EC&I - A Case Study
Over the past 20 years Inspec System’s team of skilled engineers have delivered various electrical, control, and instrumentation projects across a range of industries.
Projects follow a typical process, as demonstrated recently as we carried out the design, installation and commissioning of a new pharmaceuticals plant for a large blue chip company.
Detailed Design and Specification
Working within a tight delivery window against a maturing process specification, Inspec Systems carried out the detailed design for the full EC&I aspects of the project including:
- Full control system specification
- Full electrical and instrumentation specification and detailed design
- Fault level, co-ordination and discrimination studies
- 11 kV Network Study and Arc Flash Safety Assessment
- Panel designs - layouts, schematics, heat rise calculations, and BOMs
Machinery Safety
Our Certified Qualified Machinery Safety engineers ensured the appropriate Performance Levels were met by following BS EN ISO 13849, our scope included:
- ISO 12100 and BS EN ISO 13849 Part 1 Risk assessments
- Design and verification of all safety related parts to BS EN ISO 13849 Parts 1 and 2
- Testing and validation to demonstrate the required protections were in place
Process Safety
Our TUV Functional Safety Professionals followed the lifecycle approach set out by BS EN 61511, our scope included:
- Functional safety management
- Design and engineering of Safety Instrumented Systems and Functions
- Verification and Validation including completion of SIL calculations
- Co-ordination of Functional Safety Assessments
- Proof Testing, and Commissioning
- Issuance of all associated technical manuals
Electrical
The project required a range of complex electrical systems to be installed including:
- Electrical distribution from 11kV to 415V including full system design with protection co-ordination in accordance with BS7671
- A full site power systems study was carried out to ensure power flow, fault levels, harmonic contribution were all within the design criteria demonstrating the overall strength and capability of the system
- Performing full system designs is a precursor requirement for the development of arc flash assessments
- Specification, selection and detailed design for the new installation including Profibus controlled Variable Speed Drives
Control and Automation
The automation system was delivered on a Siemens platform. We at Inspec used our wide experience with the Siemens S7 portfolio to realise the system providing a holistic control approach integrating the facility across the site.
Instrumentation
The process involved over 700 instruments, largely located within hazardous areas.
- Level, Flow, Temperature, Pressure
- Bursting disc sensors
- Gas detectors
- Valves and feedback
Installation
Working within a compact facility required unparalleled levels of co-ordination and Health and Safety. We successfully performed the following installation works:
- Containment
- Cable laying, glanding, and termination
- Point to point and BS7671 testing
- Initial ATEX inspections to BS EN 60079 part 14
- Earth bonding and lightning protection
Commissioning
Following the installation of the system in, Inspec’s experienced team of engineers carried out the commissioning of the system.
By following prepared and approved FAT, SAT, and IQ/OQ documentation we ensured all results were recorded for GMP validation allowing the necessary licenses could be obtained to permit the plant to go into full production.
Sub Contract Management
Inspec managed numerous sub-contractors providing a turnkey service, and a single point of contact, to the Client, sub-contracts included
- Precision dosing and weighing systems
- Siemens PCS7 DCS Control Systems
- Fire and gas detection and response systems
- Lightning protection
Conclusion
Inspec Systems delivered the project in budget, on time and to the client’s requirements. Successfully fast tracking and completing a project that would usually take 1 to 2 years in approximately 9 months, with zero lost time and zero injuries.
What Next?
With over 20 years of experience, Inspec Systems have the knowledge, experience, and competency to deliver projects to your requirements.
Why not give us a call and speak to our team to see how we can help you meet your unique and specific needs.
