Implementation of HVAC System Automation (TRIGON Plc.)

Our company modernized the outdated automation of Trigon Zrt.'s existing HVAC system using the ABB Compact Product Suite. The entire top-level control system was replaced. As part of the project, we installed a new automation cabinet and, where necessary, new, modern field sensors. With the introduction of the new, fully integrated operator station, the old operator terminal was replaced by a modern solution that collects all data, improving system transparency and user experience. During commissioning, we provided continuous support for the system's re-tuning in compliance with the air handling requirements.

The new ABB system is a future-poof entry point for the pharmaceutical company's further high-level automation developments. A more detailed description on this topic is available here.

Steam Boiler Automation Developments (MOL Petrochemicals Plc. – Tiszaújváros)

During the 2024 planned shutdown, MOL Petrochemicals Plc. scheduled, among other tasks, the development of the existing Linde steam boiler automation, which was carried out by our company in collaboration with ABB Ltd. and Maxflow Ltd. The project encompassed three key components:

• Drum Level Control
• Steam Pressure Control
• Steam Temperature Control

The field implementation was preceded by a detailed survey phase, which allowed for a thorough analysis of the current operational state of the stem boiler. The goal was to increase the operational reliability and efficiency of the automatic controls by logically restructuring the control program code and precisely tuning the control loops. In all three project components, we successfully improved the regulation oscillations significantly and expanded the automatic functions.

LINE-1 Automation Implementation (Richter Gedeon Plc. – Debrecen)

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Stability tank automation implementation (Richter Gedeon Plc. – Debrecen)

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Feasibility Study for Gas Flow Direction Selector Automation (FGSZ Ltd.)

FGSZ Ltd. commissioned a feasibility study for the supervision and automation modernization of its national natural gas transmission system. As part of this project, our company conducted a comprehensive survey at two compressor station junctions and the central office. The result of the work was a study exceeding one hundred pages and a demonstration application that fully meets the natural gas transmission requirements in terms of functionality. Based on this, the client can map out and plan the possibilities for standardizing the natural gas transmission system.

Energy Systems Data Collection (Richter Gedeon Plc. – Debrecen)

In the project implemented at the Richter Gedeon Plc. site in Debrecen, our company successfully integrated energy consumption statistics into the BMS system, which includes both the existing energy systems and the newly installed TRANE cooling machines.
(See: TRANE cooling machine commissioning). Additionally, during the project, we created a daily automatic report that summarizes the energy consumption data collected by the system. This project has significantly contributed to increasing the energy efficiency of the cooling system and has opened up further opportunities for future optimization.

TRANE cooling machine commissioning (Richter Gedeon Plc. – Debrecen)

As part of the project for replacing and expanding the machines supplying the cooling water system at the Richter Gedeon Plc. site in Debrecen, our company assisted in several ways. On one hand, we worked on the hardware and software aspects of the control automation for the machines, and on the other hand, we provided extensive support during commissioning. A parallel project was carried out for displaying and analyzing the energy statistics of the cooling system (see: Energy Systems Data Collection), which increased the system's efficiency and improved operational transparency.

I/O Module Replacement (Richter Gedeon Plc. – Debrecen)

The automation system at the Richter Gedeon Plc. site in Debrecen was upgraded with ABB hardware, as part of which the 801 series I/O modules were replaced with the 810 series. The challenge of the task stemmed from the integration of the control systems in various areas of the automation cabinets, along with the strict deadlines set for the project. Our company replaced nearly 100 modules without any production downtime, ensuring that the transition could be carried out smoothly. The new system provides greater reliability and flexibility in manufacturing processes.

Cooling Tower Automation (Richter Gedeon Plc. – Debrecen)

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Replacement of Johnson Controls Automation Cabinets (Richter Gedeon Plc. – Debrecen)

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MOL Petrochemicals OLEFIN-1 Lifetime Extension (MOL Petrochemicals Plc. – Tiszaújváros)

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ESAB Heating Control (ESAB-Mór Ltd. – Mór)

After the 2021 system modernization, which laid the foundation for part of the welding rod production on ABB technology, the phased integration of the energy system began. As a first step in testing the concept, the heating control of a total of six rooms was replaced, transitioning from a single thermostat – manual radiator valve solution to a customized, ABB-controlled system, where each room can be individually regulated. The connection of the controllers, control boxes, thermostats, and boiler control was implemented using Ethernet cables. The regulation provides statistical and historical data services similar to a comprehensive BMS system and can also be controlled through the already implemented operator interfaces.

ESAB Production Control System Modernization (ESAB-Mór Ltd. – Mór)

You can read more about the project here.

Filter Dryer implementation (Richter Gedeon Plc. – Budapest)

Our company was responsible for implementing the complete control of a filter-dryer unit, integrated into the DCS system. The filter-dryer unit has a microfilter plate at its bottom. The filtrate exits through this plate from the slurry pumped into the crystallizer. The device includes a mixer that can move up and down to break up or smooth out the material. The unit is pressure-tight, allowing the filtration speed to be increased using a high-pressure air cushion or, in explosive environments, nitrogen pressure. After filtration, drying begins, usually under vacuum. At the end of the process, the material exits through a large cross-sectional discharge opening, while the mixer rotates in a direction that pushes the product toward the periphery. The discharge can take place in an isolator, with only this section in the clean room, and the product is hermetically sealed from the environment as it moves into the packaging film or barrel. Our tasks included programming the entire operation, sequencing these actions, and creating trends and reports.

Werum integration (Richter Gedeon Plc. – Debrecen)

Participation in the preparation for the installation of the MES (Manufacturing Execution System). The MES integrates all related IT systems, such as ERP, LIMS, or DCS systems, through standardized interfaces, ensuring seamless information exchange and better performance. In industries like pharmaceuticals or other technologies, paper-based manufacturing processes are slow, error-prone, and costly. A significant portion of the deviations in individual items is caused by human error. MES helps eliminate the potential for mistakes due to human negligence. It guides operators through the manufacturing process, controlling every step. Experts believe there is no Industry 4.0 without MES.

PHP Liquid Cooling (Richter Gedeon Plc. – Debrecen)

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Supercooling (Richter Gedeon Plc. – Dorog)

The existing technology was expanded with the installation of a dust separator.

Filter Dryer implementation (Richter Gedeon Plc. – Dorog)

As part of the project, a MAVAG filter-dryer unit was installed and commissioned in an existing hall at the site, for the first time at this location. MAVAG manufactures high-quality and efficient equipment with many years of experience in filtration, drying, and mixing for the pharmaceutical and biotechnology industries.

The system that was developed, commissioned, and validated meets all the requirements specified in international standards. It supports the 11CFR part regulations.

DBP Buffer preparation (Richter Gedeon Plc. – Debrecen)

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Ethylene Oxidizer (Richter Gedeon Plc. – Budapest)

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ComiCondor (Richter Gedeon Plc. – Dorog)

A Comi Condor plays a leading role in the production of centrifuges for the pharmaceutical, chemical, and food industries. It operates in over 50 countries worldwide, with more than 5,000 centrifuges. During the project, a Comi Condor centrifuge was installed, integrated into the existing system, and fully commissioned.

The system that was developed, commissioned, and validated meets all the requirements specified in international standards. It supports the 11CFR part regulations.

PAS II. HVAC System (Richter Gedeon Plc. – Debrecen)

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DBP Energy Measurement (Richter Gedeon Plc. – Debrecen)

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DBP Dew Point Measurement (Richter Gedeon Plc. – Debrecen)

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Pipe Heating (Richter Gedeon Plc. – Dorog)

A heating cable solution installed for maintaining or protecting the temperature-sensitive material tank and pipelines, located outside a heated building, at a specific temperature and according to defined design specifications. The supervision and control are provided by the ABB process control system.

The system that was developed, commissioned, and validated meets all the requirements specified in international standards. It supports the 11CFR part regulations.

Kémia III. CIP Tank (Richter Gedeon Plc. – Budapest)

In the project, an existing device, which was previously not automated, was integrated into the Monofluid system and connected to the process control environment. The complete control of its jacket was implemented based on the already used solutions. The pressure and temperature in the tank were monitored and controlled with analog measurements. Communication with the Partner Unit was programmed, and supervisory signals were established. The new software design is also capable of performing batch-controlled operations. A comprehensive display was integrated into the process control system for the device.

A unique feature of the technology is the Monofluid heating and cooling system, which allows for temperatures of +110°C and -35°C to be achieved using a single medium. This technology significantly reduces the need for mechanical piping, while requiring specialized control techniques to accurately regulate temperature on various devices, which is one of the most critical aspects of pharmaceutical manufacturing.

The developed, commissioned, and validated system meets all the requirements set forth in international standards. It supports the 11CFR part regulations.

DBP Phosphate Measurement (Richter Gedeon Plc. – Debrecen)

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Ulipristal expansion (Richter Gedeon Plc. – Dorog)

Due to the decentralization of Ulipristal intermediate production, 3 new autoclaves were installed, and 3 existing ones were relocated, involving more than 150 I/O points. A Modbus connection had to be established with the liquefied nitrogen system.

The developed, commissioned, and validated system meets all the requirements set forth in international standards. It supports the 11CFR part regulations.

PAS BMS (Richter Gedeon Plc. – Debrecen)

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Mixing Tanks (Richter Gedeon Plc. – Dorog)

By installing two large-volume mixing tanks, a solution was created that enables the parallel cleaning of two different raw active ingredients or intermediates, thereby increasing the plant's productivity and flexibility alongside expanded capacity. The software control of the tanks, their communication and cooperation with associated tanks, as well as the high-level batch recipe tour, were programmed into the existing ABB 800xA process control system.

The implemented idea and work received the RITA Award (Richter Innovative Knowledge Base Award and Archive).

The developed, commissioned, and validated system meets all the requirements set forth in international standards. It supports the 11CFR part regulations.

PHP Particle Counter (Richter Gedeon Plc. – Debrecen)

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Univerzális II. Hall Expansion (Richter Gedeon Plc. – Dorog)

The existing process control system was expanded with 3 new redundant controllers, 1 redundant Connectivity Server, and an Information Manager server. Nearly 10 operator stations were also installed, most of them with field terminals. The new system part controls approximately 30 separate, but interconnected machine units, with over 2000 I/O signals.

As part of the project, a MAVAG filter-dryer was installed and commissioned. MAVAG manufactures high-quality and efficient equipment with years of experience in filtration, drying, and mixing for the pharmaceutical and biotechnology industries. The automation of the equipment was exclusively implemented using the ABB process control system in the project.

A micronizer was installed. Hosokawa Alpine has been designing and building technological machines for material processing for over 120 years. The machine units are reliable and ensure reproducible processes. Integrated isolation solutions ensure that the operator is protected during work with materials, and vice versa. The entire equipment is controlled by the ABB process control system, with an ABB controller.

The developed, commissioned, and validated system meets all the requirements set forth in international standards. It supports the 11CFR part regulations.

Purified Water Expanson (Richter Gedeon Plc. – Dorog)

Due to the construction of a new industrial hall, it was necessary to ensure an adequate supply of high-quality and sufficient amounts of PW (Purified Water) for the equipment, which required expanding the existing service system. The goal of the PW system is to produce, store, and distribute water free from minerals and organic materials, ensuring that the water meets the required pharmaceutical quality at all user points throughout the plant. The project also involved automating the process so that each client automatically dispenses enough water from the central tank.

The developed, commissioned, and validated system meets all the requirements set forth in international standards. It supports the 11CFR part regulations.

PHP laboratory transformation (Richter Gedeon Plc. – Debrecen)

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Kémia III. automatic report (Richter Gedeon Plc. – Budapest)

In the production process, by collecting and organizing information generated during operations, useful data can be obtained, which helps in improving results and making informed decisions. The report generation automation collects both real-time and archived data, from which it generates an electronic report document either on a scheduled or manual basis. The report consists of electronic records that identify the start and end of production phases, as well as other associated activities, such as the identification of the operator performing the process. The data requested and stored in this way must be signed electronically by the operator and, where necessary, by their supervisor. A list of all alarms (Alarm List) generated throughout production, as well as operator interventions (Audit Trail), will also be compiled and displayed. For critical operations, trends are inserted alongside the data for better visualization and evaluation.

PHP Labor II. Expansion (Richter Gedeon Plc. – Debrecen)

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HVAC System (Richter Gedeon Plc. – Budapest)

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Kémia III. virtualization (Richter Gedeon Plc. – Budapest)

A VMware-based virtualization infrastructure was established at the Richter Gedeon Nyrt. headquarters in Budapest. The advantage of the virtual infrastructure is that resource utilization can be optimized better in terms of processor, memory, and storage. The access points and the services they provide are not tied to physical servers. Older versions of guest machines can run on modern physical devices. The system can be operated and managed from a central interface. Future resource demands can be flexibly expanded, redistributed, or grouped.

In the project, approximately 20 servers and client machines were reinstalled and fully configured. The ABB software was updated to the latest modern version. A complete replacement and inspection of graphic displays were carried out, along with system tests and loop tests.

Szteroid II. upgrade (Richter Gedeon Plc. – Dorog)

The solvent requirements of the production areas are met by a tank farm located farther from the plant. These supply processes have been automated, such that the system automatically measures the required solvent quantity into the target tank. A solution was needed that ensures continuous communication between controllers, maintaining dedicated connections. The requesting clients can access available serving servers, and the measurement is carried out with high precision using a mass flow meter. The system manages restrictions, ensuring that a server can measure to one location at a time and cannot be disrupted manually, such as by valve opening. An entry is made in the event log for each operation, making it possible to track material movements accurately.

The developed, commissioned, and validated system meets all the requirements set forth in international standards. It supports the 11CFR part regulations.

PHP machine reports (Richter Gedeon Plc. – Debrecen)

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TRIO module replacement (Richter Gedeon Plc. – Dorog)

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BMS Energy Measurement (Richter Gedeon Plc. – Debrecen)

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SP Hall Upgrade (Richter Gedeon Plc. – Dorog)

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PHP decontamination (Richter Gedeon Plc. – Debrecen)

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Purified Water Production (Richter Gedeon Plc. – Dorog)

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EMS incubation (Richter Gedeon Plc. – Debrecen)

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T5 Tank Farm (Richter Gedeon Plc. – Dorog)

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BMS Boiler Expansion (Richter Gedeon Plc. – Debrecen)

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NOR II. (Richter Gedeon Plc. – Dorog)

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PHP EMS (Richter Gedeon Plc. – Debrecen)

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PHP BMS (Richter Gedeon Plc. – Debrecen)

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Szteroid I. upgrade (Richter Gedeon Plc. – Dorog)

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PHP EMS (Richter Gedeon Plc. – Debrecen)

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PHP BMS (Richter Gedeon Plc. – Debrecen)

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Szteroid I. upgrade (Richter Gedeon Plc. – Dorog)

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DBP EMS (Richter Gedeon Plc. – Debrecen)

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PPP BMS (Richter Gedeon Plc. – Debrecen)

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