Biovet orders second automation project from Emerson, as antibiotic fermentation plant commences production

PlantWeb architecture with FOUNDATION fieldbus technology produces significant savings in Bulgaria plant. 

Extending a successful two-year relationship, Biovet, a Peshtera, Bulgaria-based antibiotic and pharmaceutical manufacturer, has placed new orders for PlantWeb digital plant architecture. The new project will install the digital plant architecture on a second automation project to control the production of a fermentation unit (Production Unit -3) on the same Peshtera site where the prior automation was done. This new project will involve seven further DeltaV™ digital system workstations and 450 field instruments, all using the FOUNDATION fieldbus communications protocol. Start-up for this second phase is planned for May 2003.

Biovet's new commitment follows a successful first phase implementation of the PlantWeb architecture. Biovet is a leading manufacturer of antibiotic feed additives and pharmaceuticals for farm animals and pets. Since privatization in April 2000, Biovet has collaborated with Emerson to modernize the Biovet plant, reduce costs and improve production process efficiencies using PlantWeb architecture and FOUNDATION fieldbus digital communications.

Biovet Executive Director Mr. Ivan Batakliev is enthusiastic about the simplicity and efficiency possible in completing new sections of plant installations using PlantWeb architecture and FOUNDATION fieldbus segments. "Use of the simple fieldbus wiring and technology has enabled us to reduce installation times, and achieve faster start-up of new plant sections," he commented. "The total view of the plant processes available from each workstation has enabled us to reduce operator staff numbers on these sections, freeing operators to work on other process lines. The operators are enthusiastic about the information available via PlantWeb, and the advantages and efficiency improvements that result."

Particular advantages have been found in the tighter control of the production process now available, and the consequent reduced deviations between batches. Executive Director Anguel Jeliazkov explained, "Tighter control of the processes gives a significant reduction in rework requirements, improving efficiency and reducing energy costs. More important for us at present is the increase in overall output achievable."

The first phase of the joint automation project involved instrumentation and control for the fermentation plant (Production Unit 1), using the PlantWeb architecture with its DeltaV digital automation system and AMS predictive maintenance software from Emerson. Emerson intelligent field devices power the architecture, and the devices supplied included 180 digital control valves and over 250 measurement instruments, all communicating across the architecture using Foundation fieldbus protocol.

The majority of the Emerson control valves supplied are from the Baumann range, fitted with Fisher FIELDVUE® digital valve controllers. Rosemount flow, pressure and temperature transmitters, Micro Motion Coriolis flowmeters, and pH and PO₂ sensors from Rosemount Analytical were included in the supply of measurement instruments.

Systems engineering and commissioning was undertaken by Emerson support teams in Bulgaria and Switzerland who completed the entire project within the scheduled 12-month timescale.

Peter Ward, Vice President of Emerson Process Management in Central & Eastern Europe commented: "This project shows that we can provide our customers in Eastern Europe with the very best technology available to provide advanced control, and meet modern regulatory requirements, within a tight time-scale. Biovet aims to provide quality products to improve animal health and performance in a cost-efficient manner, and we will continue to work closely with them so they achieve their aims of reducing costs and improving production efficiency still further. We anticipate further benefits will arise from the use of AMS software and process analysis information available through the PlantWeb architecture."

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