Control engineering for new biotech equipment development
Industry
Life Sciences
Scope
Design / Implementation / Commissioning
Timeframe
12 months
1
unified control application for 5 different types/sizes of system
600
tags/signals exchanged via OPC UA interface
50
pages detailed guide for integration with DCS
01
CLIENT
Our client is a leading multinational science and technology company. The organization operates across healthcare, life science, performance materials, pharmaceutical, and chemical.
02
BUSINESS NEED
Our client was in the process of releasing a new biotech equipment (upstream bioreactor) to the market and already on MVP level customers wanted to install equipment in their facilities. The need was to provide prototypes with high quality and the ability to work in regulated environments in a very limited time. Our solution helped the client to run prototypes quicker, so they could be shown at events and installed in the end-client facility.
03
CHALLENGE
To help our client achieve its goals, we faced the following challenges:
-
Different types/sizes controlled by one unified PLC application
-
Flexible integration with different DCS systems
-
Distributed work & team (US and Europe)
-
Remote commissioning & debugging (Covid restrictions & multiple locations)
-
Simultaneous testing and commissioning of prototypes
04
SOLUTION
Introducing an efficient approach to control application development, our solutions have resulted in the following outcomes:
- Developed a minimum control application integrating PLC and HMI components
- Allowed the client to initiate tests promptly, circumventing the need for full software stack development
- Provided ongoing support and made necessary adjustments to the control application during all stages of product development
- Created a unified communication interface based on OPC UA
- Ensured seamless integration of the system with various types of DCSes for the final users
Developing a single software for several similar machines, tested in different locations, requires a high degree of accuracy and flexibility. As a team, we faced challenges that were hard to foresee at the design stage. This makes the success of such a project highly rewarding.
Paweł Pestka
OT Engineer
Technology used
WAGO PLC
Codesys 3
OPC UA
Kepware
05
OUTCOME
Our client was able to speed up product development by:
- Delegating the development of the system control application to us
- Achieving system readiness for validation tests promptly
- Successfully commissioning the prototype at the final user plant during the development phase