Background
The client’s business requirements were:

• A “one-stop-shop” for the bioprocessing Industry’s training requirements.
• A dynamic catalogue of course content from which the client can build unique training solutions for their clients
• A number of training solutions ranging from operator through to the senior management which can be delivered in different formats to suit the client.
• Holistic training programmes in a realistic GMP simulated, operational manufacturing environment.

Requirements

• Provide supervisory control of PUW Distribution.
• Provide interface and process visualisation for approx 20 skids.
• Provide operator interface to recipes and routes for a centralised CIP system for the skids.
• Record historical process and alarm data for entire facility.
• Provide out of hours alarm notification.

Key Challenges & Solutions

• Control different skids from multiple vendors with minimum cost, risk and change.
  We developed a tailored interface for each skid which allowed the vendor retain their standard code and hence reduced development, change and testing.
• Provide a cost effective and flexible CIP system for the facility.
  We engineered a solution that allowed a single CIP skid be used to clean all other skids and in so doing avoid the requirement for multiple skid dedicated CIP systems.

Implementation

• WinCC V7.0 with S7-400 PLC
• Redundant OS Servers (SCADA) with archiving engineered from one ES (Engineering station)
• 8 WinCC clients to provide visualisation for training
• Simatic Teleservice was used for remote alarm notification

Benefits

• All project requirements were addressed
• Project delivered to budget and on schedule
• New system has clear upgrade path