Emerson’s PlantWeb(R) Architecture with DeltaV(TM) System for Automation Chosen by Manufacturer of Anti-Cancer Compound

  • April 15, 2003
  • Emerson Automation Solutions
  • News
Italian company Indena looks to Emerson’s pharmaceutical expertise and technology to automate its manufacturing of anti-cancer compound.AUSTIN, TEXAS (April 14, 2003) - Emerson Process Management has announced a project with Italian company Indena to automate its plant in Settala, near Milan. Indena is the world's leading company dedicated to identifying, developing and producing active ingredients from plants for use in thepharmaceutical and health industries. They are one of the main suppliers of a potential new anti-cancer compound that has been approved by the FDA for phase 1 clinical trials. Emerson is a leader in engineering and implementing pharmaceutical automation solutions including conformance to FDA code of practice, 21CFR Part 11.Emerson has implemented the automation solution for Indena based on PlantWeb(R) digital plant architecture including a DeltaV(TM) digital automation system, using FOUNDATION(TM) fieldbus technology. The Settala facility extracts the anti-cancer compound from the leaves of a plant, thensupplies the extracted product to a major pharmaceutical company for processing into the finished drug.Indena chose Emerson as a partner for several reasons. Indena wished to work with a large company that was able to guarantee continuous support as well as a company that was offering a technically advanced solution based on open protocols. Emerson was asked to supply a flexible, open system based on fieldbus technology that could be used to control the process as well as manage the instrumentation assets. Ing Piotti of Indena believes that it is essential for modern systems to do both. “It is clear that for companies to becompetitive in the future they will have to adopt a total plant vision and architecture that supports both the process control aspect and instrumentation maintenance.”Further requirements imposed by Indena were that the supplied automation system should have an easy and effective programming interface as well as having software tools that are easy to learn. It was specified that the digital information from the field instruments should be able to be used to optimize the process as well as for predictive maintenance. “At the moment, the PlantWeb architecture from Emerson is the best solution for complete automation,” Piotti said. “Moreover, Emerson is able to give not only high quality automation solutions, but also loyalty … a new trust relationship between client and supplier.” Manufacturing at the Settala facility is based on a high precision batch operation. In order to control and manage this process, Emerson worked with Indena staff to install and configure the DeltaV digital automation system. The DeltaV system and DeltaVBatch software are built for batch control solutions. They provide powerful functionality, and easy, cost-effective engineering and operations interface. AMS predictive maintenance software within DeltaV provides functionality that enables easy reproduction of device calibration certificates for past calibrations, documentation of test scheme changes, and AMS system administrator events. Indena calculated that during the installation phase of the project alonethey saved 50% of the cost when compared to a more traditional approach to plant architecture. These savings were as a result of reduced wiring and installation costs as well as a reduction in time spent commissioning by utilizing the digital communication capabilities of the field instruments.In addition to initial savings, Indena expect to see savings across the whole lifecycle of their plant. The PlantWeb architecture is modular and scalable and can be expanded at low cost should future requirements demand. Savings can be made in engineering and programming time through the use of easy graphic tools, such as block program language (IEC 1131). The PlantWebarchitecture is based around open protocols so that should they wish to, Indena can use instrumentation from various suppliers. The use of AMS software can help to reduce the need for programmed maintenance. AMS monitors device status and alerts and can present the information on the DeltaV workstation, enabling a predictive approach to maintenance to be adopted. AMS can also be used to configure the field instruments as well as managing their calibration; it stores historical data allowing graphical trends to be produced that help to identify potential problem devices. The streamlined maintenance activities that are possibleas a result of utilising the capabilities of AMS can help to reduce unnecessary costs as well as minimising unplanned failures. The result is increased profitability and an improved plant lifecycle.The equipment that has been installed consists of 4 DeltaV controllers, with redundancy, handling 1400 I/O. They are supervised by one engineering workstation and 4 field operator stations. Plant expansions or upgrades are simplified by the DeltaV plug and play approach that not only means reduced installation time for new plants, but also minimized shutdowns forupgrades. Indena staff were provided with operation training in a very short time. In the future, Emerson will provide technical support by remote connection should the extensive on-line help facility not provide the answer to any problem. About IndenaIndena (www.indena.com) is an 80 year old, privately owned Italian companythat reported a turnover of about €150m in 2000. Indena employs 700 people across a dozen countries. 10 percent of the staff is employed as full time researchers. The research that Indena undertakes is involved in the screening of medicinal plants for pharmacological benefits. They identifythe active principles and develop means of extracting and purifying them.In the pharmaceutical sector, Indena is currently focusing on the development of anti-cancer treatments.About Emerson Process ManagementEmerson Process Management (www.emersonprocess.com), an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the pharmaceutical, chemical, oil and gas, refining, pulp and paper, power, food and beverage, and other industries. The companycombines superior products and technology with industry specific engineering, consulting, project management and maintenance services. Emerson brands include: PlantWeb(R), Fisher(R), Micro Motion(R), Rosemount(R), DeltaV(TM), Ovation(R), and AMS.About EmersonSt. Louis-based Emerson (www.gotoemerson.com) is a global leader in bringing technology and engineering together to provide innovative solutions to customers in process control; electronics and telecommunications; industrial automation; heating, ventilating and air conditioning; and appliance and tools. Sales in fiscal 2002 were $13.8 billion.PlantWeb, Fisher, Micro Motion, Rosemount, Ovation, and DeltaV are marks of Emerson Process Management. FOUNDATION is a mark of the Fieldbus Foundation. Other marks are the property of their respective owners.

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