CONCEPTUAL DESIGN
We are able to provide conceptual design service for either greenfield or brownfield project. Normally, the concept study team combines about five top leveled experts in areas of architecture, process, HVAC, MEP and cost estimation. The team is not working alone. They communicate closely with engineers from user team. Our value has been recognized that EPI was able to benchmark issues from similar projects meanwhile to share Pro. & Con. experiences with client, and brainstorm on available options
Process Architecture including building layout design, personnel and material flows
Process Design
Architecture for building Interiors, finishesand external Façade
Site Master Plan
Clean Utility Design
Electrical Low Voltage Design
HVAC Design
Black Utility Design
Hydraulic for industrial water, sanitary water and waste
Automation and Instrument
±30% Cost Estimation
Project Schedule and Execution Plan
DETAILED PROCESS ENGINEERING
The custom-designed system engineering and fabrication can be deemed vital parts on a biopharmaceutical facility project. The user expectation is to buy what they need instead of what vendor is supplying. EPI is capable to deliver the detailed process design to meet the demands of the entire process system from bioreactor / fermenter, harvest system, purification system, media and buffer preparation and holding system, UF/DF system, NF system, throughout bulk formulation and filling system.
The conceptual project team has been structured to allow seamless transition to the Detailed Engineering Phase. EPI as an international engineering firm has specialized project models executing projects in different regions especially emerging business countries. Our project model during the detailed engineering stage is to execute the most critical parts of design - Process and Process Automation. Meanwhile, connecting the LDI (local design institute) who’s responsible of facility, structural, civil, clean room, HVAC, mechanical and electrical design. The facility integration methodology is to ensure drawings and specs coming from both parties are compatible to serve subsequent construction, installation and C&Q activities.
The design for the detailed engineering will follow a well proven and structured methodology that ensures the process and process automation design are aligned with client’s project business case and drivers, and the risk of project scope creep and design changes are minimised.
Flexible operation of clarification and purification units to accommodate multi-product operation with large batch sizes.
LEAN operation principles to maximise the potential for low cost operation.
High yield production with design focused on minimising product losses.
Efficient changeovers with efficient cleaning and use of closed CIP/SIP.
The design will be challenged by the use of checklists (e.g. GMP / HAZOP / Constructability / LEAN Manufacturing) to ensure it is compliant. Furthermore, EPI will focus on ensuring the business objectives and drivers are understood and met.
DETAILED AUTOMATION ENGINEERING
We can provide the automation design to meet tailored and integrated plant control requirements. The system might be PLC+SCADA or DCS structure which depends on production technology, process system and client procurement strategy.
EPI has delivered many design packages to enable our client to procure and program the process automation system in their plant. The design performed on automation systems from vendors: Emerson, Rockwell, Siemens, ABB, Schneider, Finesse.
Most frequently, our client required EPI to provide MES design. We have experiences in configuring Material Weighing and Dispensing Module, Batch Management Module, Equipment Management Module. These MES modules (ISA S95) are connected to DCS as well. In some cases, the LIMS was required communicating to DCS to bridge up the paperless information transition between QC lab and production suites.
Our work includes:
Entire plant PAS DCS configuration and architecture
MES configuration and architecture
Establish process communication to vendor-standard island control equipment through OPC
Functional specification requirement FRS composing
Hardware and software user requirement
GAMP 5 review
SITE TECHNICAL SUPPORT
It is EPI's expanding service to dispatch team of small number of process and automation engineers to construction site. The site technical supporting work is aimed to ensure the detailed process and automation design packagescan be landed on the ground.
The site work includes:
Vendor shop auditing and visits
Contract technical management includes shop design check and approval
P&ID and Layout walk down to guide the system positioning and installation
Cross disciplinary interfaces
Quality and schedule check
Site acceptance tests SAT, mechanical completion MC and verifications support
IQ/OQ support and punch items close-up
Plant start-up support and process parametersanalysis