Conf Pharma Instrumentation

Instrumentation Lead - Confidential Pharmaceutical Client

This facility was the first cell culture-derived flu vaccine manufacturing plant in the United States.

Challenge

This client is a global leader in the research and manufacturing of pharmaceutical products. Their 300,000 square feet vaccine manufacturing facility, built on a 167-acre site, is capable of producing up to 50 million doses annually of seasonal trivalent flu vaccines.

This facility was the first cell culture-derived flu vaccine manufacturing plant in the United States. Jacobs was responsible for the design and construction and selected Hallam-ICS as the instrumentation contractor for the project.

Solution

Hallam-ICS assembled an in-house team of experienced instrumentation professionals for the procurement, receipt verification, bench testing, and installation of approximately 250 devices for the balance of plant systems for the Fill Finish, Bulk Building and Central Utility Plant.

Additionally, Hallam-ICS was responsible for managing the work of electrical and mechanical subcontractors for the installation of the Process Automation System (PAS). This installation included skid interconnections and interfacing the skid systems to the site Delta V system.

Both the client and Jacobs team also looked to Hallam-ICS for control panel fabrication services. Hallam-ICS produced over 35 UL 508 certified power panels and Delta V I/O panels to support the PAS. At the completion of the project, Hallam-ICS provided detailed electronic and hard-copy Equipment Turnover Packages (ETOP) for the instrumentation to support the commissioning and validation efforts at the site.

Results

Our team accomplished the following:

  • Instrumentation Expertise: Successfully procured, tested, and installed approximately 250 devices across the facility, including the Fill Finish, Bulk Building, and Central Utility Plant, ensuring seamless system functionality.
  • Integrated Automation System Management: Oversaw subcontractors for the installation and integration of the Process Automation System (PAS), including skid interconnections and Delta V system interfaces.
  • Control Panel Fabrication and Documentation: Delivered over 35 UL 508 certified power and Delta V I/O panels, along with comprehensive Equipment Turnover Packages (ETOP), to support commissioning and validation efforts effectively.