Process automation for pharmaceutical manufacturing.

Core services

DeltaV configuration

Configuration across the full S88 stack: control modules and equipment modules, phase logic, unit procedures and master recipes, with supporting operator graphics, alarm rationalisation and historian configuration. Recipes are configured to interface with MES and enterprise-level systems where required.

Delivered across the project lifecycle, from functional and design specification development through configuration and module testing to code delivery and handover into commissioning.

Batch and recipe design

Recipe strategy for multi-product and campaign plants, including S88 modelling of the physical and procedural hierarchy, recipe reuse across equipment trains, and design for Syncade and third-party batch engines.

Commissioning and qualification

IQ, OQ and PQ protocol authoring and execution, including paperless qualification through Kneat and computerised system validation for data platforms.

Project and vendor support

Specification, technical bid evaluation, factory and site acceptance testing, and technical oversight of automation subcontractors.

FEED studies

Automation scope definition during front-end engineering design: control system architecture, I/O and instrument counts, automation philosophy documents and budgetary estimates ahead of detailed design.

Data historians and PI System

AVEVA PI System architecture, Asset Framework, Event Frames, notifications and PI Vision. Historian migrations and integrations across Canary Labs, GE iHistorian and Ignition, with SDK tooling and custom reporting.

IT/OT integration

OPC UA, MQTT and Kepware connectivity between control systems and enterprise platforms. Data collection from DeltaV, Honeywell, iFIX and Allen-Bradley sources, MES interfaces and network topology planning.

Additional services

Chartered process engineering, delivered through the company’s associate network.

Process design

P&IDs, user requirement specifications, cause and effect diagrams, equipment and relief valve sizing, and process simulation in Aspen Plus, HYSYS and HTRI.

Process safety

HAZOP, HAZID and SIL studies, hazardous area classification and basis of safety reporting, with resulting actions carried through to implementation.

Debottlenecking and optimisation

Capacity studies and troubleshooting on existing plant, identifying constraints and improving throughput and operational efficiency without capital investment.

Approach

Embedded delivery

Engagements are typically longer-term and run inside the client’s project team rather than at arm’s length. Automation decisions are made alongside process engineering, quality and validation, which avoids the rework that comes from designing in isolation.

Specification first

Configuration begins from an agreed functional and design specification. Where none exists, developing it is treated as part of the scope rather than something to work around.

Associate network

Where a project needs process design, data historian architecture or validation depth beyond core automation, specialists are brought in under the same engagement rather than handed off to a separate vendor.

Testing before handover

Modules and phases are tested before they reach formal qualification. Defects found at module test cost hours; the same defects found at OQ cost weeks.

Documentation and handover

Deliverables are written for a GxP environment from the outset, with traceability from user requirement through design specification to test evidence. Code is delivered so the client’s own team can maintain and extend the system afterwards.

Selected projects

Engagements delivered by Conor Kilcoyne, including work prior to founding Kilco Consulting. The sample below shows the range of work rather than the full record. Client names are withheld under confidentiality.

Further detail on these and other engagements is available on request.