Baxter Healthcare: Sevoflurane Plant Expansion

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Baxter Healthcare wanted to increase the capacity of an existing pharmaceutical manufacturing facility. The plant produces sevoflurane, an inhaled anesthetic particularly popular in pediatric surgery. Quality control was imperative, and high demand meant there was no room for time-consuming mistakes. It was just the kind of project we most enjoy.

CSA converted the facility’s existing DeltaV 5.2 configuration to 8.3, and created the new configuration for the expansion, carefully validating all configuration templates. We also wrote new FRS and IQ validation documentation for the expanded plant.

To support the new configuration, we developed several new control and equipment modules, all of them created, documented, and validated in accordance with GAMP4 guidelines. And though the modules were not part of the original project scope, we kept the project on schedule.

Prior to hardware and software factory acceptance testing (HFAT/SFAT), we bench-tested all new Fieldbus, ASi, and DeviceNet field instruments in an integrated test environment. We then managed HFAT/SFAT and executed the IQ protocols on-site prior to startup.

We completed the commission in record time, with no schedule delays and no surprises. The customer was, of course, delighted.

Services Provided:

  • Configuration of control and equipment modules
  • Configuration of conventional, Foundation Fieldbus, ASi, and DeviceNet I/O types
  • Operator display development
  • FRS development
  • HFAT test plan and test protocol development
  • SFAT test plan and test protocol development
  • IQ test plan and test protocol development
  • Design of control panels, control room operator console, DeltaV network
  • Procurement and installation of DeltaV control panels, DeltaV workstations and Ethernet network, and control room operator console
  • HFAT/SFAT support services
  • Loop tuning and process optimization services
  • Startup and validation services
  • Control System: Emerson DeltaV