The worldwide leading producer of blood sample collection tubes relocated a production line from one of their foreign facilities. The line produces chemically pretreated blood tubes for healthcare applications ranging from hematology to glucose testing to blood banking. The project schedule was emphasized to meet commercial demands for bringing these small but vital health devices to market. In addition to time pressures, the project faced technical challenges converting electrical components from foreign voltages and reprogramming the automation to meet production demands.
EAD’s engineers successfully solved these challenges by specifying new electrical components for equipment along the production line to convert to U.S. power supply voltage and frequency. Along with the electrical redesign, EAD updated the facility’s electrical power model to ensure arc flash safety and to determine short circuit ratings.
Due to IT security concerns, EAD completely wiped the existing Human Machine Interface (HMI) programming from the relocated equipment and reprogrammed each piece of equipment on the production line. Machine safety functions were addressed with Safety Integrity Level 3 (SIL3) components and included modification of the existing fault indicator light system with an HMI-based approach to meet the client’s site-specific protocols. Field wiring complexity was reduced by utilizing a single-cable system which reduced installation and commissioning time. EAD had controls automation engineers continuously on site for several weeks to support installation, programming and startup to guarantee the project’s success.