Johnson & Johnson: Inox Dryer Optimization

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Johnson & Johnson wanted to improve the operability of their Inox dryers with a control system that offered better control and flexibility. So they called on CSA to optimize their existing RS3 to Allen Bradley PLC5 interface.

We did a total rewrite of their PLC ladder logic code, using S88 principles to organize the PLC code into control modules and equipment modules. These modules interacted directly with corresponding RS3 templates. This made operational control of the dryers intuitive and better integrated into the DCS system.

We also historized all dryer critical parameters, and we integrated all alarms and interlocks into the DCS system for operator view and action. Before this project, operations personnel had to enter a restricted clean area to diagnose system alarms and failures. After the project, operational personnel could control the dryers in exactly the same manner as RS3 controlled I/O.

The new interface also allowed simple integration into the RS3 Batch system. The Batch system simply commanded the equipment modules using state control rather than the primitive ladder logic control of the equipment.

As requested, our work gave Johnson & Johnson much better control and flexibility for their dryers, enhancing their operability. They were very pleased with the results.

Services Provided:

  • 100% conversion of over 1,000 lines of poorly written ladder logic to control modules and equipment modules (S88) design
  • Configuration of RS3 graphics, faceplates and details
  • FRS development for PLC
  • Panelview 1400 configuration for local dryer control based on mode control
  • SFAT test plan and supporting test protocol development
  • SFAT support services
  • IQ test plan and supporting test protocol development
  • Onsite IQ and OQ support
  • Control System: PLC5’s and RS3 DCS system