Aventis Pharma Deutschland of the sanofi-aventis Group constructed two new production lines, based on fieldbus technology, for two preliminary substances of the novel antibiotic Ketec for treatment of acute respiratory infections. The engineering group of Aventis single-handedly managed the project and implemented the automation with the support of Siemens as their general engineering consultant. 'The greatest challenge of all was to retrofit a running production plant', says Bodo Bartscheit, the process control project manager of Aventis. As a part of the project the test laboratory of Infraserv Höchst Technik was assigned to commission the fieldbus technology. The Ketek plant was one of the first plants to be set up based on the 'Fieldbus and Remote I/O System Comparison' (FuRIOS) study.
The implementation uses Profibus PA. At first, Aventis and Infraserv Höchst Technik built a test segment under laboratory conditions to check the technology thoroughly and to eliminate potential problems in advance. With the exception of the safety related signals, which were still wired conventionally, all process instrumentation communication is working on fieldbus. The plant consists of 11 process-near components with 22 Profibus DP segments, to which 250 motors and transverters are connected. The two new production lines comprise a total of 200 Profibus PA segments with 1,600 Profibus PA devices. The conventional intrinsically safe valves and their end position signalling are coupled to the bus by 190 Valve Boxes, and 20 Sensor Boxes read the intrinsically safe binary switch signals. 50 Segment Couplers provide a faultless transmission of signals between Profibus DP and PA segments. The modular Segment Coupler's Power Link Modules supply high current to the Profibus PA segments which then is distributed to the individual field devices by 470 fieldbus barriers from Pepperl+Fuchs.
The plant integrates 15 different device types of multiple vendors like ABB, Endress+Hauser, Krohne, Knick, Pepperl+Fuchs, Samson and Vega. Plant commissioning was done directly in the DCS system, using a FDT/DTM (Field Device Tool / Device Type Manager) based integration tool. ”We can say today that the Ketek project confirms the FuRIOS study with regard to faster commissioning and easy installation”, says Seintsch. The basic general conditions are a different way of thinking during planning and installation as well as qualified and specially trained personnel. It is also clear that fieldbus technology alleviates the confirmation of intrinsic safety by using the FISCO model. This way, instead of calculations filling up folders, only a few parameters are to be documented.
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