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Mobility for simplicity

Highly flexible application for Remote I/O
Mobility for simplicity

Sometimes it only takes an intelligent combination of suitable components in order to come up with an innovative solution and reach new levels of flexibility and efficiency in plant operation. One typical example is a mobile application employed by GlaxoSmithKline (GSK). The solution is based upon the unique set of features offered by Pepperl+Fuchs Remote I/O modules. It fully integrates into the existing process control infrastructure and offers further options for preventive maintenance.

Rainer Hillebrand, Terry McCarthy

GlaxoSmithKline (GSK) in Cork, Ireland, is a globally positioned pharmaceutical company. The primary focus of GSK centres on the development, production and marketing of pharmaceutical products. For its certified production processes, GSK employs advanced process control technologies to ensure the highest level of quality and reliability. Many projects in the process automation field are based on Emerson Delta V in conjunction with Pepperl+Fuchs Remote I/O.
The Glovebox project
Don Brady is a member of the engineering team at the GSK production plant in Cork, which is directed by Emmet Martin. He was responsible for the company’s Glovebox project and was looking for a solution to provide ongoing production processes with maximum convenience and flexibility. His idea was to develop fully mobile process control equipment that allows cost-efficient installation and fast relocation while meeting all the safety requirements typical of the pharmaceutical industry.
The main task of the system consisted in monitoring and controlling three identical mobile Gloveboxes, which are randomly used across eight processing vessels. For this purpose, each Glovebox was equipped with a small Remote I/O module from Pepperl+Fuchs, which was wired to the respective devices for field instrumentation. After putting the mobile Gloveboxes into place, the Remote I/O simply needed to be connected to the Profibus by means of an optical Profibus coupler in order to permit communication with a standard Delta V I/O. Each of the vessels featured an analogue output, which was directly connected to the corresponding terminals on the Delta V, making it possible to determine which Glovebox was attached to which vessel and display the respective user interface and graphics.
Intelligent flexibility
The Glovebox solution resulted in a highly scalable and flexible process automation system, perfectly matched to the processes employed at the GSK plant in Cork. The system provided a simple and time-saving way to relocate the process control equipment, so that the automation system could be easily adapted to changing process requirements.
An additional benefit was the automatic adjustment of the user interface to the changed system set-up. All graphics and references to the mobile devices are automatically hidden when not in use and automatically re-appear as soon as a new set-up is in place. Relocating the hardware does not require any system modifications. There are also no I/O errors, since the solution provides the intelligence to automatically detect the presence of any of the mobile devices.
All components of the system are hot swappable. This also includes the power supplies and represents a vital aspect, allowing the system to be relocated and maintained without affecting plant operation. Swapping a module does not require any manual configuration, since all functions of the module being replaced are automatically transferred to the new one via the gateway. This avoids any configuration errors and prevents the connection of incorrect modules. All circuits are galvanically isolated, while the complete system is based upon a redundant structure in order to achieve maximum reliability and availability.
Communications infrastructure
One major benefit of the Glovebox system at the GSK plant in Cork is the use of a Profibus communications infrastructure. This not only results in substantial cost savings due to reduced wiring requirements and the elimination of marshalling cabinets, it also offers considerable operating benefits due to the centralised engineering and the support for needs-driven maintenance.
A Pepperl+Fuchs Remote I/O is basically an interface component that is connected to the field devices and transfers their data streams via Profibus to the process control system. Three Hart-compatible, mobile Remote I/O substations of the application are used to connect all sensors and actuators that are part of the control system. They also offer sufficient space for the system’s pneumatic control valves. Due to their built-in intelligence, they are sometimes called intelligent junction boxes. Since they need to operate within the hazardous area, they fully conform to zone 1 and zone 2 specifications.
Preventive maintenance
Hart field devices can be configured and parameterised independently of the control communication protocol, using Pactware as a separate engineering tool. For this purpose, Hart devices support the open, non-proprietary FDT concept and can be connected to the Remote I/O via the Profibus infrastructure of the process control system. Thanks to the specific DVP1 features of Profibus, Pactware uses time slots between plant control communication and therefore does not interfere with normal plant operation. Profibus DPV1 services allow on-demand access to all device-specific parameters of Hart field devices through the FDT/DTM concept.
The Hart protocol enjoys increasing popularity in the process industry, since it allows online monitoring of field device parameters directly from the control room. This feature can be used for preventive maintenance and offers an ideal means to stretch regular maintenance intervals and cut operating costs. Hart secondary variables can also be included in the process data exchange and used for control tasks. Since the introduction of WirelessHart, the Hart protocol can even be employed in connection with wireless devices.
Proven key technology
The engineering team at GSK was supported by Pepperl+Fuchs specialists from the early design stage all the way to the factory acceptance test, installation and commissioning. They were absolutely satisfied with the results, pointing especially to the substantial cost savings during installation and the truly simple operation. Ongoing plant operation has fulfilled all expectations and continues to demonstrate the outstanding reliability of the solution. For this reason, GSK has decided to continue using the Remote I/O technology from Pepperl+Fuchs for future projects.
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