New construction of a multi-purpose plant for active pharmaceutical ingredients

Dottikon ES is building a new multi-purpose chemical production plant for active pharmaceutical ingredients. CTE was mandated with the planning and implementation of process instrumentation and the control and automation. The project involves 4 steps: concept phase, basic design, detail design, construction and commissioning. The mandate includes:

• Creating concepts for EI&C (including power supply, route concept, room concepts, etc.)

• Creating concepts for automation

• Evaluation of systems and instruments

• Cost calculation

• Creating schematic diagram

• Creating function descriptions

• Procurement and expediting of all EMSR-A packages

• Preparation of implementation documents (electrical diagrams and plans)

• Programming PLS incl. FAT

• Commissioning and handover to operation

Our work is based on the RI diagrams and the measuring point lists. The data is managed with a CAE tool and prepared for detailed processing.

In EI&C planning, we attach great importance to cooperation with architects and pipework planners, whether for switch rooms, space optimisation, routing and placement of the elements in the production room (ATEX) or in the clean rooms. Coordination between planners takes place through a 3D model. The requirements for the automation are defined in the form of functional descriptions. The system structure corresponds to the S88 specifications. This means that the entire complexity of a multi-purpose system can be divided into independent modules. Each module can thus be discussed, described and released for programming. The system is divided into units. A unit consists of instances of modules.

The visualisation is created in accordance with ISA101 and in consultation with the operator of the system.

The software is qualified in two steps: First, the FAT - software test with simulation - is carried out together with the operator. The software is then tested in the system. This SAT is carried out together with the process planner and the operator.

During the construction phase, CTE also acts as a specialist site manager. We coordinate the delivery and installation of the switchgear, the installation of cable routes and electrical installations. The EI&C systems are qualified using the line test. Each signal is tested from the sensor to the display on the DCS. All actuators are operated from the DCS in manual mode and tested on site.

Since 2020, CTE has been working in the detailed design phase with a team of eight specialists. The activities are EI&C planning, functional descriptions and programming, procurement and preparatory work for other specialist planners. The first IBS activities are planned for mid-2023. Project completion is 2025.

With our system knowledge and experience in the application of standards such as S88 or ISA101, but also in topics such as ATEX, we support the customer with the best solutions for them. Thanks to our many years of cooperation, our experienced employees and the flexibility of our resources, the customer has been able to rely on CTE for many years.