Blending Hall Upgrade

The current plant was to be modified to integrate the new CIP system and upgrade the existing formulation process control system. The modifications included:

• Central PLC System and Operator HMIs: Replacing the existing operator control push buttons, switches, lamps, and discrete instruments with a central Siemens S7-1500 PLC system with Remote ET200 IO, Burkert AirLINE SP valve island and operator WinCC Comfort 1500 HMIs.
• PROFINET Protocol: Connecting networked devices using the Siemens PROFINET protocol.
• Manual Operation via HMIs: Allowing manual operation by process hall staff using the new HMIs.
• Future Process Automation: Designing the system to allow further process automation in the future.

Design Specifications

The system design was provided to GAMP 5 Standard in the form of the following documents:

• Functional Specification (FS): Document defining in detail the proposed design solution and describing how the design requirements will be met.
• Hardware Design Specification (HDS): Document defining the system hardware design.
• Software Design Specification (SDS): Document defining the system software design.
• Requirement Trace Matrix (RTM): Document tracing the addressing of the design requirements by design documents and test phases. This document was continually updated as the project progressed.

The user facilities, and the engineering characteristics in terms of functionality, system operation, and performance, are specified in these documents. The documents are approved by the client or client’s representative before detailed works commenced.

Scope of Supply

The scope of supply for the Electrical Control & Instrumentation (EC&I) element included the following:

• Survey Existing Panels: Correct existing drawings and re-create any missing drawings.
• Survey Existing Equipment: Confirm motor sizes, types, etc.
• Lead Investigation: Propose design solution for Emergency Stop and Manway switch safety circuits for approval.
• Interface with CIP Skid Vendor: Ensure proper interface between the systems.
• Document the New Design: Create FS, HDS, and SDS document sets and issue for approval.
• Document Detailed Design: Create new and revised drawing packs and issue for approval.
• Remove Redundant Panels: Remove X11 Operator Control Panel, Vessel 8 Operator Control Panel, and V2/V5/V6 Additional Panel from the process hall.
• Design/Build/Test/Install New Panels: Including PLC panel, X11 operator panel with 2 HMIs, Remote I/O and Valve Panel, and HMI panel for CIP Skid.
• Re-design/Modify/Test Existing Panels: Including X19 Motor Control Panel, Vessel 1 Silverson Softstart Panel, Vessel 2 Silverson Softstart Panel, and Vessels 2/5/6 Motor Control Panel.
• Install Required Field Wiring and Valve Air Pipework: Including Stainless Steel containment for process system and CIP return pumps.
• Create New PLC Software and HMI Configurations: To meet the requirements of the approved FS/HDS/SDS.
• Create and Maintain RTM: Ensure traceability of requirements.
• Create and Execute DQ: Design Qualification.
• Create Validation Protocol Documents: Including FAT, IQ, OQ for approval.
• Execute Validation Protocols: FAT, IQ, and OQ tests using approved protocol documents.
• Provide Support for Site PQ Validation Works: Performance Qualification.
• Provide ‘As Installed’ Design Document Sets and O&M Manuals: All documents were issued in native format (Word, Excel, AutoCAD, etc.).