Case Studies - Barnet (Shanghai) Automation System Engineering Co., Ltd.

PCS7 Project for a Biotech Company

A demonstration automation system based on the Siemens PCS7 platform has been provided to achieve batch automation control for the tank system used in oligonucleotide production, facilitating processes such as cleavage, deprotection, quenching, and annealing reactions. The system integrates real-time data from third-party equipment like synthesizers, chromatography, and ultrafiltration onto this platform.

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DeltaV Project in Chengdu

This project is based on the DeltaV automation platform, seamlessly integrating ultrafiltration and depth filtration control functions into the existing server architecture. Below the controller level, the open industrial Ethernet protocol EtherNet/IP is adopted to enable efficient communication, stably connecting Siemens ET200 series distributed I/O racks and related functional cards. The platform integrates key third-party process detection instruments (such as pH, conductivity, pressure, temperature, turbidity sensors, etc.) to establish an automated control platform that complies with data integrity requirements. The configuration meets cGMP regulatory requirements and provides a comprehensive depth filtration and ultrafiltration system solution. The system is deployed in production environments with different cleanliness levels: depth filtration is performed in a Grade D clean area to effectively remove cell debris and particulate impurities from samples; ultrafiltration concentration and diafiltration operations are carried out in a Grade C clean area to increase the concentration of target products and perform buffer exchange, respectively. The depth filtration system integrates feed pumps, sample flow paths, permeate flow paths, CIP cleaning flow paths, and drainage flow paths, with all flow path switching automatically controlled by pneumatic diaphragm valves. The ultrafiltration system offers more comprehensive functionality: in addition to all the above flow paths, it specifically integrates membrane integrity test gas flow paths and permeate recirculation flow paths. Similarly, fully automated flow path switching and process control are achieved through highly reliable pneumatic diaphragm valves.

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PCS7 Project for the API Manufacturing Facility in Fujian

A demonstration automation system based on the Siemens PCS7 platform has been implemented to achieve batch automation control for production in synthesis workshops, recovery workshops, tank farms, sterile API workshops, and formulation workshops. It fully automates processes such as tank feeding, initialization checks, inertization, liquid solvent addition, solid material charging, TCU temperature control, pH-controlled dropping, and extractant addition. Real-time data from third-party equipment—including chromatographs, rotary evaporators, drying ovens, medium/low-pressure preparation systems, TCU units, integrated high/low-temperature machines, dry screw vacuum pumps, washing-filtering-drying tri-function units, centrifuges, purified water systems, chillers, cooling towers, nitrogen generators, oil-free vacuum machines, and air conditioning systems—are integrated into the DCS system via PN communication, Modbus RTU, Modbus TCP, and hardwiring. This enables real-time monitoring, alarm management, and remote control.

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SCADA Project in Guangzhou

A virtualization SCADA solution based on Stratus ftServer has been provided, utilizing the Siemens WinCC system to achieve real-time 3D visual display of various process units in the upstream and downstream workshops. This solution enables key information collection, alarm handling, historical data archiving, database backup, time synchronization, and large screen display functionalities.

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Downstream Pipeline and Tank Project in Jiangsu

An automation system based on the Siemens PCS7 platform has been provided to achieve batch automation control for the downstream pipeline and tank system. The system uses an S7-410 Smart CPU with ET200SP distributed I/O. It adopts a server/client architecture, integrating OS server, Batch server, and operator stations.

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Oligonucleotide Project for a Biotechnology Co., Ltd. in Shanghai

This project will classify the pipeline and tank systems based on criteria such as production floor layout, process lines, and upstream/downstream stages. The control system employs the SIEMENS PCS7 platform with Batch functionality. The system architecture is built on a 410-5H CPU, with communication between the CPU and I/O modules realized via a Profinet ring network. The overall design adopts a server-client model and is equipped with a corresponding number of HMI industrial computers. All electronic and electrical equipment must comply with explosion-proof requirements applicable to their respective zones.

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SCADA Project in Suzhou

A virtualization SCADA solution based on Stratus ftServer has been provided, utilizing the Siemens WinCC system to achieve real-time 3D visual display of the automation systems of various process units in the upstream and downstream workshops. This solution enables key information collection, alarm handling, historical data archiving, database backup, time synchronization, and large screen display functionalities, as well as completing the migration and validation of historical data from the PCS7 system. The WinCC system employs the OPC DA communication protocol for real-time data acquisition and alarm processing of process equipment on the Siemens platform (such as bioreactors, virus removal filtration, ultrafiltration, BMS, water systems, etc.), and uses the OPC UA communication protocol for real-time data acquisition and alarm processing of process equipment on the DeltaV platform (such as chromatography and online liquid preparation).

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Automation Design Project for a Biotech Company in Wuhan

Provided automation system solution design services for a biotech company in Wuhan, covering upstream and downstream process automation control solution design, instrument selection, control system architecture design, and Functional Specification (FSS) writing.

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