APC (Air Pollution Control) Controls Retrofit, Thermal Oxidizers TO3 and TO4

Industry

Pharmaceutical

Business Issue

The client was faced with new mandated MACT requirements to improve air quality.

Project Summary

The project involved the use of DeltaV to control the redesigned APC (Air Pollution Control) system and other functionality of an existing pair of Thermal Oxidizers (TO3 and TO4).  The Cornerstone Controls project group coordinated their efforts with the client, mechanical design group, and the electrical installation contractor.

This facility consists of OEM skid mounted equipment, stick built processes and utilities with a total of 3,000 I/O points.  This equipment includes equipment prep, media prep, blending, fermentors, bioreactors, filtration, formulation, filling, freeze-drying, clean and plant utilities. 

The automation system also needed to tie together all of the OEM equipment installed in the plant into an integrated system.  This required coordinating all of the OEM interfaces and equipment acceptance testing.

Scope Responsibility:

Cornerstone Controls was responsible for the following areas:

  • Furnish a functional requirements document for the APC based on O’Neal process descriptions and discussions with client personnel.
  • Furnish additions to the existing functional requirements documents for TO3 and TO4 that only include the changes to be made for both systems as part of the project.
  • Provide a design document for the APC.
  • Provide additions to the existing design documents for TO3 and TO4 that only include the changes to be made for both systems as part of the project.
  • Provide control panel drawings for the APC.
  • Provide a system architecture drawing for the APC, TO3, TO4, and Tank Farm systems.
  • Furnish LDIS data for the APC to include panel terminal blocks and DeltaV card/channel assignments.
  • Assist with the control room layout.
  • Furnish Cornerstone DeltaV configuration standards for use in the Source Code Review.
  • Furnish Source Code Review documentation for the APC.
  • Perform the Source Code Review on the APC.
  • Furnish Source Code Review documentation for the TO3 and TO4 PLC changes.
  • Perform the Source Code Review on the TO3 and TO4 PLC changes.
  • Furnish Source Code Review documentation for the TO3 and TO4 RSView32 changes.
  • Perform the Source Code Review on the TO3 and TO4 RSView32 changes.
  • Provide DeltaV configuration for the APC system.
  • Provide PLC program changes for the TO3 and TO4 systems.
  • Provide RSView32 configuration changes for the TO3 and TO4 systems.
  • Create a simulation for the APC and the interaction between the TO3 and TO4 systems.
  • Create reports for the APC similar in scope to the T49 reports being implemented in 1Q03.
  • Provide software test cases for the APC.
  • Provide software test cases for the changes to the TO3 and TO4 systems.
  • Execute software test cases for the APC.
  • Execute software test cases for the changes to the TO3 and TO4 systems.
  • Lead FAT execution for the APC, and changes to the TO3 and TO4 systems utilizing the test cases developed for each area.
  • Provide a test summary report.
  • Provide support for onsite commissioning.
  • Provide support for CEMS testing and integration.
  • Provide Backup and Restore Documentation.
  • Host operators during the FAT.
  • Furnish a training manual, which will include screen navigation and alarm handling.
  • Provide project management of the Cornerstone effort.
  • Develop and maintain the project schedule of associated Cornerstone activities.
  • Develop Cornerstone’s project management plan.
  • Conduct project review meetings as needed.
  • Provide project status reports.
  • Provide cost estimate data for Cornerstone activities and associated materials.
  • Provide the DeltaV system BOM.
  • Procure the DeltaV components.
  • Provide the PLC components BOM.
  • Procure the PLC components.
  • Procure the APC control panel.
  • Procure the control room furniture.
  • Assist with control room layout.
  • Create a recommended spare parts list.
  • Install the DeltaV system software and hardware.
  • Provide loop tuning assistance.

Results

Incinerator meets the client’s functional requirements and passes environmental agency testing requirements.