In a water catchment plant, there was a need to upgrade the Controls and SCADA system to facilitate a more robust and efficient operation of the plant.
Operation of the plant encompasses the inter-operability of Electrical and Mechanical plants. Equipment required for these components needed to function as one to deliver key operational objectives. With the centralisation of the SCADA system, linking various parts of the Plant and Equipment became feasible with efficacy.
Redesign the architecture controls for high availability and robust features – ensuring that if one system fails, another would come online.
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Adoption of open and secure Ethernet/IP network and upgrade network speeds for real-time access to data.
Centralisation of the SCADA system to control the entire plant with an audit trail and backup features to eliminate risks.
We installed the water process control system including Redundant ControlLogix controllers and Distributed IO for the Controls, FactoryTalk AssetCentre and VantagePoint for asset management and visualisation display respectively.
Real-time data allows WWW companies to utilize alarms to notify employees when a remote pump fails. This reduces downtime for troubleshooting and communication.
Our installation also provided the requirements for high availability system and security features needed for a critical plant. Security is reinforced through our defense-in-depth approach to identifying ways of protection such as temper detection or theft of intellectual property.
We were required to provide a solution that would increase the Overall Equipment Effectiveness (OEE) of a homogeneous mixer to blend liquid and powder. Using a rigid system that only allowed a fix number of steps and materials due to ladder programming in the customer’s existing system, we had to develop a solution that would resolve their limitations.
Their existing solution required two separate systems to attain desired results and batching sequence that was not flexible and configurable by users.
Mid-range control, HMI, Drive and Safety.
Expand number of steps and materials within the system.
Ability to change recipes and save for future use.
Integration into power and field devices.
We used Logix Batch and Sequence Manager (LBSM) based on ISA88 to process the object (code and graphics) to run a batch with configured steps. Ideal for stand-alone units (mixers, blenders, reactors), this solution makes it extremely configurable and easy to use. This gives flexibility for recipe management, single unit supervision and control with support for multiple units.
By integrating the Powerflex Variable Frequency Drive into the Logix controllers, the Automatic Device Configuration feature allows for easy replacement of faulty drives, and automatic program downloads from the controller to the new drive, minimising downtime.
The LBSM significantly reduces engineering and commissioning time, while speeding up the time to market and eliminate engagement costs for process changes. The integration into power components provides an immediate and measurable impact on asset availability, operational efficiency, and energy management.
With the new system, the end user can now enjoy the safety of monitoring energized devices on operator screens, receive a mixture of data types, and save development time.
|Conventional Architecture||RA Architecture||Benefits|
|Separate PLC and batch controller system||Single platform with discrete and batch control||Using only a single software for all functions (PLC, Batch, Drive) we were able to reduce engineering time with ready template and ease of configuration and programming.|
|Analog control of drives||Integrated Ethernet/IP communication for PLC to Drives||Premier integration reduced engineering time and effort by 30% with ADC feature that helped improve end user experience.|
|Static Batch Sequence||Flexible sequence of batch configurable by LBSM||All product recipe now changes through HMI and cuts down development time by 50%, with easy upgrade capability and maintenance diagnostics.|
|No support||OEM technical consultant engineering support||OEM Technical consultant will be engaged with programming engineers to jointly develop the program.|
|Drives and motion accelerator toolkit (DMAT)||Free available toolkit to reduce engineering time and faster time to market by at least 50%.|