Product category:
Fieldbus systems, Fibre-optic systems
News Release from: The Profibus Group | Subject: Profibus PA and DP at Aventis
Edited by the Processingtalk Editorial
Team on 24 March 2006
Profibus upgrade for pharmaceutical
plant
Profibus PA and DP fieldbus techniques applied to pharmaceutical manufacturing at the Aventis plant near Frankfurt, have confirmed the expected faster commissioning and reduced installation costs
Profibus PA and DP fieldbus techniques have been applied to pharmaceutical manufacturing in an installation at the Aventis plant near Frankfurt Here an existing facility manufacturing the antibiotic "Ketek", used for the treatment of acute respiratory infection, was retro-fitted so that all process instrumentation works over Profibus fieldbus systems, in a Zone 1 hazardous area
This article was originally published on Processingtalk on 11 Jul 2008 at 8.00am (UK)
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The only exceptions were the safety related signals, which were left working using conventional wiring techniques.
Twenty two Profibus DP segments were used to connect to 250 motors and drives across the two production lines.
Then a total of 200 Profibus PA segments were used to interface with 1600 Profibus PA devices.
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The latest market figures confirm that in April 2008, the number of installed Profibus nodes in ALL manufacturing plants, which includes process plants, broke the 25 million barrier
The background to the new IO-Link
With an aim to improve the total cost of ownership of machines and plants, manufacturers and operators are continually on the look-out for optimisation potential.
IO-Link - The fieldbus gap is now filled!
IO-Link aims to revolutionise the sensor and actuator interface: Profibus introduces IO-Link, that allows all sensor and actuator data to be available throughout the entire plant
Segment couplers provide transmission of signals between the Profibus DP and PA segments, and their PowerLink modules supply up to 400mA power for devices on the PA segments.
For Zone 1 operation, a total of 470 Pepperl + Fuchs fieldbus barriers are installed on the plant, typically allowing for 12 Profibus PA devices to be connected via four of these barriers on each segment.
The 1600 Profibus PA devices included the existing conventional valves with position signalling, coupled to the bus using 190 valve boxes.
The plant instrumentation consists of 15 different types of device, from several separate vendors, for example devices were used from ABB, Endress + Hauser, Krohne, Knick, Pepperl + Fuchs, Samson and Vega.
Within the fieldbus segments Aventis have left typically 20% spare capacity to allow for production line expansion and further installation of instrumentation in the future.
Plant commissioning was done directly in the DCS system, using a FDT / DTM (Field Device Tool / Device Type Manager) based integration tool.
Infraserv Hoechst Technik assisted the Aventis engineers in this commissioning task, and had to overcome several obstacles in incorporating all the different devices and different manufacturers involved.
These obstacles were not related to the Profibus fieldbus itself.
Overall the project confirmed the expectations with regard to faster commissioning and easier installation using fieldbus.
In particular the fieldbus barriers were identified as providing the major factor that enabled reduced wiring planning and installation costs, by allowing a number of devices to be included in each hazardous area fieldbus segment, using the FISCO concept.
Using this FISCO model also reduced the paperwork and documentation required to confirm intrinsic safety for the installation.
As a result of this project, Aventis/Infraserv presented this conclusion to the fieldbus working group at the 2004 NAMUR general assembly, confirming similar reports from DSM and Novartis.
Aventis and Infraserv Hoechst Technik will use this fieldbus technology for future projects at the Frankfurt location, and can confirm the acceptance of fieldbus technology in the chemical and pharmaceutical industry.
For the future Aventis are looking forward to the anticipated life cycle cost savings predicted, which will become apparent after some further operational experience on site.
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