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在无菌药物生产中驱动最大正常运行时间

2022年2月5日，星期六

在制药世界中，没有错误的余地。这意味着在连续生产周期的机械系统中肯定没有停机时间。对于这些无菌环境，HVAC在保持高度控制的温度和空气质量方面起着至关重要的作用。尽管修复潜在的系统故障可能只需要一个小时，但重新建立无菌环境需要更多的时间 - 这意味着许多昂贵的生产时间损失了。因此，一家领先的全球制药公司决心找到一种智能HVAC解决方案，可防止通过实时系统监控和可自定义的即时警报进行停机。另外，解决方案需要适合组织雄心勃勃的数字化策略。

保持无菌环境对于药物生产至关重要。对于一家位于丹麦的制药公司而言，集成的数字解决方案是实现其机械系统支持的安全和连续生产过程的野心的关键。
在这种情况下，重点是HVAC系统。HVAC分解可能会立即污染制造业务，而没有问题。这可能会使该公司损失的收入损失（损失产量），每小时都需要重新建立无菌环境。

该项目的公用事业工程师解释说：“对我们来说，可预测性对于维持24/7的生产至关重要，这就是为什么对HVAC系统的监视和控制是防止停机时间的关键的原因。”因此，这需要一种智能解决方案，对空气处理通风系统内的振动进行实时监控，并在崩溃发生之前精确地发送警报。

挑战

丹佛斯（Danfoss）被带入合作制定可以帮助制药公司的数字解决方案：

  • 实时监控防止停机时间
  • 立即对系统的违规行为做出反应，并将警告和警报集成到其生产SCADA系统及其建筑管理系统中
  • 提高整体生产可靠性和安全性
  • 支持雄心勃勃的数字化议程

由于细菌污染的零容忍度和零停机时间的野心，挑战被定义了。为了找到最佳解决方案，Tyhe Pharmaceutical Company测试了HVAC系统的三种不同的振动设置。实验的目的是找到满足其特殊要求的解决方案。具体而言，该项目的公用事业工程师解释说：“数据使我们能够根据肠道的感觉做出明智的决定。”有了这个目标，实验开始了。

Danfoss为制药公司的HVAC系统提出了VLT®HVACDrive FC 102，其基于集成条件的监控（CBM）。CBM解决方案赋予了充当智能传感器的驱动力，监测电动机的状况并应用于早期检测潜在问题（例如AHU内的机械振动）。这意味着智能驱动器不仅会产生数据，还可以将数据解释为可行的预防性维护见解。

在AHU应用程序上测试Danfoss CBM解决方案
在实验中，申请基线定义了警告1和警告2的触发级别

在AHU应用程序上测试Danfoss CBM解决方案

制药公司的工程团队建立了AHU风扇系统，以评估不同的振动解体育投注必威决方案。内置了振动不规则，以模拟AHU的实时变化，并使用两个受控因素来监视检测解决方案的性能：受损的球和运动不平衡。在实施故障条件之前，工程师在Danfoss CBM解决方案中定义了健康的系统基线，该解决方案在直观的应用程序中进行了校准。基线及其警告和警报阈值反映了CBM对指定应用程序中的变化的反应，并记录了CBM的实时准确性。CBM基线通常是应用程序操作稳定性的第一个指示。另外，当承包商完成新的安装时，基线提供了用于故障排除的服务案例，因为它可以监视应用程序的运行状况从最低速度到最高速度。

可预测维护支持的最大正常运行时间

可预测维护支持的最大正常运行时间

在经过测试的三个系统中，Danfoss CBM解决方案是唯一在将故障引入应用程序中的确切时刻捕获AHU测试钻机的唯一一种解决方案。由于CBM解决方案成功地报告了实时警告和警报，因此证明现场技术人员可以防止昂贵的停机时间，而不是对自动关闭做出反应。

该制药公司的模拟AHU振动测试证明，具有基于集成条件的监控（CBM）技术的VLT®HVACDrive FC 102支持工厂的无菌操作条件，并与其数字化策略保持一致。通过直观的调试，易于安装以及实时监控和警报，Danfoss CBM解决方案有效地消除了停机和污染的威胁。

“有些事情即使是安排的维护也无法检测到，例如磨损的弹头。借助Danfoss CBM解决方案，我们获得了防止昂贵停机时间的智能驱动器。”公用事业工程师总结道。

该制药公司现在有信心在其运营中以工业规模实施CBM，并知道其生产设施可以安全，可靠地运营

了解有关基于条件监控的更多信息
基于条件的监控

驱动器具有不仅仅是简单的电源处理器，旨在充当传感器和传感器中心，以处理，存储和分析数据，此外它们的内置连接功能。基于条件的监视可以帮助现代化和优化您的自动化系统。在此处了解有关CBM的更多信息。

VLT®HVAC驱动器

在您的供暖，通风和空调装置中获得智能，可靠性和低总拥有成本（TCO），并针对建筑自动化系统进行了优化的独特驱动器。

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