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| OVERVIEW |
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| Xyntek has successfully installed many real-time batch and continuous process control automation solutions at major manufacturing facilities using a variety of DCS/PLC platforms. Our automation solutions have ranged from small installations involving only a few vessels, pumps, and valves to some with over 26 process classes, 60 units, and over 7500 field I/O points. Xyntek’s engineers have experience in all aspects of process automation, including development of user requirements, level I and II hardware and software design specifications, hardware procurement, control software development, staging, system testing, Factory Acceptance Testing (FAT), system installation, on-site startup, loop tuning, optimization, validation, and total system documentation. |
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| METHODOLOGY |
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| Developing a process control solution requires a thorough understanding of the process. By reviewing process descriptions, P&ID drawings, and I/O lists, Xyntek’s engineers design a process model that will best fit the customer’s requirements. In creating the Functional Requirements for a system, Xyntek develops and adheres to programming and documentation standards such as ISA S88 standard, which will ensure that the system is easy to test, debug, and validate. These Functional Requirements are implemented using the models defined in the Detailed Design Specification. Each stage of implementation, including Factory Acceptance Test (FAT), installation, start-up, validation and support, is verified against the Functional Requirements to confirm that the system meets all user and business needs. |
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| CASE STUDY |
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| Please take a look at the following case studies to see how Xyntek implements "turn-key" Batch Process Control solutions. |
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Batch Process Control Design and Implementation
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One of our clients, a leading human therapeutics company in the biotechnology industry, requested Xyntek to design & program system control logic and develop the graphics for batch process control in their pilot plant in Washington. The system architecture consisted of two batch servers, two historians, two tag servers, and multiple touch screen clients. The control logic was designed utilizing 4-mation from Siemens Moore Automation. |
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Configuration and Implementation of Hybrid PLC/DCS System
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| In accordance to the ISA S88 standards for batch processing applications, Xyntek utilized Moore Products APACS hybrid PLC/DCS system to configure the world�?????�????�???�??�?�¢??s largest biotech process, that spanned from process modeling, HMI schematics development, database development, to foreign device interface configuration. At completion of the project, Xyntek had successfully executed the Hardware Factory Acceptance Testing (FAT) and User Acceptance Testing (UAT), which included testing of units, phases, and control modules to ensure user requirements was met. |
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Real Time Batch Process Control for Fermentation Units
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| With our unique expertise in batch process control, Xyntek was selected by one the top pharmaceutical company to develop process control for eight fermentation units in their new Rhode Island drug manufacturing facility. Developed in accordance with our stringent Software Development Life Cycle (SDLC) methodology, the real-time batch process control system controlled over 30,000 I/O and had over 200 graphical screens. |
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| CONTACT US |
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| For more information on Xyntek's Batch Process Control expertise or to find out how Xyntek can help your organization automate its next process, please contact us here. |
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