Introduction
In the rapidly evolving life sciences industry, maintaining operational continuity and compliance is crucial, especially when leveraging legacy control systems. One leading life sciences company faced a significant challenge as their Emerson DeltaV systems with DeltaV Operate graphics approached the end of support in 2029. To address this, Catalyx led a strategic migration to DeltaV Live, ensuring long-term system viability and regulatory compliance.
Context
Ensuring Compliance with Strict Korean Serialization Regulations
The life sciences company relied heavily on Emerson DeltaV systems to support GMP manufacturing processes. However, with Emerson planning to discontinue support for DeltaV Operate graphics by 2029, the company needed to proactively migrate to DeltaV Live. The primary challenges included:
End of Support:
DeltaV Operate graphics would no longer be supported after 2029, risking system reliability.
Compliance and Validation:
The migration had to adhere to GMP standards to maintain regulatory approvals.
Complex Migration Requirements:
Years of customized graphics, alarm configurations, and user interfaces needed to be meticulously preserved.
Operator Training:
Transitioning to a new platform posed the risk of increased learning curves and reduced productivity.
Catalyx recognized the urgency and complexity of this migration and developed a comprehensive, phased strategy to ensure success.
Our Solution
Catalyx executed a structured migration plan focusing on compliance, usability, and minimal downtime, adopting the following steps:
Step1: Future-Proofing with DeltaV Live:
Transitioned from legacy systems to DeltaV Live, offering long-term support and improved scalability.
Step 2: Modernized HMI Graphics:
Replaced outdated graphics with ISA 101-compliant Human-Centered Design interfaces, enhancing usability.
Step 3: Regulatory Compliance & Validation:
Ensured GMP compliance by delivering thorough validation protocols, traceability matrices, and FAT (Factory Acceptance Testing) procedures.
Step 4: Alarm Management Upgrade:
Implemented dynamic alarm handling aligned with ISA 18.2 standards, improving operational safety and response.
Step 5: Seamless Migration Approach:
Employed a dual-platform strategy to validate the new system while maintaining ongoing operations, minimizing disruptions.
Step 6: Operator Training & Adoption:
Provided targeted training programs to facilitate smooth adoption and minimize learning curves.
Results
The phased migration strategy delivered immediate and long-term benefits, including:
Immediate Benefits:
Maintained operational continuity, enhanced usability, and ensured compliance with GMP standards.
Long-Term Gains:
Established a scalable system that supports future growth while mitigating risks associated with legacy technology.
Technical Achievements:
- Successfully migrated over 5,000 DeltaV Operate displays to DeltaV Live.
- Integrated advanced ISA 18.2-compliant alarm handling.
- Developed modular and scalable HMI interfaces, aligning with modern operational standards.
Conclusion
By strategically planning and executing the DeltaV Live migration, Catalyx ensured that the life sciences company maintained compliance and operational efficiency. This future-proof solution not only addressed immediate challenges but also positioned the company for sustained growth and technological advancement. Through meticulous planning, phased implementation, and robust training, the transition was both seamless and successful.