E Tech Group expanded a Qualified Building Automation System (QBAS) while simultaneously providing the validation documentation and testing in accordance with GAMP 5.0 guidelines.
Built on GE Proficy iFIX SCADA and VMware ESX, the upgraded system provides alarming, historical data logging, and reporting functionality for the biotech manufacturer. The expansion addressed improvement of the system’s reliability, improvement of the user interface, and improvement of system performance.
Qualified Building Automation System (QBAS) Expansion
Virtualized QBAS Architecture Overview
The scope of this QBAS upgrade involved adding 16 remote panels (PACs), each connected to six rooftop AHUs. The building required an update to its qualified building automation system that would support trend logging and alarming within a GAMP 5.0-compliant infrastructure. Key project specs included:
- A GE Proficy iFIX SCADA platform for signal monitoring and alarm/trend logging to SQL
- Deployment on VMware ESX with virtual machines for the Data Historian and Web HMI
- VLAN network segmentation between PACs and client/server traffic
- Implementation of a failover SCADA configuration with dual-NIC Windows rack servers
These changes ensured long-term scalability and consistent access across the system architecture.
QBAS and SCADA Integration: Project Specifications
A GE Proficy iFIX SCADA monitors analog and digital signals fed to the process automation controllers (PACs) and third-party skid equipment process automation controllers (PACs). The SCADA logs alarm and events data to a relational database and provides access points for trend and alarm data loggers.
The SCADA hosts the QBAS security configuration. One of the many QBAS clients on the network provides access for QBAS users. Client PCs enable users to monitor system health, monitor and acknowledge process alarms, view trends and reports, and save alarm set points to the SQL database.
E Tech’s engineers configured VMware’s ESX Server to serve as the platform for the QBAS Data Historian and Web HMI virtual servers. The PACs and Client/Server networks operate on different VLANs. The QBAS monitoring PACs are connected in a Device Level Ring topology for high-speed and high-performance, all the while providing a resilient process automation controller network for maximum uptime.
The SCADA was built on iFIX in an Enhanced Failover configuration. Microsoft™ Windows® operating system and rack-mounted computers are used as the platform. The computers contain two (2) network interface cards (NICs); one NIC is dedicated to the QBAS communications with PACs and QBAS iFIX clients, and the other NIC is for the exchange of Enhanced Failover messages between the redundant pair of SCADA nodes.
The QBAS operates under cGMP, so all project lifecycle documentation from URS to IOQ was maintained.
The QBAS was also designed to meet future needs. Strategic grouping of GMP data points, providing additional control panels with I/O and Ethernet communications, and definition of templates with modular scope, all position our customer for a straightforward, time and cost-efficient expansion of their future needs. Focused on biotechnology and the life sciences, E Tech Group has been a trusted systems integrator, providing automation and validation services for over 3 decades. E Tech Group relies on its 800+ systems integration and automation engineers to create custom system solutions for clients in the pharma industry, biotech, and food and beverage industries. E Tech Group also offers comprehensive automation services for the chemical and renewable energy industries.
Key Benefits of the QBAS Upgrade
- Improved reliability through a redundant SCADA system and failover configuration
- Centralized access with web-based HMI functionality
- Enhanced data management via SQL historian and optimized VLAN network segmentation
- Scalable, compliant architecture aligned with GAMP 5.0 guidelines
- Minimal disruption during deployment, maintaining system integrity throughout
Addressing Challenges in QBAS Modernization
A primary challenge in expanding this qualified BAS was maintaining seamless integration with legacy controls while introducing modern technologies. To avoid downtime, the E Tech team:
- Installed and configured the virtual SCADA environment using VMware ESX
- Integrated additional PACs into the existing VLAN-based control network
- Configured redundancy and backup protocols via a failover SCADA system
- Ensured system validation under GAMP 5.0 and cGMP compliance guidelines
These solutions provided reliable infrastructure while reducing risk during deployment.
Project Results: Improved Performance and GMP Compliance
The expanded qualified building automation system successfully supported additional hardware while improving accessibility and data reliability. The virtualization of SCADA, combined with a browser-based Web HMI, allowed personnel to access key system metrics remotely.
The architecture’s built-in redundancy also enhanced system availability, while adherence to GAMP 5.0 ensured continued compliance with cGMP regulations.