Control of an industrial ventillation system at a pharmaceutical factory

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Supervisor:
Dr. Kiss Bálint
Department of Control Engineering and Information Technology

Gedeon Richter PLC the market leader pharmaceutical company of Hungary has started a green field investment project. The scope of this project is a new injection manufacturing plant. There will be a separate system for the ventilation of the Small Volume Vial weighing room and its joining rooms. Both hormone and non-hormone containing products will be manufactured in the new plant. In order to prevent the risk of cross contamination the dispensing areas will be separated. One dedicated dispensing hood will be used for hormone and a second dedicated dispensing hood for non-hormone raw materials. In order to meet the high quality requirements, the air handling system will be equipped with an automation system. This system will control all critical environmental parameters such as temperature, humidity and pressure differences between the rooms according to the approved design specification.

The system contains one air supply unit and two air exhaust units. The whole mechanical system is controlled by the hardware and software components of Schneider StruxureWare Building Operation. The visualization happens on both PC and HMI panels, which are located in the production area and in the central control room.

The dissertation describes the adequate control of the environmental parameters (temperature, relative humidity, pressure differences between the rooms, constant pressure in the supply air and exhaust air-channels) of the dispensing hood, as well as the graphic visualization, the handling of errors and alarms in the air handling unit.

I worked out the task in several steps. First I learnt the components and the technical background of ventilation system and in the following step the system structure. After I had basic knowledge about the system I prepared the Process and Instrumentation Diagram (P&ID). Based on the approved P&ID I implemented the control programs and graphic panels. During this step I became familiar with the development environment of the Schneider StruxureWare Building Operation. In the last step I got acquainted with diverse communication protocols. I realized the communication with the device which is connected to the system, through the interface of Modbus TCP.

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