DSM uses Emerson's PlantWeb® digital plant architecture to cut maintenance time in half
DSM anti-infectives, based in Delft, the Netherlands, has reported significant operational savings by using PlantWeb® digital plant architecture from Emerson Process Management. Savings have been made by utilizing the predictive capabilities of PlantWeb that include accessing the online diagnostic capabilities of the intelligent field devices networked throughout the plant. The information that is provided enables a move towards predictive maintenance, a more effective maintenance strategy that makes it possible to limit the potential for unplanned shutdowns and extend the time between planned shutdowns.
Further savings have been made because the integrated modular software, one of the key elements of PlantWeb, is based on open technologies such as Windows; this has reduced time spent on operator training because operators are familiar with many of the commands and menu structures.
DSM is a leading worldwide producer of life science products, performance materials and industrial chemicals. They installed PlantWeb towards the end of 1999 to automate a new and complex pharmaceutical plant that produces raw materials, intermediates and active products for use in anti-infectives such as antibiotics (for combating bacterial infections) and antifungals (for combating fungal infections). The PlantWeb architecture consists of a DeltaV(TM) digital automation system, AMS(TM) Suite predictive maintenance software and Rosemount® pressure, temperature and flow transmitters.
The PlantWeb installation was built under FDA validation guidelines, using Good Automated Manufacturing Practices (GAMP) as the project execution methodology. GAMP is an independent forum with an interest in the validation of automated systems in pharmaceutical manufacturing. AMS Suite software was used to streamline the validation process. Loop testing can be performed by one engineer using the software, instead of the traditional team approach with one control room engineer and one or more field engineers. In addition, the software automatically generates and stores the evidence that the loop test has been performed, which helps to speed up the validation process.
"Because the DeltaV software is based on Windows technology, our operators were familiar with many of the commands, key strokes and menu structures as they have used them on other programs. This saved time on operator training," continued Hulst. "Based on my experience from more traditional control systems, I believe we saved as much as one month of training per operator, and we have forty operators. This saving in time enabled us to reach full production sooner and saved us training costs."
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