The Challenge
MSD Brinny was looking for an automation integration partner to design, supply and commission a new Clean Utilities and Process Control system for a brownfield contract manufacturing plant.
Requirements included:
- Integration of PW, CIP, WFI, Chemical Additions, Glucose Skid, Media Prep Vessel and PTS, Harvest Process and Centrifuges systems and WWTP upgrades
- Design, build and test of all necessary software configurations, including the production of GAMP 5 compliant design and test documentation
- Specification, design, build and test of IT architecture (hardware and components), including the delivery of all documentation and configuration
- Provision of support and automation services to external vendors
- Integration of Vendor Skids with site systems (e.g. Active Directory, File Shares and Data Historian)
- Full commissioning and qualification support from packages delivery through SAT to IOQ and training
Our Approach
A team of 20 NeoDyne automation engineers delivered a multi-platform control system built on customer specified software and hardware, including:
- Siemens S7-1500 PLC & WinCC HMI
- AVEVA (Wonderware) InTouch SCADA on Microsoft RDS platform
- Thin Client Operator Interface through ThinManager
- SSRS reporting
As a brownfield installation, we overcame several challenges with the Clean Utilities control system, including:
- SSRS reporting
- Full control of the WWTP and compliance with EPA license while completing significant upgrades
- Hardware and software compatibility issues with legacy equipment
- Trouble-shooting systems provided by external vendors
- Development and adoption of an agile change control strategy
About MSD Brinny
MSD in Brinny, Cork, is an integrated site for the development, testing and manufacturing of biologics. MSD Brinny specialises in the fermentation, purification and sterile filling of biotech products, including some of the company’s most successful treatments for oncology, hepatitis C and rheumatoid arthritis.
NeoDyne is a trusted partner for the site and has been providing automation system integration services for MSD for close to 20 years, including Siemens control systems, Wonderware SCADA, Historian and Information Server as well as a broad range of validation services.
Customer Requirements
- Seamless integration of several Clean Utilities and Process Control systems
- Control and monitoring functions for all inputs and outputs, including alarms, logs, trends, status and data reports
- Industrial grade hardware and software
- Engineering services to deliver the system from customer requirements to project handover as per the SDLC in a GMP environment
Challenges
- Delivering a complex control system in a brownfield site
- Integrating a central control system with multiple platforms and external vendors
- Maintaining change control and traceability in a dynamic environment with multiple parallel activities
- Ensuring business as usual for the Brinny plant while modifying IT systems and shared utilities
Outcome
- Fully qualified system as per customer requirements
- 21CFR11 compliance throughout
- Introduced new technologies with system capabilities maximised
- Delivered on schedule with zero safety incidents
- Forged new relationships and enhanced existing ones with MSD Brinny and main contractor
Other Case Studies
See other System Integration projects below to see our solutions in action
Huhtamaki
Design, configuration and delivery of a multi-lingual, paperless shop floor MES.
Lakeland Dairies
Automation control system and associated MES modules for a new Lactose extraction and drying plant.
