BMS System

Our client- a major manufacturer of pharmaceutical drugs, needed a Building Management System (BMS) to monitor and control the conditions of all areas of the facility. Adherence to strict conditions of the US FDA’s 21CFR Part11 within all units of the manufacturing facility is imperative in the production of Pharmaceutical drugs. Radix as manufacturers of sensors and as providers of  SCADA solutions understood this need of our client and provided a turnkey solution for Controlling and monitoring.

The BMS monitored and controlled the Relative Humidity, Temperature and the Differential Pressure of all the major rooms of the plant. We provided Radix-make sensors and Hawkeyes, to monitor and display Relative Humidity, Temperature and Differential Pressure across all these units. The BMS also integrated utility with 80 Air Handling Units (AHUs).

Products Used
  • Comprehensive Integration of Radix sensors, Valve and Damper Actuators, Hawkeyes, DDCs, VFDs and SCADA.
  • Real time clock based ON-OFF scheduler for 10 air-handling units (AHUs).
  • Individual and group data and trends for all instruments.
  • Provision to set real time clock in room display units (Hawkeye). 
  • Mimic for users to identify instruments and respond quickly.
  • 21 CFR compliant SCADA.
  • AHU Speed Control based on Air Velocity in Supply Air Duct.
  • Relative Humidity and Temperature control by controlling opening and closing of Chilled and Hot Water Valves.
  • DP Control in rooms by opening or closing of Dampers.
  • VFD Communication on Modbus.
  • On / Off sequence of AHUs for maintaining DPs of critical areas.
  • An AHU summary screen for quick overview of all the AHUs data.

All the departments directly related to production and storage of the pharmaceutical drugs – manufacturing line, packing, quality control, and warehouse had 34 Hawkeye Room Display Units (Radix make) placed to measure Relative Humidity, Temperature and Differential Pressure. Radix made Relative Humidity, Temperature and Differential Pressure Transmitters were installed on the Ceiling floor and connected to the Hawkeyes in each room. Hawkeyes measured Relative Humidity, Temperature and the Differential Pressure of the rooms.

A 21CFR compliant Elipse E3 SCADA 1500 tags, connected all areas of the plant in a centralized system.

Radix provided a user friendly interface for a large and complex system. Operators had status screens, mimic screens, AHU summary screen, Fire Alarm screen, trend and historical data, audit trails, alarm logs and more at their disposal.

A standard status screen showed operators the status of all instruments and present room conditions at a glance. Also, the Low and High alarms are shown on the same page with Low and High Set points. A quick report compiling a time-stamped status of every instrument in the facility could be generated at the click of a button.

Mimic screens displayed individual mimics for each AHU to make it easy for the operator, to independently monitor and control every instrument of AHU, like RH, Temperature, Air Velocity etc.

AHU Summary screen had given for the quick overview of all the important parameters of all the AHUs at a single glance.

Fire Alarm screen had given to view if any AHU caught fire, so that the necessary action can be taken immediately.

Trend and historical data screens allowed operators to view instrument data over any time frame starting from the installation of the BMS. The SCADA easily generated PDF and Excel reports.

RH and Temperature of the rooms was controlled by operating the Chilled and Hot Water valves.

29 nos. of DP transmitters were used to measure the Differential Pressure of rooms. Out of which, 14 nos. of DP transmitters were used for controlling and rest for only monitoring.

Since the DP signal of the room was to be given to two instruments simultaneously - one to the Hawkeye and one to the DDC Controller, for DP control – Signal Isolators were used to multiply the DP signal.

Total 39 nos. of dampers, of 14 rooms, were controlled through DDC Controller to maintain respective DP signals.

As the 14 DPs were controlling the 39 nos. of dampers, the Signal Isolators were used to multiply the Damper Modulation signal from the DDC Controller.

Air Velocity at the AHU supply air duct was measured to modulate the speed of AHU. Third party VFDs were communicated through Modbus.

3 nos. of DP transmitters for each AHU, were used to measure the differential pressure across Pre-Filter, Fine Filter and HEPA Filter respectively. An alarm was generated if any of these differential pressure goes above the set limit.

Initially, Radix linked utility equipment like the water system as well as production machines to the BMS for monitoring. In a later phase, real-time-clock based scheduling of Air Handling Units was given via a DDC panel.

Radix also provided validation documents for Design Qualification, Installation Qualification, Operational Qualification and Performance Qualification for the BMS projects.

RH+T Transmitter - SC805

  • Surface / Wall / Duct Mount
  • LCD Display
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Differential Pressure Transmitter - SC504

  • 2-wire
  • Dual Display
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Serial to Ethernet Converter - DCC201

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Hawkeye - RH+T+DP Indicator - HAWKEYE

  • Micro-controller based
  • RH+T+DP Indicator
  • 3 User programmable channels measurement
  • Slave display unit - RH+T+DP remote
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Data Acquisition System - using SCADA

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