CASE STUDY #3 International Biopharmaceutical
Fast Track Plant Expansion & Renovation
The Challenge: The
Owner had the schedule and performance of a capital expansion
and renovation project for a major new rheumatoid drug seriously
at risk due to a log jam of unresolved contractor questions
and issues due to a lack of onsite field engineering for
automation during construction. CHT was contracted to join
the team as the Owner’s Representative for Instrumentation
and Automation construction and commissioning activities
with the directive to get the installation back on track
to meet the required project completion dates.
The Solution: CHT deployed
multiple engineering resources to the site. At the time of
deployment, there were more than 650 Requests for Information
on the Process Control System backlogged in the site office.
CHT worked with the contractors and the Construction Manager
to classify and prioritize the RFI’s and to set about
immediately developing answers for the highest priority items.
CHT worked hand in hand with the Design Engineer and the contractors
for the next 12 months providing 20 hour per day direction
to their installation crews and resolving any and all issues
that came up in the Automation area. CHT was frequently called
upon to engineer alternative designs in response to changes
in scope and or problems encountered with the initial design.
This was a fast track project and there was simply no time
to waste waiting for engineering to go through the normal A&E
The automation installation included more
than 8000 conventional I/O with no buss technology. The massive
instrument wiring and tubing runs were in many cases subject
to revised field installation since the design engineers were
required to issue construction documents prior to equipment
or instrument selections being finalized. Working with an outstanding
construction crew, the CHT engineers resolved all the issues
as they came up and kept the installation moving forward on
CHT also participated in the initial plant
commissioning for the instrumentation and DCS systems successfully
directing the Installation and Operational Verification of
the DCS hardware, power supplies, communications networks,
and instrument I/O.
The Result: The facility
was completed and placed into operation in record breaking
time largely due to the fast track field approach of multiple
team members including CHT. The customer seized this opportunity
and implemented the tech transfer to initiate manufacturing
operations also in record breaking time and ultimately received
licensing and was able to ship product less than 2 years from
start of commissioning activities.