
Hydrogenator Upgrade Turnkey Solution
The foundation of Hallam-ICS’s project approach is to work cooperatively with Client's User Group and Projects Engineering Group to fully satisfy the project intent.
Challenge
Pfizer Global Research and Development need to upgrade an existing, stand-alone legacy control system on a 30L hydrogenator that was no longer supported by the original equipment manufacturer. In addition, Pfizer wanted to automate certain operations to improve operational safety of the hydrogenator. To accomplish these goals, the system had to be integrated into an existing Delta V control system. This required the installation of new instrumentation, refurbished control panel and a reconfiguration of the skid components.
Solution
Pfizer selected Hallam-ICS to lead this effort providing a full turn-key service, filling the role of Construction Manager, Controls Contractor, and Validation Contractor. Our responsibilities included coordinating and managing of the mechanical, electrical and system integration subcontractors as well as specifying, furnishing and installing all of the new required field instrumentation and design and fabrication of a UL508A control panel.
The foundation of Hallam-ICS’s project approach was to work cooperatively with Pfizer’s User Group and Projects Engineering Group to fully satisfy the project intent. To that end, a project team was assembled that had established working relationships with both groups to build upon the successes of our previous projects.
Once the team was assembled, the successful retrofit of the system controls was based upon:
- A thorough description of the existing conditions
- A clear understanding of the user requirements
- A logical strategy to execute the project.
Once the as-built conditions were verified, the focus shifted to clearly understand the User Requirements (URS) and expectations. The design work followed the guidelines of Good Automated Manufacturing Practice (GAMP5) and utilized the V-Model strategy including Functional Specification (FS) and Detailed Design Specification (DDS) documents defining how the system was to operate and the details for implementation in support of the URS.
Hallam-ICS worked closely with the Pfizer validation group to develop system testing documents (FAT, SAT) that could be leveraged for use as supporting documents for validation, reducing the overall time required to start-up, commission and validate the system. Upon completion of the work, Hallam-ICS provided a turnover package including as-built design documents, executed test documents and software programs to support Pfizer’s ongoing use and operation of the system.
Results
Our team accomplished the following:
- Seamless System Integration: Successfully upgraded the legacy control system and integrated it into the existing Delta V system, enhancing operational functionality and safety for Pfizer's 30L hydrogenator.
- Comprehensive Turnkey Execution: Provided end-to-end services, including design, fabrication, installation, and validation, while managing subcontractors and ensuring adherence to GAMP5 and V-Model standards.
- Streamlined Validation Process: Developed and executed system testing documents (FAT, SAT) that reduced startup, commissioning, and validation timelines, ensuring efficient project delivery.