PLANT MANAGEMENT
The MOM dashboard
and analyse causes for lost capacity or equipment downtime.
A building management system (BMS) was integrated into the common distributed control system (DCS) based on ABB Ability System 800xA, which is not only a DCS but also an electrical control system, a safety system and a collaboration enabler. Anthem is now able to monitor and control the environmental conditions of its manufacturing facility, including temperature, relative humidity, ventilation and differential pressure functions. Integration of process automation and an effective energy monitoring system have made a crucial difference. Having all of these elements within one unified system that delivers remote and real-time data has ensured the entire plant can operate at optimum capacity. Anthem also made use of ABB’s
Remote I/Os concept and adopted the intelligent MCCs integrating the controls through the DCS, reducing cable and installation time and costs.
OPERATING ANYTIME, ANYWHERE
A key component of the brief from Anthem was to ensure the mobility of the system and solutions provided. Affording industrial plant operators the same
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flexibility, accessibility and availability as office workers was a key driver. Te team wanted an environment where plant operations could thrive with a mobile workforce that could access control system data in real-time, anywhere at the facility. Tis was particularly important for addressing critical operations and troubleshooting in the field. To achieve this, ABB built a Mobile
Operator Workplace into its sytem, which enabled operators and management to view their entire plant operations and get alerts on customised iPads and mobile devices.
Tis approach offered Anthem
improved visibility into its current plant status, regardless of the user’s location, and enabled remote monitoring and control for field operations and maintenance activities. Moreover, it has removed a reliance on hardware, by virtualising servers and operator stations, providing higher reliability, access and availability from anywhere on the network.
ENSURING QUALITY, COMPLIANCE AND SAFETY
Te solution for Anthem complies with global standard practices, including US FDA norms and 21 CFR Part 11, ISA 88, NFX1 and GAMP V. Tis means that Anthem can confidently comply
to quality standards demanded by these international bodies not only for upstream and downstream processes, but also PAS controls and monitoring of cleanrooms, equipment cleaning and sterilisation, and PW & WFI distribution and environmental management systems. Furthermore, by automating all the
processes within the plant, operators can quickly communicate and respond to issues and emergencies as and when they occur, placing safety, security and incident response (both occupational and cyber) at the top of the agenda.
CUSTOMER COLLABORATION Production at the facility began in 2017 and has been successfully operational for the past two years. Moving forwards, Anthem has recently instructed ABB to support it in expanding the scope of the initial project which will include the addition of new bioreactors into the existing facility. Further solutions such as the adoption and integration of predictive maintenance technology are planned for the future.
Vinu Kurup is with ABB Energy Industries.
www.abb.com
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