Amgen headquarters in Thousand Oaks, CA
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Amgen B23 BMS/UCS Upgrade
Amgen B23 BMS/UCS Upgrade
2023-2024
PURPOSE
To upgrade Amgen headquarter building 23 from GEMS to PPAx (updating Rockwell library).
SCOPE
$3,000,000+ in proposals spanning 1,024 control modules, 244 HMI displays, and 8 PLCs.
Team of 4-6 RoviSys engineers working with Amgen’s BMS team of 4.
Terminology & Definitions
Terminology & Definitions
Rockwell - Rockwell Automation, an industrial automation company.
Control Modules - Objects in code that represent things that can be controlled. Common examples include analog inputs/outputs, digital inputs/outputs, PID loops, variable speed drives, motors, pumps, etc.
HMI - Human Machine Interface. The graphics seen by an operator. Connected to the code such that the operator can easily control the system.
GEMS - An outdated library of provided by Rockwell, used to program control modules and their equivalent HMI objects.
PPAx - PlantPAx. A brand new library of provided by Rockwell, used to program control modules and their equivalent HMI objects.
PLC - Programmable Logic Controller.
BMS - Building Management System.
UCS - Utilities Control System.
P&ID - Piping and Instrumentation Diagram.
Studio 5000 - The Rockwell software used to design and edit code that is run through a PLC.
FactoryTalk - The Rockwell software used to design and edit HMI screens.
CONTRIBUTIONS
Redesigning legacy code to updated standards in Studio 5000.
Constructing HMI displays using PlantPAx global objects.
Independent ownership of Cold Room and Waste Neutralization system migrations.
Shared ownership of Building Management System migration.
Standard code for a simple analog input.
Visual overview of a cold room system.
COLD ROOMS
3 simple units controlling separate temperature-sensitive rooms.
50 control modules, 3 PLCs, 3 HMI displays.
Code migration:
Converting and re-organizing control modules.
Developing custom code, testing, and debugging.
Coordinating with other RoviSys and Amgen teams involved in other projects affecting the same controllers.
Updating technical documentation.
Visual overview of the waste neutralization system.
WASTE NEUTRALIZATION SYSTEM
1 complex unit controlling acid-base reactions of chemical waste.
76 control modules, ~20 HMI displays.
Code migration:
Converting and re-organizing control modules.
Developing custom code, testing, and debugging.
HMI displays:
Updating P&ID based overviews, analog input trends, alarm screens, and parameter controls.
Updating technical documentation and conducting in-house testing
FORMER CLIENT HMI
Clip art images from external sources
Objects from outdated GEMS library
Multicolored objects (Not recommended for ease of alarm viewing)
UPDATED CLIENT HMI
Images from Logix Designer Symbol Library
Analog input object from PPAx library v5.10
Display layout based on client provided P&ID
Maintained layout for operator understanding
Floorplan of the connected buildings showing the 12 distinct units.
BUILDING MANAGEMENT SYSTEM
12 complex units controlling BMS of 2 connected buildings.
Pressure cascades used to sweep dust and pollutants from the most sterile room to the least sterile room.
546 control modules, 1 PLC.
Code migration:
Converted and re-organized control modules.
Updated technical documentation.
An example electrical drawing (not from this project).
TECHNICAL DOCUMENTATION
Edited 500+ pages and counting of design specifications for all systems, including:
Development Testing
Functional Specifications
Software/Hardware Design Specifications
User Requirement Specifications
Installation Verifications
Appendices (spreadsheets)
Made changes to ~20 electrical design drawings in AutoCAD Electrical
Performed in-house development testing following Amgen GMP protocol
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