Pfaudler Systems Engineering Rhodia ChiRex Scale Down Plant Case study

Transcription

1 Pfaudler Systems Engineering Rhodia ChiRex Scale Down Plant Case study

2 Supporting speed of product to market Speed to market is all important for our pharmaceutical customers if they are going to reap the maximum benefit of any patent. Bill Thomson, Rhodia ChiRex Major Projects Manager, is summing up why the company commissioned Pfaudler- Balfour to project manage a multi-million pound investment in a scale down plant, one-tenth normal capacity. He explained: This scaled down, fully-validated production facility supports us in developing small quantities of materials for initial clinical trials. It has been designed so that processes can then be reproduced quickly and much more easily on our full-size process lines. Apart from the production knowledge we build up, customers can save time and associated costs by registering the Annan site with agencies like FDA or CSM for manufacturing during the pre-production stage. This means avoiding delays re-registering the site for full production. Page 2

3 Supporting speed of project completion The speed of development of the pilot plant was also important for Rhodia Chirex, with Pfaudler-Balfour designing and delivering a fully validated and commissioned plant within only 13 months when 18 would usually be the industry standard. This included conceptual design as part of a front-end study. Pfaudler can achieve this, as it can undertake the role of principal contractor and manufacture the plant in modular format at its Leven facility. Pfaudler-Balfour Managing Director Andrew Wills said: It s very unusual to find a company capable of both, but our major investment in Systems Engineering ensures we can offer a full multi-disciplined approach encompassing all services necessary to realise a processing concept. This extends from concept support, design and engineering through to project management. Ian Faulds of Rhodia ChiRex, who co-ordinated project management with Pfaudler, said: The module philosophy works well, as the more you can do offsite the better. This not only supported quality control, but health and safety by avoiding people working in what was a very confined environment. We have an exemplary record on site, never having a lost time accident for this project. This means we check all contractors safety records before appointing them to work on site. Advantages of single responsibility and modular construction: Reduces the time and cost involved when a designer specifies to a manufacturer who then has to effectively engineer the product again. Better productivity and quality control can be achieved in the factory. Factory pre-testing possible. Shorter time to delivery improving product time to market. Because less construction required on site, plant downtime and site disruption are minimal. 3D models are translated into completed modules. Page 3

4 Meeting the customer s requirements Given that the plant was for test purposes, it had to be: multipurpose flexible fully validated Glasteel and Hastelloy are among the corrosion resistant materials used to ensure the plant can handle the widest range of pharmaceutical processes. A main requirement was that the design should include manual valves throughout. This results in total versatility which means Rhodia ChiRex can adapt the pilot plant for almost any use without having to continually invest in new equipment. Each part of the pilot plant is completely traceable from concept to installation and testing. Documentation, available as hard copy or on the Rhodia ChiRex Intranet, covers method statements, health and safety, HAZOPs and other criticalities right down to the CVs of people who worked on each area. Pfaudler-Balfour s Head of Systems Engineering, Stuart Cox, emphasised: This not only ensures what has been done is done correctly but gives an added degree of security for the client by ensuring any future problem can be identified and corrected as quickly as possible, helping to avoid potentially lengthy and costly shut downs. Page 4

5 Development Within a month of Rhodia ChiRex supplying an initial PID, Pfaudler-Balfour had delivered a design specification for the supply of the complete system. This was based on Pfaudler project managing and manufacturing all process equipment, while Rhodia ChiRex would prepare an existing warehouse. Pfaudler-Balfour s designers produced a further seven PIDs which formed the basis for HAZOP, full design and equipment specification. Stuart Cox of Pfaudler commented: Construction at our Leven facility went relatively smoothly as we were able to manufacture and engineer concurrently. Pfaudler-Balfour has risen to the occasion and there was very good collaboration between both companies, said Ian Faulds of Rhodia ChiRex. Single responsibility for design, manufacture and project management meant they were more easily able to alter the design to accommodate what we wanted as we went along. Equally important, the modular format meant a lot of equipment could be fitted within what was a very confined space for fitting into an existing building, very quickly. Indeed, installation took only three months. The reactor module was supplied in two sections. The first was suspended from the roof and the second element slid under gradually with a margin for manoeuvre of only a few millimetres. The service skid was lowered through the roof and the scrubber module was bolted to the outside within a day. Ian Faulds of Rhodia ChiRex said: Commissioning was also much quicker than normal with the number of problems encountered relatively small. Page 5

6 Modular approach The Rhodia ChiRex fully validated scale-down production facility is based on four modules: scrubber, services, reactor and filter dryer. All were produced in modular format and supplied as complete or part systems. Reactor Module Based on two reactors, two receivers and two azeotropic separators this module includes stateof-the-art health and safety features. A lamina contaminant booth incorporates a decontamination chamber and an extractor unit that ensures any dust particles are directed to the latest HEPA filters that recycle the air. Other features include a fibre optic system for viewing inside the vessel and a modern (Novotec) sampling system. Tantalum condensers were produced by Pfaudler-Balfour s sister operation in the US and lined pipes were supplied by another sister operation, Edlon. Filter Dryer Other major equipment, not supplied by Pfaudler, was installed by them in the same modular design as the reactors, vessels and heating and cooling systems. Scrubber A main requirement was that the design should include manual valves throughout to give operators flexibility in altering the process. Instead of a fixed console, which Pfaulder could have also delivered, this meant more complex hardwiring to the computer controls in the service module. Services Proven at 25 o C, this module incorporates thermal fluid loops, expansion tanks, refrigeration units and storage tanks. A three-way valve for heating and cooling connects through a ring main into the reactor module. The control package includes power supply, local control panels and a Motor Control Centre. Bill Thomson of Rhodia ChiRex comments: Our customers who have visited the plant are extremely impressed by the standard of equipment and engineering, including the very high quality finish and general appearance of the plant. We are introducing a design development lab to complement the facility with five development chemists who will work on process development. He summed up: Like the pilot plant itself, this is all part of helping customers optimise and improve their processes. Page 6

7 Equipment supply - 5 Modular Packages Comprising Reactor Skid Module: 1 x 1000L Hastelloy conical reactor 1 x 1600L Glasteel reactor 3 x 1600L Glasteel receivers 2 x 150L Glasteel headers 2 x Hastelloy azeotropic separators 2 x Tantalum heat exchangers 1 x Reactor charge booth Scrubber Module: 1 x Scrubber column 1 x Liquor tank 1 x 1500L Expansion tank 1 x Carbon block heat exchanger 1 x 225L Catchpot 1 x Drum discharge station 1 x 225L Glasteel Receiver Service Skid Module: 1 x 1500L Expansion tank 1 x 4500L Drain tank Dry run vacuum system Central chiller unit ( o C) 3 x HC 160-DI TCU s Filter Dryer Module: 1 x 12m 2 Filter Dryer 1 x 1600L Glasteel receiver 3 x 200L Glasteel receiver 2 x Carbon block heat exchangers Control System: Local operator panels for: Reactors Receivers and headers Filtrate receiver and vacuum pump Scrubber Motor Control Centre Instrumentation Data Logging Skid Electrics. Page 7

8 PFAUDLER SYSTEMS ENGINEERING WORLDWIDE DESIGNED BY CATCHLINE PR AND COMMUNICATIONS, FIFE, SCOTLAND Pfaudler Reactor Systems Total solutions for your processing requirements Pfaudler-ProSol Next generation mixing systems Pfaudler-Balfour Leven, Fife, Scotland, KY8 4RW. Tel: ( ) Fax: ( ) Website: