The original systems consist of numerous independent sensors and the display is given at the local monitor. During the batch processes the user/operator is supposed to take the proper readings of the different parameters and write it down on a piece of paper. Sometimes the readings are not accurate due to human errors. So, to avoid this type of problems we have designed a system named as Data Acquisition and Control System (Datalogger).
Some companies came up with an idea to store the local display data and to take reports whenever needed. So, we being an automation company designed a solution for our customers with which fulfill their requirement to improve more accuracy and to avoid rework and manipulations.
We have designed a system called Online and Offline DACS, which involved HMI, Computer/SCADA and some of the modules to convert or amplify the signals coming from different sensors or devices and to bring all the signal at a single platform which is read by the HMI and will be logged into it. And with the help of different utilities developed by our team we can provide customized reports as per customer requirement.
The original systems consist of numerous independent sensors and the display is given at the local monitor. During the batch processes the user/operator is supposed to take the proper readings of the different parameters and write it down on a piece of paper. Sometimes the readings are not accurate due to human errors. So, to avoid this type of problems we have designed a system named as Data Acquisition and Control System (Datalogger).
The Power Generation Center provides high- and low-pressure steam to heat. Excess high-pressure steam is routed to two turbine powered generators to recover much of the excess energy as electricity. Low pressure exhaust steam from the generators is directed to other building heating equipment. The OEM installed PLCs that control the generators and steam regulation became obsolete. Replacement parts were unavailable and support was difficult to find. Industrial Automation was hired to update and replace the aged and failing control system
Each of the two generators was refitted by employing an Allen Bradley Compact Logix PLC and an 8” color touch screen. Each of the touch screens is capable of communicating with either generator control system for operator control redundancy. Each touch screen includes a graphic “running” screen, set up screen, service screen, and a power generated history screen for both generators. The two PLCs also share power production and steam usage data with a building management system for viewing at multiple locations on campus by maintenance, supervisors, and students.
The new control system now controls the turbine supply steam precisely. The generators now start up dependably and after a programmed idle speed warm up, synchronize to line voltage and go on line very quickly. Once on line, the generator power produced is maximized while the exhaust pressure (low pressure steam) is precisely controlled for use in other building requirements.
The water supply control system that was no longer dependable. Control system alarms were becoming more prevalent as the components and infrastructure used to support the system were becoming undependable. Industrial Automation proposed modernizing the water control system. This would make the addition of remote troubleshooting and monitoring possible which would provide for better system control and help defray future control system maintenance costs.
Industrial Automation designed and quoted a new control system. This system utilizes Allen Bradley MicroLogix PLCs and MDS radios at each of five locations. At the main point of operation is a color touch screen that graphically indicates the state of the four pumps and the two reservoir levels. The touch screen allows the operator to view and adjust system variables such as pump sequence selection and reservoir level pump switching points. The touch screen also displays alarm conditions, such as low reservoir level, pump motor overload, and communications problems. Alarm messages and system status messages are transmitted to operator cell phones for instant notification.
Quality, Dependability, Low Cost Previous leased line connections were eliminated and ethernet radios are now being utilized. This eliminates maintenance and monthly rental fees of the land lines. The control equipment has been updated and numerous old pieces of control equipment have been eliminated. The new system also provides a single graphical point of interface showing status and providing control of the multiple remote locations tied to the water system. With the new radio connections all sights can be accessed remotely for future service and updates helping to hold service costs to a minimum.
The existing SCADA system was developed and running on the Microsoft XP operating system. The Microsoft XP OS was due to expire and, without support, the SCADA system was deemed insecure. In addition, the existing software was out of date, the system was labor intensive to maintain, it was slow to respond, and it had limited deployment and expansion capabilities, including the capability to communicate directly to Allen Bradley Compact & Control Logix processors. The waste water management team wanted a new platform that was operating system independent, scalable, web-based, server centric, database driven, redundant capable, and flexible.
The waste water management team choose Industrial Automation to provide a complete Ignition solution for the new SCADA replacement system. The control system consists of more than a dozen Allen Bradley SLC, Compact logic, Siemens S7-300 and MicroLogix PLC's. The SCADA system polls approximately 6500 OPC tags from these controllers with a scan rate of 1-2.5 seconds. It utilizes a MSSQL Database server for historical and real-time data storage. Inductive Automations "Mission Critical" software packaged was installed. The Master and Redundant Ignition gateways were installed on Windows platform OS's. Many additional client machines running Windows OS's are utilized for SCADA, LIMS, and reporting. The management team wanted the Ignition design to "appear" on the front end like the old system, but to use the capabilities inherent to the Ignition platform for enhanced performance and reliability under the hood. The trending capabilities of Ignition were an area of great satisfaction. What was once cumbersome and inaccurate is now easy to use, flexible, and customizable. The speed and response time of Ignition control system was also a great improvement over the old system. The project also included a "laboratory and instrumentation management system" (LIMS) component. What was once an isolated, slow, and hard to use system is now easily deployed to any machine on the waste water network, fast to respond, more accurate, and more user friendly. Ignition's standard components were utilized to build these windows, including the ability to create and update records in the SQL Database. Custom components with scripting were also added to allow for the windows to be easily updated and modified.
The installed Ignition project delivers the reliability, speed, and availability as promised and more. The management team is pleased with the installation and the ability to update and change the project on the fly. Knowing that the Ignition system is not dependent on any specific operating systems removes machine dependency concerns. System reliability has been tested and verified by shutting down the master Ignition server and allowing the backup to take over. This process takes less than 5 seconds for the backup server to take complete control of the SCADA system. Additional alarm notification was scripted into the system to monitor the database traffic. The number of pending and quarantined records are monitored and alarmed if outside the allotted threshold.
Part of the manufacturing process for heat exchangers is to test the core under high pneumatic static pressure. The old process was performed manually, provided rough test documentation, and had the potential to over pressure the core to the point that it would need to be scrapped. Any over pressurization beyond specification would need to be reported to the customer and, at times, the customer would not accept the core or it would need to be down-graded. Frequently, multiple cores streams would need to be tested at the same time, called a Simultaneous test, which required multiple chart recorders.
Industrial Automation was asked to design, construct, and program a heat exchanger pneumatic pressure tester. The new pressure tester utilizes an Allen Bradley Compact Logix PAC controller to monitor all system pressure and limit sensors and control all pressure testing and plant air valves. A 15-inch industrial touchscreen connected to a PC running Ignition from Inductive Automation serves as the HMI/ SCADA system. The ignition SCADA/HMI system controls, monitors, and records regulated core stream pressures along with supply-side high-pressure values. Since the Ignition system is not dependent on any specific operating system, there’s no concerns about operating system dependency. The tester design included valves and pressure sensors to monitor and control the inlet test gas pressure to two isolated single stream zones, simultaneously. Three qualified persons are each required to enter the core test parameters (via the touch screen) prior to starting each test. Each person is assigned a specific key to gain access to the corresponding test setup screen. When all three sets of data match, the appropriate valves are energized to allow the pressure test to start. In addition to the test setup security, there is also a maintenance setup and calibration page that requires a key and password to enter. As the core is being manually pressurized by an operator, the control monitors the core pressure. If the core pressure is greater than or equal to the test pressure and less than the dump settings, the core is ready for the operator to start the pneumatic test. If the core pressure reaches the “Inlet close” pressure settings, the control will close the supply gas valve. If the core pressure reaches the “dump” pressure settings, the control will open the discharge valves from the appropriate core stream to relieve the core pressure. If the core loses too much pressure during a predetermined time, the test is aborted. If the test is passed, then all of the test data is gathered into a printable report. In addition, the data is saved to a database for future use.
The heat exchanger pneumatic pressure tester delivers the machine safety, simplicity, reliability, speed, and a test data report as promised. The management team is pleased with the installation and the ability to update and change the project on the fly.