S88 Compliant Batch & Continuous Process
To meet the growing challenges of today's increasingly
complex pharmaceutical, specialty chemical and biotechnology industries;
U.S. Automation's experienced system engineers have designed & commissioned
a wide range of customized S88 Compliant Batch and Continuous Process
Control Systems. Our advanced control system designs have been installed
in many large pharmaceutical production facilities to insure absolute
product quality & full compliance with detailed FDA regulations.
In addition, our highly flexible automation platforms have been
instrumental in reducing the time to market for several new bio-technology
products and because of the inherent need to support a wide variety
of process formulations, each process control system is specifically
designed to easily adapt to support rapidly evolving technology
From the conceptual design of our first industrial
control system, U.S. Automation has always utilized non-proprietary,
open systems architectures for our automated batch and continuous
process control. The ANSI/ISA-88 (S88) compliant control systems
designed by U.S. Automation's experienced control engineers have
been extremely effective in the implementation of automation strategies
to sustain flexible cGMP operations not only in batch, but also
in discrete and continuous industries. Over the past 10 years, the
modular structure and standard terminology of S88 compliant systems
has proven to significantly improve plant-wide communications between
product engineering, plant personnel and equipment vendors. U.S.
Automation's strict implementation of S88 has always resulted in
more effective control system installations at a minimum total cost
of ownership. In addition, each of our customized system designs
are optimized to assure ease of service, support, and future upgrades
to meet changing market requirements.
Our principal batch S88 and process control system
applications has been developed for pharmaceutical, chemical, biotech,
industrial building automation (including clean room, HVAC, & utility
system controls), and municipal water/wastewater treatment projects.
In addition, most of our DeltaV, iBatch, & other S88 installations
were batch operations, which required full FDA validation and compliance
with 21CFR Part 11 Electronic Records/Electronic Signature regulations.
U.S. Automation engineers have extensive experience
programming DeltaV, iBatch, and several other S88 compliant software
platforms. To insure all our valued customers a successful installation,
U.S. Automation always maintains a dedicated professional staff
of skilled system integration engineers, with more than fifty (50)
man-years of control system software programming, configuration,
installation, and upgrade experience. To further improve our customer
service, U.S. Automation has numerous factory trained and certified
automated system engineers to provide complete turn-key project
designs & installations or to assist our clients with any phase
of the project implementation process. In fact, we are one of the
very few major system integration firms, which offers 24 hr., 7
day/week field service contracts; including complete field instrumentation
calibration services. For your review, we have listed below a few
examples of U.S. Automation's project design/execution experience
of our system engineering staff:
Technical Background and Project Management
typical project responsibilities include initial engineering, electrical
and field instrumentation design, control panel fabrication, system
configuration, loop checkout/tests, and commissioning/start-up.
system engineer's have extensive design experience with both S88 Batch
and Continuous Process Control, using the latest application software,
PLC/DCS hardware, field instruments and advanced I/O networks.
||U.S. Automation has
a library of over 75 custom pre-configured, programmed, field tested,
and validated Delta V batch phases to implement a wide variety of
complicated process control operations. Our system engineers provide
detailed documentation for these phases, including comprehensive validation
protocols and testing procedures for cGMP processes.
engineering staff has decades of successful Delta V design experience
and maintains an excellent working relationship with the worldwide
Emerson Delta V Support Organization.
V engineering experience is continually updated with several ongoing
projects for 2003 and 2004. U.S. Automation's years of Delta V system
design expertise spans more than five generations of control processors,
I/O modules, operating systems, and application software.
of Factory trained and certified Delta V Engineers.
Functional Specifications, P&ID Drawings,
& Design Requirements Development:
of our standard project management cycle; U.S. Automation generates
a comprehensive Functional Requirement Specification (FRS) for each
of our clients, which outlines the overall batch automation strategy,
identifies specific phase/control module operations and defines the
phase input/report parameters.
complete scope of work is created, U.S. Automation develops control
system flow charts, works with clients to develop project implementation
plans, creates verified system P&IDs, and generates fixed-price project
estimates for all of the control system hardware, I&E installation,
and engineering efforts.
||U.S. Automation designs
and fabricates all required control panels, configures DeltaV system
graphics, controllers, & batch recipes. To insure a successful implementation
our engineering staff also provides operator training simulators and
training assistance, customized for each of our valued clients.
S88 Batch Software Program Development
has successfully installed, configured, and upgraded DeltaV Application
Software; Windows NT Versions 5.3.2; 6.3.2; 7.1; and the latest Windows
XP Versions 7.2; 7.3.
system configuration expertise includes the setup of Thin Client Networks,
multiple Batch Application Servers, and remote access capability via
Virtual Private Networks (VPN).
the Complete SP88 Phase Logic for Running, Holding, Restarting, Stopping/Aborting
phases, and Error Detection/Operation Fault Logic; as part of our
standard implementation for Industrial & Pharmaceutical applications.
& transmit control data from third party support utilities and process
skids (which are controlled by a wide variety of PLC's including Allen-Bradley,
Modicon and others); U.S. Automation has designed and programmed complex
industrial procedures using standardized batch software functions.
redundant Distributed Control Systems (DCS) with multiple DeltaV batch
executives capable of running multiple concurrent lines of production.
DeltaV OPC servers to communicate with 3rd party interfaces like XL
Reporter and ASPEN IP21 database. These advanced communications interfaces
enhance the reporting and analytical capabilities of our customers.
I/O Network Installation & Control System
engineers have implemented complex field I/O networks with multiple
ASI, Profibus, Fieldbus, DeviceNet, and Serial I/O protocols.
Programmed, and Implemented Serial Communications Interfaces to link
proprietary Allen-Bradley and Modicon PLC controlled ultra-filtration
& centrifuge skids with the main process control system.
tested, and verfied numerous physical control networks; including
fiberoptic Ethernet, multi-drop RS-485 PLC networks, wide-area PC
networks, and numerous Field Communications Bus technologies.
control system engineers have extensive practical experience in the
start-up/commissioning of a diverse range of batch & continuous control
systems; including Foxboro IA, Emerson DeltaV, Intellution iBatch,
Westinghouse WPDF, Bailey Infi90, Andover Infinity, Johnson Metasys,
& numerous PLC-Based DCS Systems from all major control system equipment
engineering staff has years of field instrumentation selection, start-up,
troubleshooting, & calibration experience; including all standard
analog/ digital transmitters (flow, pressure, level, temperature)
and advanced analytical devices (pH, ORP, streaming current, turbidity,
water quality residuals) .
the problem-free operation of your control system investment, our
staff of senior system engineers has many years of practical field
experience isolating difficult software errors, troubleshooting unstable
control systems, programming VFD drive systems, and tuning PID loops.
Site Acceptance Testing & FDA Validation
plant equipment models and control modules/phases for batch & continuous
process control systems. U.S. Automation has a complete in-house software
library of more than 50 validated, custom control modules. As part
of our comprehensive support services, we provide detailed documentation
for each control module/phase; including fully documented validation
protocols & testing procedures for cGMP processes.
of our comprehensive project management, our system engineers can
be contracted to provide independent FDA control system validation;
which includes fully documented evaluation protocols and testing procedures
for all cGMP processes.
has provided complete project management services for control systems
ranging from 100 to 1200 I/O points. Our professional control engineers
have successfully designed, programmed, & commissioned numerous plant-wide
DeltaV systems incorporating up to 10 controllers over a fully redundant
staff has provided complete software programming services and validation
support for OEM filtration, water purification, vacuum drying, & other
OEM skids, which are being integrated into existing pharmaceutical
recently, U.S. Automation has completed extensive batch control
software testing, phase code validation, SAT (site acceptance testing),
and implementation of OQ protocols for AMGEN's Bio-next project.
Advanced Control System Support and Long-Term
customized software programs to perform daily data backups of all
critical historical data (over the plant Ethernet LAN) to ensure
that the DeltaV data server will not get overloaded.
system programmers provided extensive self-diagnostic and field
troubleshooting/ support/ troubleshooting tools using advanced Historical
Data Collection programs & Trending modules (with data extracted
from the PI Historian Database).
Automation offers long-term 24 hr. 7 day/week maintenance support
and emergency service contracts to all of our valued customers.
customized analytical tools for each of our clients by creating
customized Access & SQL report queries to extract critical report
data from the Delta V Batch Historian Database. This data is then
formatted to meet each customer's specific production tracking,
quality control, and historical record keeping requirements.
configured, and implemented comprehensive historical/real-time data
back-ups & automated periodic backups of entire Delta V System configurations
to ensure no loss of critical data and/or control system programs.
U.S. Automation currently has
numerous annual engineering service contracts to provide monthly
personnel/operator training, software modifications, and routine
field instrument calibrations
Automation's extensive pharmaceutical control system experience
& project management background assures our customers that their
project will be completed using proven state-of-the-art system designs,
on schedule and within your planned budget costs.
Once again, it is important to mention
that when you hire U.S. Automation on your next control system project,
you will have instant access to over 75 custom developed phases,
and more than 50 custom developed control modules; which are all
fully tested with detailed documentation (including validation protocols
for all cGMP processes). In order to satisfy the individual needs
of each of our industrial, commercial, municipal, and local/ state/federal
government clients, U.S. Automation's system integration teams shall
be lead by experienced project managers, who have a proven success
record in the implementation of other similar automation projects.
One of the key selection criteria for our pharmaceutical project
managers is their past experience providing the specific field progress
reports and other detailed documentation which are required for
each particular control system application. If you would like to
discuss your specific pharmaceutical, bio-technology, environmental
compliance, and/or specialty chemical control system application;
please contact us at your earliest convenience: