Intellution Project Reference List

Following is a sample of recent Intellution projects with which we have been involved. Please contact your Applied Control Engineering, Inc. representative if you require additional information.

Wyeth

ACE constructed a line control and reporting system for a solid dose bottle filling line at Wyeth, Puerto Rico. An Allen-Bradley ControlLogix PLC collects data from eight vendor-supplied skids and provide conveyor control and supervisory line control. Using GE’s iFIX Version 4.0 in a client/server configuration with one SCADA node and three clients, operators are able to monitor and provide supervisory control for the line. The SCADA system connects to GE’s Proficy Historian to record real-time line data. This data is monitored by GE’s Plant Applications Efficiency module. Line efficiency and productivity reports are presented via a web interface using Proficy Information Portal.

ABEC

ACE provided engineering services on a process control and data collection system for a fermentation process at Berlex’s Seattle Washington site. The project included a SCADA architecture with four clients. Intellution iFIX Version 3.5 was used as the HMI package. ACE also installed and configured the 21 CFR Part 11 ER/ES features of this package. The SCADA system connected to Intellution’s iHistorian real-time historian. The control systems were integrated with the vendor supplied skids containing Allen-Bradley and Siemens control platforms. ACE also provided design and test documentation.

Pall

ACE provided SCADA configuration, documentation, and testing for a filtration skid for PALL. Intellution iFIX version 4.0 was used as the HMI package. The SCADA system connects to Intellution's iHistorian real-time historian. Intellution's iBatch version 5.0 is interfaced with an Allen-Bradley ControlLogix controller. ACE also provided design and test documentation.

Noramco

This project was an HMI upgrade for a pharmaceutical facility in Wilmington, Delaware. ACE upgraded two existing FIX32 systems to iFIX 3.0 SCADA nodes. The main project driver was a set of new EPA reporting requirements. An Excel-based report was developed that pulled process data from the local historians and alarms into the specified format. This report also required the addition of several new alarms and I/O additions to the existing PLC programs (an Allen-Bradley PLC5 and SLC5/04).

Wyeth

ACE provided engineering services on a process control and data collection system for a fill line at Wyeth’s Pearl River site, including a vial filler, lyophilizer and isolators. The project included a redundant SCADA architecture with six clients. Intellution iFIX Version 3.0 was used as the HMI package. ACE also installed and configured the 21 CFR Part 11 ER/ES features of this package. The SCADA system connected to Intellution’s iHistorian real-time historian. The control systems were integrated with the vendor supplied skids containing Allen-Bradley SLC, Allen-Bradley ControlLogix, and Siemens S7 control platforms. ACE also provided design and test documentation including a Hardware Design Specification (HDS), Software Design Specification (SDS), Site Acceptance Test (SAT) and Installation and Operation Qualification (IOQ).

VPI Mirrex, Inc.

ACE implemented the iFIX SCADA product on two separate projects in Delaware City, Delaware. Both of these projects involved the upgrade of an existing HMI system to multiple iFIX nodes, interfacing with GE Series VI PLCs. ACE also provided the flat panel displays that were mounted into existing panels.

Schering-Plough Corporation

ACE provided SCADA configuration, documentation and testing for a Kinetics WFI system for Schering-Plough’s Manati plant. Intellution iFIX Version 3.0 was used as the HMI package. ACE also installed and configured the 21 CFR Part 11 ER/ES features of this package, and provided GAMP design and test documentation, including Software Quality Assurance Plan (SQAP), Software Design Document (SDD), and Factory and Site Acceptance Tests (FAT & SAT).

Johnson Matthey Corporation

ACE implemented an iFIX SCADA and manufacturing execution system (MES) at the JMC facility in Wayne, Pennsylvania. This multiple-project effort involved the development of a new configuration for multiple iFIX nodes integrated with Siemens Series 505 PLCs. Intellution’s VisiconX was used to interface large quantities of plant data with an Oracle database. Visual basic code was used to integrate a QC data entry system, iFIX, and an Oracle database. Visual Basic code was also developed for a logistics system and its interface with the Oracle database.

AstraZeneca Pharmaceuticals

As the preferred systems integrator at AstraZeneca’s Newark, Delaware site, ACE provided FIX32 configuration services for several projects. In all cases, the FIX32 nodes interfaced with Modicon PLCs.

DuPont Pharmaceuticals

ACE provided DuPont Pharmaceuticals in Deepwater, New Jersey with FIX32 configuration on several projects. These projects consisted of upgrading existing HMI systems to FIX32 as well as developing the FIX32 configuration from scratch. Most of these projects involved interfacing with Honeywell control systems. ACE also provided the life cycle documentation required for system validation.

Colorado Interstate Gas

This project was an HMI upgrade for a Helium extraction facility in Keyes, Oklahoma. ACE upgraded an existing Moore Products
MycroAdvantage HMI to FIX32. The application was then merged with CIG’s corporate operations in Colorado Springs so that the plant could be remotely monitored. ACE continues to support this site with a maintenance contract for minor control changes and enhancements.

CT Films

For this Dover, Delaware customer, ACE provided integration between a FIX DMACS HMI and a GE 9030 PLC. Configuration enhancements were also provided to take advantage of additional product features.

Applied Control Engineering, Inc.

ACE engineers have taken both the iFIX Fundamentals and iFIX Advanced Developments courses and passed a certification exam to become certified by Intellution. ACE is also an Intellution 2nd Tier Solution Provider. In addition ACE engineers have taken the Intellution Batch Development course.