Case Study: Turnkey ABB 800xA DCS & Control Panel Solution for a New Pharmaceutical Plant in Kerry
Client: Global Pharmaceutical Manufacturer
Partner: BONNER
Scope: ABB 800xA DCS, 16 Remote I/O Panels, 6 Pneumatic Panels, Full EPLAN P8 Design Package
Overview
A leading Pharmaceutical manufacturer selected BONNER to design and deliver a complete Distributed Control System (DCS) and control panel solution for a greenfield facility in County Kerry. The project required the latest automation, robust documentation, and a lifecycle-ready infrastructure capable of supporting compliant pharmaceutical operations from day one.
BONNER engineered, built, and tested:
- 1 ABB 800xA DCS control panel
- 16 remote I/O (RIO) panels using ABB S800 I/O
- 6 pneumatic control panels for actuation and clean instrument air distribution
- A full EPLAN P8 drawing suite, compliant with ISA, IEC, and GAMP standards
This case study outlines the technical scope, engineering approach, and quality-driven execution that positioned BONNER as the trusted automation partner for advanced manufacturing in Ireland.
The new facility required a fully integrated, maintainable, standards-compliant automation architecture to ensure:
- Safe and GAMP-aligned operations
- Clear IT/OT boundaries and cybersecurity foundations
- Long-term maintainability with 20% design spare capacity
- Accurate, validated electrical and pneumatic documentation
- Seamless interfaces with OEM packages and utilities
BONNER was tasked with delivering all control panels, schematics, documentation, FAT/SAT support, and engineering design.
Project Scope & Technical Delivery
1. Engineering & System Architecture
BONNER developed a complete ABB 800xA Distributed Control System architecture, designed with redundancy and compliance at its core:
- Key engineering highlights:
- Redundant ABB 800xA controllers & redundant network topology
- Segregated industrial Ethernet with RSTP/MRP rings
- Dual 24 VDC control power with redundancy
- ABB S800-class I/O across all RIO panels
- 20% growth allowance for panel space and I/O
- EMC, earthing, shielding, and cable segregation to IEC/EN best practice
- Time synchronisation (NTP/PTP) with GPS source allowance
This system architecture provides a stable, scalable platform for future plant expansion.
2. Control Panel Design & Manufacture
ABB 800xA DCS Control Panel
The main DCS panel includes:
- Redundant controllers and managed switches
- Patch panels for fibre/copper connectivity
- Engineering/workstation allowances (physical or virtual)
- Power distribution, diagnostics, and dual PSUs
16 Remote I/O Panels
Each panel features:
- ABB S800 DI/DO/AI/AO I/O racks with HART capability
- Per-panel marshalling and terminal management
- IS barriers where hazardous area instruments apply
- Internal lighting, door interlocks, 24 VDC health monitoring
6 Pneumatic Panels
Delivered in SS304 cleanroom-ready enclosures, each panel includes:
- FRL assemblies (lubrication-free for instrument air)
- Manifolds with 24 VDC solenoid valves
- Gauges, regulators, isolation valves, and relief valves
- Condensate and leak management features
Each panel was built to EN 61439 and instrument air design standards.
3. Full EPLAN P8 Model-Based Design
BONNER produced a complete EPLAN P8 design suite for manufacturing, FAT/SAT and lifecycle maintenance, including:
- Drawing index, title blocks, legends, symbols
- GA layouts, door layouts, gland plates, earthing plans
- Power schematics, single-line diagrams, protective coordination notes
- Terminal plans, cable schedules, interconnection diagrams
- I/O lists, loop diagrams, hook-up details
- Pneumatic P&IDs, manifold layouts, valve lists
- Panel drilling files, wire cutting lists, BoMs
- ISA-5.1 compliant tagging and naming
This documentation ensures unmatched traceability, accuracy, and maintainability.
4. Testing, FAT, and Site Support
BONNER executed a comprehensive Factory Acceptance Testing (FAT) process, including:
- Electrical FAT
- Insulation resistance and continuity tests
- Functional I/O simulation
- PSU redundancy checks
- Wiring quality (IPC/WHMA-A-620 good practice)
Pneumatic FAT
- ISO 4414 pressure and leak tests
- Solenoid and valve actuation tests
A formal FAT report with punch-list closeout was delivered.
BONNER also supported SAT witnessing, loop checks, and produced as-built drawings directly in EPLAN P8.
Compliance & Standards
The project adhered to stringent regulatory and engineering standards, including:
- EN/IEC 61439-2, IS 10101 (Ireland)
- GAMP 5 for pharmaceutical automation
- IEC 62443 baseline cybersecurity alignment
- ISO 4414 (pneumatics) and ISO 8573-1 (instrument air)
- ISA-5.1, ISA-18.2, ISA-88, ISA-95 where applicable
This ensures the system is fully auditable and ready for regulatory scrutiny.
Project Results & Outcomes
Delivered Outcomes
BONNER successfully delivered:
- Standards-compliant control & pneumatic panels ready for installation
- Complete EPLAN P8 documentation for lifecycle support
- Structured I/O, network, and electrical design supporting long-term maintainability
- Clear OT/IT, OEM, and utility interfaces
- A validated panel architecture with documented change control
Client Impact
- Faster commissioning with clean documentation and spare capacity
- Reduced long-term maintenance costs
- Higher reliability through redundancy and good engineering practice
- A future-ready automation platform for plant expansion