Engineering
Engineering
The Engineering division covers all aspects of comprehensive industrial planning for plants and machinery in the process and manufacturing industries.
Unser Leitspruch lautet: „Wir verbinden Kompetenz mit Qualität“
With this in mind, we plan from an economic perspective and in accordance with technical requirements, with the aim of achieving customer satisfaction.
Building on our quality management system in accordance with DIN ISO 9001 and embedded in a sophisticated project management system, we work together with you in a spirit of partnership and transparency.
We are your partner for all phases of consulting, concept development, planning implementation, commissioning, and production support.
Use our experience for your success!
Core Competencies
- Consulting on safety issues (E/MSR area according to DIN EN 62061, DIN EN ISO 13849)
- Consulting on the introduction of hardware and software standards (supplier specifications)
- Consulting on qualification measures in the pharmaceutical industry (GxP, GAMP5)
- Consulting on the selection of automation and process control systems
- Concept development
- Preparation of specifications
- Basic and detailed planning of electrical and MSR system components and field installations
- Installation execution and installation supervision
- Basic and detailed planning of automation and process control technology
- Commissioning of plants and machinery
- Support with the maintenance and optimization of plants and machines
Overview of services
Dokumentationteam
Operational & Plant Safety (BAS)
Operational & Plant Safety (BAS)
Consulting
Our engineering services begin with basic engineering and extend to specific planning topics.
Including:
- Concept development across all engineering and IT disciplines
- Selection of complete system and automation technology
- Technical consulting WinCC®
- Technical consulting WinCCflexible®
- Technical consulting for TIA Portal®
- PCS7® technical consulting
- Security technology – Software
- Security technology – Hardware
- GMP plant validation
- GMP validation measures for the software
- Creation of functional plans in accordance with standards
- Supplier specifications for end customers
Process Control Technology
Since 1992, we have been working as a competent process control engineering team for process engineering processes in the pharmaceutical and chemical industries.
From basic engineering and detailed engineering to commissioning, we cover all phases of a project efficiently and comprehensively.
Our skilled team stands out thanks to its effective solution methodology and sophisticated project management. We have focused our core business on the three most powerful systems from Siemens, Emerson, and ABB, offering particular expertise in these areas.
Our industry focus is:
- Pharmaceutical industry
- Chemical industry
- Power plants, incinerators
- Water and wastewater
- Food and luxury foods (NuG)
- Petrochemical industry
Our range of services includes:
- Batch applications (Siemens, Emerson) and product control solutions
- Step chains (SFC) and basic functions
- Basic functional element level (CFC)
- Delivery of standards (supplier specifications and libraries)
- Solutions for maintenance and maintenance optimization
Siemens PCS7®
For many years, AGU has been one of Siemens AG's selected partners for process control and automation systems.
Since the launch of the PCS®7 partner program in 2005 by the Siemens headquarters in Karlsruhe, AGU has been accepted into the circle of specialists due to its extensive know-how with the PCS7® control system.
Since 2006, AGU has also been an industrial partner of the Pharma Competence Center in Karlsruhe.
Areas of experience with PCS7®:
- Concept development and system selection
- Connection of MES data systems (Werum, etc.)
- Simatic Batch
- SFC-Application
- CFC-Applications
- S7-400 H and F
- Redundant client/server architecture
- Network structures with Profinet, Ethernet, and Profibus
- Interfaces to other safety controllers (such as HIMA)
- Telecontrol
- PCS7® standard creation (references from Bayer AG and Sm@rtLib)
ABB – 800xA and Freelance
Our partner Sedna Automation is currently working on a major project for the chemical industry in collaboration with ABB. The 800xA control system with the M-Controller is being used in this project. The project involves the development of a chemical standard for modules and faceplates.
Emerson – DeltaV
As specialists in Emerson's DeltaV control system, AGU and Sedna Automation have been working successfully with the system in the chemical industry for many years. Our expertise lies in solution strategy and knowledge of effective engineering with the system.
Areas of experience with PCS7®:
- Concept development and scaling
- Configuration in SFC and CFC
- Faceplate and dynamo creation
- Batch applications
- Basic functions with own GF master (16 operating modes, 10 setpoint values and 6 binary values each)
- Standard development and standard maintenance for renowned companies in the chemical industry
- Interfaces to other systems (HIMA, Siemens, ABB)
- Pre-engineering via Access database with test report generation and export to DeltaV
Teleperm M
- AS220, AS230, AS235, AS488
- OS252, OS265, OS525
Customers are increasingly opting to migrate from Teleperm M to Simatic PCS7®.
Due to the discontinuation of the old systems by the control system manufacturer Siemens, operators of production facilities are required to replace their control systems with modern, future-oriented, and economically effective automation systems.
However, the success of a migration depends not only on an optimal technical solution tailored to customer needs, but also on its high-quality implementation.
Thanks to our many years of experience with the Teleperm M and Simatic PCS7® process control systems, we are able to implement migration projects that fully meet the high demands of our customers. We can load and test your application on our own test systems (Teleperm M and PCS7®).
We are happy to assist you as your partner, consultant, and full-service provider! Our test center features a Teleperm M setup that allows us to edit the programs.
Automation Technology
We live and breathe the concept of “Totally Integrated Automation.” As a system integrator, we connect systems from a wide range of manufacturers to form a complete plant. We cover a broad spectrum of automation technology. From drive technology and operating and monitoring systems to control systems and the necessary connections to IT systems, we can offer you professional solutions that take economic aspects and technical requirements into account.
Our references and experience in the fields of mechanical engineering, special machine construction, and manufacturing technology are extensive and demonstrate our partnership-based approach to projects.
Our focus is:
- Operating and monitoring systems WinCC flexible®, WinCC®, TIA Portal®
- S7-300® and S7-400®, S7-1200® and S7-1500® applications
- Desigo® building automation system
- Special technologies for positioning
- Bus systems (Ethernet, Profibus, Profinet)
- Drive technology
Electrical engineering plant design
We are your partner for all planning activities in the field of special machine construction, mechanical engineering, and production technology.
Our strengths:
- Special solutions for manufacturing plants
- Planning pneumatic systems
- Creating plant concepts
- Consideration of functional safety in accordance with DIN EN ISO 13849-1
- Detailplanung
- Maßnahmen am Aufstellungsort
- Feldinstallation (z.B. dezentrale Peripherie, Bussysteme und Komponenten)
- Aufbau der Sicherheitstechnik mit SSPS oder in konventioneller Technik
- Schaltschrankaufbau (Berechnung und Auslegung)
- Antriebstechnik (Positionierung, Servotechnik, Frequenzumrichter)
- Anschlüsse zu Automatisierungssystemen
- Aufbau der Bedien- und Beobachtungssysteme
- Carrying out the assembly or coordinating your assembly department or companies
- Functional testing and commissioning
- Maintenance and service for your systems
Systems we use:
- EPLAN 5.7
- EPLAN P8
- Cadett
- Autocad
MSR plant design
We are your partner for all MSR planning activities in the process engineering industry. We use our CAE tools to plan process engineering plants in the pharmaceutical, chemical, and NuG industries for you, taking into account your factory standards, current laws, and norms.
Our strengths:
- Basicengineering
- Creating plant concepts
- Definition and interpretation of systems engineering
- Sicherheit
- Risikoanalyse der Anlage (z.B. A3 Testat)
- Consideration of functional safety in accordance with DIN EN ISO 13849-1
- Betrachtung der SIL Klassifizierung nach DIN EN 62061:2005
- Ex-Schutz Auslegung (Ex-Dokument, Eigensicherheitsnachweis)
- Detailengineering – Infrastruktur
- Stromversorgung (gepuffert)
- Schaltraumplanung
- Messwartenplanung
- Feldinstallation (z.B. dezentrale Peripherie, Bussysteme)
- Detailengineering – Systemtechnik
- Auswahl Sensorik und Aktorik
- Planung der Messstellen
- Planung der Antriebe
- Planung der Bussysteme
- Planung der Automatisierungs- und Leitsysteme
- Installation implementation and/or installation supervision
- Functional testing and commissioning
- plant optimization
- Service and maintenance
Technical building equipment
We plan systems in the field of technical building equipment for the pharmaceutical and process engineering industries as well as public buildings.
Our services cover a wide range of technical building equipment:
- Electrical engineering infrastructure measures for offices, laboratories, warehouses, and industrial facilities
- Energy management (consulting, analysis, and optimization)
- Classic and modern building automation
- Lightning protection and surge protection in buildings and outdoor areas (certified according to VDS)
- Building and facility air conditioning (heating, air conditioning, and ventilation systems)
Electrical infrastructure planning
We plan the electrical infrastructure of your office buildings, laboratories, and industrial facilities in basic and detailed engineering. Our services also include the coordination of related trades and specialist departments.
Basic and detailed engineering covers:
- Power supply up to 6 kV (see also Power supply up to 25 kV)
- Switch rooms, switchgear, and control rooms
- conventional installation technology
- professional lighting design
Energy management
We pool our expertise in the field of energy management for your benefit. We provide comprehensive advice and support throughout your project and the implementation of measures.
Our services include:
- Creation and implementation of energy management concepts
- peak load optimization
Building automation
We carry out certified planning in the field of building automation (KNX (EIB) / Ethernet). Our team has built up its expertise over many years and focuses on the following areas:
- Planning of network structures
- Smart building technology
- Use of modern bus technology (KNX (EIB) / Dali / Ethernet)
- Interfaces to other systems
VDS/EMV
“We combine expertise and quality.” This motto also applies to this area. Our VDS-trained employees analyze your systems and buildings and develop concepts for modernization. In doing so, we take current standards and legislation into account.
- VDS experts in the field of lightning and surge protection
- VDS experts in the field of EMC and harmonics
Heating, ventilation, and air conditioning (HVAC) systems
As part of building automation in the pharmaceutical industry, we carry out basic and detailed engineering for all building and automation technology. This includes everything from hardware and software planning to commissioning and handover to the end customer.
We work closely with the plant design (process engineering) and assembly departments, or supply entire plants as a general contractor.
The performance characteristics of the heating, air conditioning, and ventilation systems include:
- project management
- Consultant for validation and qualification measures according to GAMP5 (also for retrospective plant qualification)
- Creation of the bus system infrastructure
- Creation of concepts and specifications (hardware and software)
- Implementation of GMP measures (QP, QPP, FDS, FAT, SAT, IQ, OQ, DQ, PQ)
- Implementation of detailed engineering for hardware and software
- Commissioning and optimization
Power supply
In the field of power supply, we work on medium-voltage and low-voltage projects. In cooperation with the specialist departments of network operators and power suppliers, we plan the entire system, including all related tasks.
Brief description of services:
- Recordings of existing facilities
- Power supply concepts
- Secure and buffered networks
- Transformer and reserve transformer logic
- alarm systems
- Preparation of documentation
- Coordination of related trades
Documentation
Our team of CAE/CAD systems experts supports the specialist departments of E/MSR and technical building equipment in creating documentation for the following systems:
- EPLAN 5.x
- EPLAN P8
- AutoCad
- Cadett (MG-Cad)
- Microstation
- ESplan
- Planeds (within the scope of MSR plant design)
We migrate vector- and database-oriented CAE/CAD programs or take over the documentation of legacy systems professionally and quickly, checking for compliance with standards.
Dokumentationteam
Operational & Plant Safety (BAS)
Planungs- & Dokumentationsteam
Operational & Plant Safety (BAS)
We support you in implementing the safety requirements arising from standards and laws.
Our experience in this field is the result of 25 successful years of cooperation with large companies in the chemical and pharmaceutical industries. Implementation is based on our PEC product.
Our services include, among other things:
ZÜS inspections
- Preparation and supervision of expert inspections by approved monitoring bodies (ZÜS)
Inspection preparation
- Erstellung von Prüfplänen gemäß §15 und §16 BetrSichV
- Planung und Strukturierung von Prüfabläufen für die Inbetriebnahme und wiederkehrende Prüfungen überwachungsbedürftiger Anlagen.
- Erstellung von Eigensicherheitsnachweisen
- Dokumentation der Eigensicherheit für eigensichere Stromkreise und Komponenten gemäß geltendem Normen und Richtlinien.
- Support in the creation of security concepts
- Erstellung des SIL-Nachweises
- Durchführung und Dokumentation gemäß VDI/VDE 2180 sowie DIN EN 61508 zur Bewertung der funktionalen Sicherheit von PLT-Schutzfunktionen.
- Ausarbeitung praxisgerechter Wartungs- und Prüfpläne
- Basierend auf NA106, speziell für PLT-Schutzfunktionen unter Berücksichtigung betrieblicher Anforderungen.
- Entwicklung individueller Prüfkonzepte
- Maßgeschneiderte Lösungen zur Umsetzung funktionaler Sicherheit in Neu- und Bestandsanlagen, angepasst an technische und organisatorische Gegebenheiten.
- Erstellung rechtssicherer Dokumentationen
- In analoger und digitaler Form, z. über kundenspezifische Systeme wie PEC-FS, zur lückenlosen Nachverfolgbarkeit und rechtlichen Absicherung.
Operational & Plant Safety (BAS)
Testing Team
Operational & Plant Safety (BAS)
We support you in reviewing the safety requirements arising from standards and laws.
Our experience in this field is the result of 25 successful years of cooperation with large companies in the chemical and pharmaceutical industries. Implementation is based on our PEC product.
Our services include, among other things:
EX-protection tests
- Commissioning test in accordance with §15 BetrSichV (German Ordinance on Industrial Safety and Health)
- Durchführung bei Neuerrichtung oder wesentlicher Änderung von überwachungsbedürftigen Anlagen.
- Sicherstellung der Errichtung nach dem Stand der Technik.
- Wiederkehrende Prüfung gemäß §16 BetrSichV
- Ausgeführt durch befähigte Personen gemäß Anhang 2 Abschnitt 3 Nummer 3.1 BetrSichV.
- Digitale Dokumentation:
- Im eigenen Format oder über kundenspezifische Systeme (z. B. PEC-EX).
- Prüfungstiefe
(2.2 Prüfarten bei überwachungsbedürftigen Anlagen im Sinne des § 1 Abs. 2 Satz 1 Nr. 3 BetrSichV) Nachzulesen in TRBS 1201 Teil 1- Ordnungsprüfung
- Technische Prüfungen
- Sichtprüfung
- Nahprüfung
- Detailprüfung
Functional safety tests
- Eigenverantwortliche Durchführung wiederkehrender Prüfungen an PLT-Schutzeinrichtungen
- Einschließlich digitaler Dokumentation in kundenspezifischen Formaten (z.B. PEC-FS).
Commissioning tests
- Loop-Checks und Inbetriebnahmeprüfungen
- Im Rahmen von Neuerrichtungen, Umbauten oder turnusmäßigen Wartungen.
ZÜS inspections
- Vorbereitung und Begleitung von Sachverständigenprüfungen
- Durch zugelassene Überwachungsstellen (ZÜS).
Further education
Our seminar program is led by experienced practitioners who teach participants the course material using numerous practical examples. The seminar program is continuously revised and kept up to date with the latest technical developments.
Our workshop and training offerings for you – practical experience for practical application!
Training: Troubleshooting and diagnostics in Siemens systems for operations supervisors
S7 machine control
S7/WinCC flexible applications
S7/WinCC applications
PCS7® applications
Safety controllers Siemens F controllers
High-availability Siemens H controllers
Telecontrol systems: Sinaut, Telecontrol
Bus systems: Profibus, Ethernet, Profinet
Training: The basics of planning for facility managers
Changes in AWL/FUP programs
Changes in CFC programs
Changes in SFC programs
Changes in step chains (bit step chain, wall block, SFC type, S7Graph)
Visualization WinCCflexible®
Visualization WinCC®
Visualization PCS7®
Training: Project planning with Sm@rtLib for planners and practitioners – introduction for beginners 1-3 days
Project-related training in automation and process control technology
Workshop – Building services engineering: Lightning and surge protection in practice
Workshop – Pharmaceuticals: GMP-compliant software development
Workshop – Pharmaceuticals: Qualification of systems and software in the GMP environment
Workshop – Supplier specifications – Professionally designing specifications for your planning suppliers
Training courses:
⫸ Operations Supervisor Practice I
⫸ Operactions Supervisor Practice II
⫸ Projektieren mit Sm@rtLib
⫸ Projektbezogene Schulung
Workshops:
⫸ Blitz- und Überspannungsschutz
⫸ GMP Softwareentwicklung
⫸ GMP Qualifizierung
⫸ Lieferantenvorgaben
Feel free to contact us for more information!
