Automation

Test
Test

automation

We place your electrical, instrumentation and automation (EIA) on a sound footing.

Continuous, comprehensive structures for the EIA equipment ensure cohesion throughout the life cycle of a pharmaceutical production facility. In close cooperation with customers, suppliers and our specialists in process engineering, device engineering and EIA equipment, we offer the following range of services:

  • Budget planning
  • Basic Engineering
  • Detail Engineering
  • SW specification
  • SW creation
  • Commissioning
  • FAT, SAT, IQ and OQ as the basis for qualification and validation

SW = Software

FAT = Factory Acceptance Test

SAT = Site Acceptance Test

IQ = Installation Qualification

OQ = Operational Qualification

 

Cabinet construction

We create accurate electrical consumer lists and power distribution concepts based on them.

In Basic Engineering, variants for MCC, MV and RIO barriers are created. In order to ensure optimal operability, accessibility and maintenance friendliness of the process plant, the positioning of the E-/MSR barrier is a component of the 3D plant model as part of our detail engineering.

E-/MSR = Electric/measurement/control/regulation technology

MCC = Motor Control Cabinet

MV = Magnetic Valve

RIO = Remote I/O

 

Electrical consumers

The list of electrical consumers is the basic document for further electrical engineering (energy distribution, control cabinet construction, ... ). The detailed data for electrical consumers is extracted from a central plant database. All unnecessary redundancies and possible sources of error are avoided by this means. Changes are made and managed at a central location - an important criterion for enabling consistent engineering.

 

Energy distribution concept

We develop the engineering for the energy distribution together with the customer and partner companies - in every desired depth of detail. Surmising from an electrical consumer list, the necessary documents are created.

Starting with the determination of the connection values for normal, emergency and uninterrupted supply up to the detailed planning of motor control and on-site barriers - according to customer requirement.

 

Testing/commissioning/qualification

We provide support to the plant during all steps necessary for completion and validation. With our engineering tool FS INPUT®, we provide the basis for the necessary documentation of the test steps - right from the concept to the operation of the plant by the customer.

As part of a software FAT, the implementation of the functional specifications in the programming and visualisation of the automation system is reviewed. In the “dry run” in an early stage of the project, any defects and faults that occur can thus be remedied cost-effectively and damage to the production system and problems during commissioning can be avoided.

In addition to testing the functional sequence, focus is also given to the interaction and communication with other process plants during the software FAT. With the help of simulation software, process sequences can be realistically adjusted and the functional sequences extensively tested.

A well-executed software FAT raises the quality of the application software and thus represents an essential prerequisite for an efficient commissioning of the production plant.

During commissioning, our specialists ensure compliance with the necessary qualification steps in IQ and OQ - with the aid of the documentation functionalities of our FS INPUT® automation tool.

FAT = Factory Acceptance Test

IQ = Installation Qualification

OQ = Operational Qualification

 

System architecture

Our automation technology specialists, close collaboration with customers and suppliers, and our experience in using state-of-the-art automation devices from various manufacturers form the basis for a high-performance, future-proof system architecture.

The hardware and software concept is individually adapted to the circumstances and requirements - once created, its validity is checked during the entire project and documented with our engineering tools.

Concept development

Descriptions of plant operation

 

Descriptions of plant operation

The functional descriptions of a pharmaceutical process plant include not just the phase specifications that define the process sections in a module-based manner, but also higher-level plant functionalities, controller descriptions and I/O lists. These functional descriptions are created, edited, revised and managed by VOGELBUSCH BIOPHARMA.

Phase specifications are used to describe partial sequences of the process and are therefore also referred to as sequence strings. Required switch states of actuators as well as the use of sensors, definition of parameters, communication with other phases, behaviour in emergency situations, etc. are only a few of the contents to be specified.

In the higher-level plant functions, all safety-related interlocks (e.g. behaviour at overpressure) are defined for the plant and personal protection.

The functionality of controllers, their actuators and sensors, as well as the interaction with the phases, are specified in the controller descriptions. It contains a diagram to clarify the controller strategy and the illustration of input and output variables. Internal and external parameters as well as their use complement the specification of controllers.

 

Device selection/instrumentation

When we select the sensors and actuators for your future process plant, the experiences during commissioning and insights from the daily production process by our personnel are the solid basis for success.

Moreover, good contacts to well-known manufacturers guarantee a wide range of implementable products and optimal support and ensure state-of-the-art instrumentation matching the requirements.

Depending on your requirements, we provide you with all the documents needed, from basic specifications to the order specification. We are happy to take over the entire procurement process right through to the incoming goods inspection and documentation, with tools such as COMOS and EPlan, PPE and with databases we developed ourselves.

Construction of Cabinets

We prepare exact lists of all electrical loads and electrical energy consumers forming the basis for all energy distribution concepts.

Different types of MCC, MV and RIO cabinets are designed as part of the basic engineering stage. 

 

Electrical Loads

The list of electrical energy consumers forms the basic document for further electrical engineering and design. A central facility database is used to extract detailed data on specific electrical loads.

Energy Distribution Concept

Together with our customers and partner businesses, we develop an energy distribution concept according to the required level of detail.

 

Testing | Commissioning | Qualification

We support you during all the stages required for your plant’s completion and validation. This is why, our engineering tool
FS INPUT® provides the necessary documentation of each testing. This provides a consistent record, starting from the concept design of a facility to its day-to-day operation.

In a software FAT the implementation of functional specifications in programming and the visualization of each automation system is reviewed. Over the course of the commissioning process, our specialists will ensure compliance with the required qualification steps in IQ and OQ.

In a software FAT the implementation of functional specifications in programming and the visualization of each automation system is reviewed. In this way, any emerging defects and errors can be eliminated at an early stage during a 'dry run' to avoid unnecessary costs, damage to your 
production facilities as well as any problems that may arise during commissioning.

Apart from reviewing functional procedures, a software FAT also focuses on the interaction and
communication with other process facilities. Using simulation software, process sequences can be plotted realistically and functional procedures can be tested in a comprehensive way. 

A thorough software FAT significantly improves the quality of application software and sets the basis for the efficient commissioning of production facilities.

Throughout the commissioning process, our specialists ensure compliance with the required qualification steps during IQ and OQ. Also here they profit from the documentation functionality of our automation tool FS INPUT®.

FAT = Factory Acceptance Test  IQ = Installation Qualification
OQ = Operational Qualification

Concept Development

Defining the degree of automation, selecting the hardware manufacturers, coordinating interfaces as well as estimating the costs are just a few examples of the tasks involved in the concept development process. 

 

Automation Tool

The functional specifications for pharmaceutical production facilities can be extremely complex sometimes. The automation tool

FS INPUT® by VOGELBUSCH BIOPHARMA helps to define these sequences (phases) and neatly plots them for programming purposes.

Functional Specifications

Functional specifications of systems and facilities  include the specification of phases as well as the definition of general functions, controller descriptions and I/O lists. 

 

Selection of Equipment | Instrumentation

We have excellent business connections with well-known manufacturers offering a large variety of suitable products as well as optimum support. Moreover, they guarantee state-of-the-art instrumentation in conformity with your requirements.