing VMware virtualization infrastructure. Virtualization has helped provide
cost savings of over $100k by reducing capital and maintenance expenses. FactoryTalk VantagePoint, View SE and Historian increased data insight and provided validated, electronic reporting, saving additional costs, reducing batch losses and allowing proactive
maintenance to reduce downtime.

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Mallinckrodt: Pharmaceutical Plant Saves $100k with Virtualized PlantPAx Platform

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Mallinckrodt: Pharmaceutical Plant Saves $100k with Virtualized PlantPAx® Platform Don Geers Senior Maintenance Engineer Mallinckrodt Pharmaceuticals
  2. 2. Agenda Company Overview Project Team Our Challenge (2 phases) Justification What’s Out, What’s Left, What’s New Virtualization Factory Acceptance Testing Qualification & Startup What Went Well Lessons Learned Going Forward Q&A 2
  3. 3. Company Overview 3 Pharmaceutical manufacturer  Bulk Active Pharmaceutical Ingredients (API)  Specialty Chemicals  Imaging agents  Drug chemicals Based in St.Louis Mo  140+ year old facility on 40 acres  500+ Employees at the St.Louis plant Other Manufacturing Sites  Hobart NY, Raleigh NC, Dublin Ireland, others FDA Validated Facility  Long term data retention is critical
  4. 4. Project Team Mallinckrodt Pharmaceuticals  Don Geers – Lead Controls Engineer  Lead Process Engineer  Various other Process Engineers, Validation and Quality personnel. Rockwell Automation  Jim Wardell – Lead Project Engineer  Minimum of 6 additional engineers for support  Local Rockwell Automation engineering support – Long term 4
  5. 5. Our Challenge Phase 1  Develop a programming standard for all new PAC based installations in our facility. Provides for a common programming structure across our different manufacturing units. Phase 2 (the upgrade)  Replace a legacy HMI and Allen-Bradley PLC3 / PLC5 based Control System. 5
  6. 6. Justification How did we justify this project.  Cost avoidance.  Process runs 24x7x364. Uptime is extremely important.  Control equipment installed in 1985, so spare parts are getting hard to find.  Available support for this system was minimal from Mallinckrodt & vendors. 6
  7. 7. Phase 1 (programming standard) Why develop a Programming Standard.  There are basically two different control systems in our facility. • Traditional DCS which has a programming standard. • The rest are a combination of WonderWare, FactoryLink, RSView®(x), Siemens, with various types of Allen-Bradley PLC based controls. No common programming structure. 7
  8. 8. Phase 1 (programming standard) No common programming platform for the PAC based systems.  Develop a programming standard for future PAC systems that has the same look & feel as our DCS systems.  For operators, the HMI graphics look the same. This helps when moving between manufacturing units with different control systems.  For programming, the control module structure is similar between the DCS & PAC based systems. 8
  9. 9. Phase 1 (programming standard) What was needed to develop this standard.  Partnered with Rockwell Automation Systems and Solutions Business (SSB) & local Systems Integrators to help develop the standard.  Functional Specification jointly developed with Rockwell Automation (you have to know what you want)  Design Specification developed by Rockwell Automation based on the Functional Specs.  Test Specification needed to validate the various control modules. • Once validated, these Standard Modules could now be used on multiple projects without re-validating.  Lessons learned • It won’t be perfect the first time. You will miss something. • We are on version 3 of our standard. 9
  10. 10. Phase 2 (the upgrade) Scope  Partnered with Rockwell Automation Systems and Solutions Business (SSB) to execute the project. • This required very close collaboration of the project team. Process Engineer, Automation Engineer, Validation, Rockwell Automation Engineer. All the way through the entire project.  Replace a legacy Allen-Bradley PLC based Control System & HMI. • Total PLC code re-write (~10K rungs) using S88 phase manager & FactoryTalk® Batch. Utilized the Standard Control Modules created in phase 1.  New HMI Graphics re-drawn from original HMI graphics. • ~200 HMI screens (process graphics and Batch Record screens)  Re-created 60 Digital Batch Records and 6 Process & Environmental reports utilizing Microsoft Reporting Services.  Utilize existing field I/O to reduce cutover time and risk. 10
  11. 11. Phase 2 (the upgrade)  Scope – continued  As-Built 64 Process Logic Descriptions (PLD’s) per existing PLC code for accuracy. Then updated to a new Class-Based document format. • Managed only one document per operation per Class. Used Excel Mail Merge function to populate the document with the correct devices. This concept worked extremely well. A separate spreadsheet contained the unique elements relative to all module classes in the application. • 33 Unique Module Designs, + 31 Instances of those Designs. Class-based documentation can be viewed and printed and be specific to the instance with respect to Equipment and Devices. • Class-based Methodology also served (i.e. focused us) to clearly identify all differences between instances of the same class. (Fail open vs. Fail Closed valves, extra instrumentation, etc.) 11
  12. 12. Phase 2 (the upgrade) 12 Process Logic Description Development Structure Documentation Development: • Each unit on Train 1 has its own Process Logic Description in MSWord. • MSExcel is used to provide the Mail Merge data to each document. The Train 2 documents can be automatically generated at the click of a button. • Modifications to one Train are automatically captured for the other Train. • Support Systems require their own documents.
  13. 13. Phase 2 13 Mail Merge Demonstration
  14. 14. What’s Out, What’s Left, What’s New 14 Out 1 - PLC3 2 - PLC/5’s DOS based prog. terminal 4 - FactoryLink HMI operator terminals (WinNT) Oracle Historian/Datalogger (WinNT Server) Batch Record Server (WinNT Server) 3 - Alarm printers Serial interface to Delta V control system in adjacent building Left All field I/O •1771 Remote I/O •1756 CLX I/O •Flex I/O •Profibus PA •AS-i bus •Ethernet VFD’s Used existing I/O to reduce cutover risk. Plan to upgrade I/O in the future.
  15. 15. What’s Out, What’s Left, What’s New 15 All Servers and Terminals are virtualized. Servers FactoryTalk® Batch FactoryTalk® Historian Site Edition FactoryTalk® VantagePoint® FactoryTalk® View Site Edition (primary & secondary) FactoryTalk® Directory MS SQLSvr Hardware 3 - HMI workstations 1 - Engineering terminal (all thin clients) 3 – ControlLogix® L74 controllers (all redundant) 13 – Ethernet EN2T comm. Modules 3 – Remote I/O Modules (interface to existing Remote I/O) Delta V Ethernet Virtual Interface Module (VIM) 3 – Stratix 8000 Network switches 2 – Blade servers for our existing VMWare Batch Record/Graphics printer
  16. 16. Virtualization Built upon our existing VMware infrastructure. Two identical systems in two separate buildings. Automatic backups of virtual images on periodic basis for disaster recovery. Currently running 16 servers & 30 workstation images on VMWare. And growing. Eliminates the need to rebuild a computer due to hardware failure. Saved ~$100K in computer cost by using virtualization. 16
  17. 17. Factory Acceptance Testing Joint venture with Rockwell Automation and local Systems Integrators. Accelerated schedule. Startup moved up by two months. Performed on-site utilizing existing VMWare system while production unit was still operating. Allowed us to test the throughput on our actual system. Three months duration working two shifts. Still finishing design/code development when FAT started (required numerous code merge procedures to avoid invalidating FAT efforts). Leverage FAT testing for Validation. (did not re-test sequencing functions during shutdown OQ) 17
  18. 18. Qualification & Startup (IQ/OQ) Installation Qualification (IQ)  Old controls removed and new controls installed in 4 days ready for I/O checkout.  Round the clock testing.  2 weeks duration working two shifts. Every device manipulated. • 1000 digital, 500 Analog. Operational Qualification (OQ)  Introduction of utility chemicals with water as the product  Round the clock coverage  2 weeks duration running multiple batches 18
  19. 19. Qualification & Startup (PQ) Process Qualification (PQ)  Introduction of actual product.  Five batches were run initially. • All five passed quality requirements. Best of all:  No Safety issues  No Environmental issues  No lost batches 19
  20. 20. What went well 20 What went well Programming Standard (HMI & controllers). Excellent documentation for FAT testing and validation. Good in-depth reviews of the Process Logic Descriptions. VMWare & Thin Client usage. Utilize our existing virtualization infrastructure to lower control system maintenance cost & downtime. FAT performed on-site and on our existing VMWare system. We can then see how the system will perform before startup. Get your people involved. Process Engineers, Facilitators and Operators all know the process the best. Near-duplicate Virtual Environment at Rockwell Automation Office used for development, functional testing, mid-project demonstrations (Webex’s), troubleshooting, and long term support .
  21. 21. Lessons learned 21 Lessons learned You can’t have enough help. Get involved earlier in the details of the program code to better understand its structure by the time the FAT & Startup begins. Validation protocol reviews could have been better coordinated. Needed a better understanding of the VMWare infrastructure in our facility. Get a better handle on the Ethernet Network Infrastructure in our facility. Get your Systems Integrator(s) involved with all aspects of the project… Network Architecture and Configuration, other IS-related functions.
  22. 22. Going Forward 22 Future State  The Programming Standard has been used on 4 upgrade projects to date, with another grass roots project set to begin in Q3/2014.  Virtualization will only grow in the future as our current control systems become outdated. This has greatly reduced our computer maintenance and infrastructure cost.
  23. 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 23 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  24. 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Thank you for participating! Please remember to tidy up your work area for the next session. We want your feedback! Please complete the session survey!
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