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PUMPS, VALVES & ACTUATORS
CREATING CUSTOMISED CONTROL CABINETS
Damien Moran, pharmaceutical industry specialist at Bürkert Fluid Control Systems, explains the challenges of creating new production lines or expanding existing ones in ATEX areas
harmaceutical plants and those creating active pharmaceutical ingredients (APIs) face many challenges in delivering end products to the highest standards. With a variety of solvents and other combustible ingredients used for manufacturing, many production areas are classified under ATEX/Ex regulations, which stipulate rigorous build specifications for all equipment installed in zoned areas. Creating or expanding a production process within a pharmaceutical environment offers a number of challenges. From the creation of an automation concept and developing it into a physical model to sourcing all the components, connecting them together and integrating the new process with the wider infrastructure, the whole process requires considerable expertise. Process automation predominantly uses either a distributed pneumatic control concept or a decentralised one. The former uses control cabinets that are positioned close to the process, usually within the zoned area, and therefore they must also be certified for their location together with all the control valves and sensors.
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When there is a more wide-ranging project, such as modifying an existing control system or building a completely new one, the task of delivering a fully certified installation is more complex and requires special skills and expertise. In such situations, it is important to select partners that understand process control design and have the ability to deliver bespoke solutions using the latest technology - all certified to the standards in force locally. Systems can only realise the expectations of the client if they are conceived, designed
30 FEBRUARY 2024 | PROCESS & CONTROL
and manufactured by a single, dedicated, experienced team. Bürkert’s Systemhaus concept uses expert teams of designers, project managers and engineers that work together to produce innovative solutions. One of the first decisions is the size of cabinets required for the project, which may be restricted to a few ‘standard’ sizes from some suppliers. Cabinets can occupy too much space, which is not ideal in pharmaceutical environments. A custom control cabinet that is destined for Zone 1/21 must be built using ATEX certified components, but the enclosure itself does not automatically receive ATEX approval, it will have to be independently certified after the build has been completed. This can cause delays for
installation and commissioning, unless the manufacturer is approved to supply a declaration of conformity.
For the components and pipework inside the cabinet, every item must be correctly specified for the application, with documentation to support it. The control equipment within the cabinet can be quite complicated and include valve islands, intrinsically safe valves, remote I/Os, components for filtration and pressure regulation as well as electrical connections and switches.
At the heart of the control system is the pneumatic island. For installations in zones 2/22, the choice is quite extensive, but to satisfy the demands of Zone 1/21, there are fewer options. However, this does not detract from the features that are available, in fact some of the latest offerings provide excellent integration and connectivity with components commonly used in these applications.
Creating or expanding a production process within a pharmaceutical environment offers a number of
challenges.The Menden
Systemhaus helps overcome these challenges by delivering control cabinets for installations in potentially explosive atmospheres
For Zone 1/21 installations, Bürkert’s Type 8650 (AirLINE Ex) offers features and benefits such as ability to integrate seamlessly with the Siemens ET 200iSP remote I/O system. This enables Bürkert valve control to operate within the Siemens software, which is commonly used in the pharmaceutical industry. A useful feature of the Type 8650 is the ability to hot swap pneumatic valves without interrupting the manufacturing process or causing financial losses from unexpected downtime.
Production plants that are operating the Siemens PCS7 distributed control system can now seamlessly integrate Bürkert process control equipment that is tailored to each application. Furthermore, plants that operate in a non-Siemens environment can still take advantage of the Bürkert product lineup including the Type 8650 (AirLINE Ex). Bürkert has experience in designing and building ATEX control cabinets at a dedicated facility that not only designs and constructs customised panels, but also certifies the complete assembly before it is dispatched. Beyond the actual build of the control panel, in order to meet ATEX certifications, each product must be accompanied by the correct paperwork. Every project delivered by Bürkert is accompanied by a documentation package that is supported by the company’s accreditations.
Due to the multiple competencies within each team at the Menden Systemhaus, it is possible to design compact, integrated solutions that often contain both electrical and pneumatic circuits and even fluidic connections as well. In this way, it is possible to deliver a single control cabinet which reduces commissioning time and improves final delivery.
Bürkert Fluid Control Systems
www.burkert.co.uk
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