Control System Validation
Challenge
In order to maintain optimum production, it is critical to find a way to reduce the time and expense it takes to introduce a new pharmaceutical product to the marketplace. Replacement and validation of a new control system is both costly and time-consuming. It is typically performed by high-cost experts such as control systems engineers, validation specialists, and management.
Solutions
Seeq helps users to save time and increase efficiency. The Seeq Boundary tool allows users to identify a statistically-good control scheme based on the actual process variable (PV) and to detect deviations. A novel approach encodes many valves for aggregated comparisons with high accuracy. Users can create reports to share and showcase their results within Seeq Workbench or Organizer to reduce validation time, saving money as well.
Benefits
Operators using Seeq can reduce manpower costs by $115k compared to using spreadsheets and printouts from more traditional trending tools. These savings were observed for bioreactors with only 29 unit operations.
Data Sources
- Process Data Historians
Data Cleansing
Easy comparisons provide users with additional insight. Batches from old control systems (PLCs) could easily be compared against the DeltaV system using capsules.
Calculations and Capsules
With Seeq, valve line-up Equipment Modules were encoded into a binary number using Formulas. Boundaries were applied to the new control system based on validated runs and findings from Seeq’s Deviation tool detected anomalies.
Summarizing Results
Final results were able to be shared easily in a report from the commissioning team with the use of Seeq’s export to PowerPoint feature. This allows for increased understanding and collaboration across the company, and helps to increase operational efficiencies as well.