Biotech / Pharmaceutical
Biotech client in
Oregon
- This
project required custom code modules to be
integrated within the existing
Cimplicity SCADA
system. The client had unique
requirements for user interaction with
various software packages while
maintaining the existing security rights
and policies including 21-CFR-Part 11
compliance. CSI wrote Perl and .NET
applications that limits the users
control for navigation, switching
applications, etc.. while in an Explorer
window or an IE browser. These modules
allow the users to perform activities as
specified by their group security
policies within the SCADA system, not
Windows.
Biotech client in California
- Provided
a turnkey solution for a train of 5 each
20L fermentors (bioreactors) including
21-CFR-Part 11 compliance, IFIX, RSView SE, OSI PI, Alarm Paging,
Reports, and CLX PLC
programming.
Pharmaceutical client in
Arizona
- Provided
design specifications for 4 CIP systems.
Pharmaceutical client in Colorado
- This
project was to implement a redundant OPC
based alarm callout/paging system
including 21-CFR-Part 11 compliance. The
existing RSLinx application was used as
the OPC server, and the RSView32 SCADA
provided the alarm database template.
CSI modified the database to work with
our software. By using the existing
software and applications, this
Messenger application was delivered for
less than $3000.00!
Biotech client in California
- This
project started as upgrades and
enhancements to the functionality of the
Fedegari Autoclaves. Upon completion of
Phase 1, the Fedegaris were converted to
the Cimplicity SCADA system including
21-CFR-Part 11 compliance.
Pharmaceutical client in
California
- This
project was to implement Crystal Reports
2008 into an existing Historian SQL
database for weekly reporting
requirements. A total of 56 reports were
implemented. The Intellution SCADA was
modified to allow user interaction with
Crystal Reports while maintaining
desktop security.
Biotech client in California
- Project
requirements included IFIX 4.5
development and CLX PLC programming for
several utility packages. This project
required complete equipment and
application redundancy and 21-CFR-Part
11 compliance. The utilities implemented
within this project were WFI, AWFI, HWFI,
Pure Steam, Primary and Secondary DI,
Mixed Gases, Gas Monitoring, BMS, Fire
Control, Automatic Transfer Switches,
UPS systems, and Generators. The
system included redundant SCADA servers,
dual iHistorian servers, redundant
networks, and redundant PLCs.
Pharmaceutical client in Colorado
-
Programmed a train of 6 each 45L
fermentors (bioreactors) including
21-CFR-Part 11 compliance, IFIX,
IHistorian, Alarm Paging, Crystal
Reports, and PLC
programming.
Pharmaceutical client in California
- Turnkey
solution for a mobile CIP (Clean In
Place) skid which included 25 individual
recipes and 128 paths using IFIX with a
CLX processor. A secured wireless Draft N
network was implemented to allow
complete mobility.
Biotech client in California
- Project
required the conversion of an existing
RSView SE project to Intellution 4.0 (IFIX).
The client had serious stability issues
with the RSView SE system originally
installed by Rockwell Automation. Our
client had to have a reliable emergency
backup SCADA system to prevent losing a
batch when RSView SE crashed. CSI
converted all graphics, alarms and
tagnames to IFIX. The IFIX server was an
old P3 1000mHz provided by the client,
while the RSView SE system was on
several P4 servers.
Using the IGS driver, we added the IFIX
server to the existing Rockwell network.
Initial startup showed the IGS driver to
be extremely efficient compared to
RSLinx, and the IFIX updated 10 times
faster than RSView SE (using the exact
same network). Additionally, the IFIX
server has not required a reboot since
installed while RSView SE continues to
crash. GE Fanuc is currently writing a
white paper for this project due to it's
success.
Pharmaceutical client in California
- This
project features an RSView SE project
providing 100% redundancy/hot standby.
This project featured 15 PLCs (mixed
between CLX, PLC 5/80 and SLC-505), and
a 21 CFR Part 11 compliant Historian.
We Rock very Well !
Biotech client in California
- Project
included programming of an Intellution
SCADA system and Allen-Bradley CLX's to
control a new fermentation system. The
client requirements included
engineering, complete documentation, development, panels,
programming, validation, and CQ.
Biotech client in Spain
- RSView project that provided a total
manufacturing solution for clinical
grade pharmaceuticals. This project
included 12 areas and S88 compliant
Batch Control. Phase logic implemented
with control modules provided the
flexibility for future upgrades at
minimal costs.
Biotech client in California
- Project
included programming of Intellution
SCADA system and Allen-Bradley PLC504
and PLC5/30 to control a new WFI (water
for injection) system. The client
requirements included tying the existing
system into the new WFI loop,
validation, and CQ.
Biotech client in
California
- Project required replacement of an
antiquated hardwired relay panel,
redesigning of the compressed air
controls, and reprogramming of the
Allen-Bradley PLC5/80 to automate the
utility air compressors. Upon completion
of wiring and local testing, CSI
modified the Cimplicity SCADA to allow
complete automated control, lead/lag,
reporting, and custom alarm modules.
Biotech client in California
- Project included adding new I/O points
to the existing PLC program to provide
acid wash capabilities to the GPMF CIP
skids. Upon completion of the PLC
testing, CSI modified the Intellution
SCADA System to allow control and alarm
functions.
Biotech client in
California
- Project included reprogramming a new
vendor supplied pure water generation
system. The client required additional
functionality and controls to meet the
FDA requirements for the clinical use
area. Hardware included a SLC504 and a
PanelView HMI.
Biotech client in California
- Services included programming
various Intellution packages, Foxboro AI
DCS, and Allen Bradley PLCs. This was a
blanket contract to assist the
automation group with their needs using
contracted engineering services. This
included ACAD drawings, validation,
engineering submittals, custom interface
modules, and maintenance work orders.
Semi-Conductor
Large Chip
Producer in
Ireland
- Contracted to troubleshoot and
repair alarming issues and RSMessenger
failures in the Fab. The project
included RSView SCADA and RSMessenger.
Large Chip
Producer in Arizona
- Contracted to program FMS
(Facilities Management System) using
Cimplicity SCADA, MS SQL Database, and
AB PLC 5/80 for all utility systems in a
semiconductor fabrication facility.
Flash Memory
Manufacturer in New Mexico
- Troubleshoot and
reprogram existing Wonderware Factory
Suite 2000 application.
Flash Memory
Manufacturer in Colorado
- Program and commission FMS
(Facilities Management System) air
handlers, chillers, and generator
controls.
Large Chip
Producer in Washington
- Services included the design and
programming of the Wonderware SCADA for
the gas distribution system. Highlights
of system included interfacing 24 TCP
touch screens to the existing SCADA
system.
Large Chip R&D
Facility in
Texas
- Services included designing an Intellution
SCADA system for the hazardous gas
handling systems. This client is
currently one of the largest Intellution
based facilities in the world, with 24
active SCADA masters (servers), and 280
view nodes (clients). Highlights of this
system included using custom control
functions designed exclusively for the
client by Intellution.
Power / CoGen
Smart Grid Architecture and Engineering
- CSI has performed as a Subject Matter
Expert for 4 different clients for the
analysis and design to upgrade their
existing legacy systems to be Smart Grid
compliant. Requirements ranged from
basic wire mesh network designs, site
studies, AMI implementation, and
interfacing OSI PI with SAP.
Solar Project
in Arizona - Project
required integrating several remote
sites with OSI PI WebParts to provide
the client a web based portal for
viewing available data and compliance
reports.
Electrical Provider in California
- Smart Grid Project for a large
utility. This project is separated into
8 distinct phases. Phase 1 was creating
the requirements and 'use' cases for the
project life cycle to include Functional
Requirement Specifications, User
Requirement Specications and SDLC. Phase 2 was
completed with the design/ architecture
for a complete wireless mesh network GIS system including AMI
functionality. The design included OSIsoft PI as the database with the PI
AMI interface to communicate with the
Head End System. This system is a compliant ESRI
mesh network which is scheduled to
replace the existing Back Haul. Phase
3 for this project is currently in
commissioning mode. Phase 3 included T&D
asset management, client web interface,
integrating existing IEDs, Iconics SCADA/EMS,
Utility Gateway for SAP, and OSI PI
notifications. Phase 4 is currently in
design and this phase includes
alarm management, SAP integration,
reports, and automated
predictive &preventive maintenance
modules. Phase 5 is next and this is
the modeling used for dispatcher
training, operational studies,
transmission loading, power flow,
transient stability, post transient
voltages, external disturbances,
resonance, short circuitry, transfer
availability/capability, reactance, and
transmission
outage planning
Electrical Provider in Arizona
- This project required implementing
RSView32 for a standalone power system
which spanned 30 miles. The system
featured 5 RSView32 Works stations, each
one being a completely standalone
application. Any system modifications
are performed on the engineering
workstation, then automatically pushed
to all of the HMIs via the dedicated T1
network. When an alarm is acknowledged
on one HMI, the other HMIs automatically
acknowledge it and update their status.
Due to the remote and rugged conditions,
the client wanted an application that
could be run as a standalone with no
server requirements involved. Additional
interfacing included SEL relays with a
Modbus interface.
Electrical Provider in Arizona
- Project responsibilities included
upgrading OSI PI and interfacing with
Foxboro, GE Mark VI, and RTE for
historical data to be captured in PI.
OSIsoft OPC interfaces were used to
complete all project requirements
including legacy data from Unix based
systems.
Solar Farm
in Arizona - Project required comprehensive site survey to determine the security compliance requirements based on NIST SP 800-82 and ISA 99.
CSI served as Subject Matter Experts for the SCADA/EMS compliance portion.
California Telecomm Client
- Project included
programming redundant Quantum PLCs with
Modicon Concept using the Function Block
diagram (FBD) language. This project
provided complete generator control
functions (4 Caterpillar 2.5 mW) for the
trans-pacific switching station.
Federal Facility
- Services included the development and
programming of the Factory Link SCADA
System to monitor all sub-stations,
generators and transfer switches. Custom
report modules and interface modules
were required due to the different
protocols involved. In the event of a
power failure, the SCADA system would
transfer either utility or generator
power to the area that had failed, and
post the information on the company WAN.
Federal Facility
- Services included the
design/production/programming of a
Modicon 984-120 to replace the existing
Landis & Gyr RTUs for the high voltage
system. The existing RTUs could not
provide the existing SCADA with the
required protocol for transferring data.
This project allowed the existing SCADA
system to display the substations,
switchgear and transfer switch status.
Electrical Provider in California
- Project basis was cyber security analysis of an existing EMS/RTU/SCADA system backbone of a power utilities company. The client required assessment and documentation of the system architecture to define and limit the Attack Surface Area and establish a security protocol.
Solar Farm
in California
- Project management with scope of complete centralized SCADA system utilizing RTUs and field IEDs. Project completed with 100% compliance with NERC and NIST standards.
Wind Farm
in California
- Developed proprietary SCADA/EMS
applications and delivered NERC
compliant solution.
Water / Wastewater
Oregon Wastewater Client
-
Project included the electrical
design/engineering for a radio
controlled loadout system. CSI
constructed the panels and programmed
the Allen-Bradley PLC/580 and the
Panelview 1000 touchscreens (object
oriented).
Utah
Wastewater Client
- Project included the electrical
design/engineering for a radio
controlled dispensing system. CSI
constructed the panels and programmed
the Allen-Bradley PLC/580 and the
Panelview 1000 touchscreens.
California
Freshwater Client -
Services included programming the
Factory Link SCADA system and the
Modicon PLCs. Highlights of this system
included radio telemetry communications
from remote well sites to the plant, and
Web-client (HTML/ASP) for internet
access to the SCADA system.
Idaho
Wastewater Client -
Services included Allen Bradley PLC-5
PLC programming using RSLogix5 for a
sludge dispensing system. Highlights of
this system included Toshiba radio
telemetry communications for the
load-out system, and multiple BCD
displays using a common data bus and
individual strobes over AB Remote I/O.
California
Wastewater Client -
Services
included the design and programming of
the Factory Link SCADA system and
Modicon PLC programming. Highlights of
system included interfacing 2 Lucas
Deeco (object oriented) touch screens to
the SCADA system with 16 PLCs providing
control functions.
California Wastewater Client
-
Services included
programming/commissioning the Factory
Link SCADA system. This project included
a hybrid network that interfaced seven
(7) SCADA masters with 32 Windows based
MIS terminals for viewing. Additional
services included designing the Modicon
PLC architecture/programming.
Chemical / Steel
International Airport Client
- Services included the development of
the RSView SE control system and modular
programming of the CLX processors for a
fuel hydrant delivery system. This
project also included RSSQL, SQL, and
custom report modules.
California
Chemical Client -
Programming services included
modifications to the calciner kiln to
allow acid injection for cesium pellets.
This project included panel
design/fabrication, programming Xycom
touchscreens, Quantum PLC programming
and a custom MES interface.
California Steel Client
- Services included the
design and programming of a acid wash
skid based on Allen Bradley SLC504 PLCs
using a PanelMate HMI (character based
graphics). This project was a prototype
skid developed for cleaning rolled
steel. The highlights of this project
included using multiple cascaded PID
loops for acid dispensing.
California
Chemical Client -
Project included upgrading this facility
from Modicon 584's to Quantum TSX with
remote I/O. In addition to the upgraded
PLCs, CSI also installed/programmed five
(5) Xycom 3300 ACT touch screens using
bridge mux’s for the Modbus+ network.
The HMI's were housed in a custom built
NEMA 4X panel built in our shop.
Pipeline
Client - Services
included development and implementation
of a custom GUI (Visual Basic program)
and Modicon PLCs for a concentrate
pipeline. The Visual Basic program
allowed a custom user interface
utilizing a SQL database and
Modbus protocol.
Gasoline
Pipeline Client -
Services included programming and
commissioning the Intellution SCADA
system and GE 90/70 PLCs for a gas feed
pipeline requiring cut-over for
different grades from the tank farm to
port.
Cement / Minerals
California
Cement Client -
Services included installation and
programming for a PanelMate 3300 and a
Modicon 984 PLC. This project replaced
hard wired relay logic control for the
discharge gates at the truck loading
facility with a fully automated control
system.
California
Cement Client -
Developed SCADA, Historian and PLC
programs for production facility using
RSView32, RSHistorian, and SLC505 PLCs.
Integrated weigh scales, tariff tickets,
security cameras, and environmental
monitoring into the SCADA.
Nevada
Gold Mine Client -
Services included
programming/commissioning the Modicon
PLCs and Factory Link SCADA system for
gold production. The Modicon PLC system
consisted of 19,800 real IO points, and
600,000 database tags. Other features
included hot standby and redundant
networks. Additional requirements
included developing Visual Basic &
Crystal Report modules to provide real
time trending and reporting.
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