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WONDERWARE MANUFACTURING EXECUTION SOLUTIONS
SUM IT ALL UP FOR YOU!
From product track & trace through enterprise integration - Wonderware MES gives you solutions not problems, options not roadblocks, scalability not “one-size-fits-all”Chalk it up to the power of ArchestrA! Learn how Wonderware has helped hundreds of customers to do the maths and unleash their potential!
Editorial Introduction by Mark Davidson .......................................................................................5 Chemical Azoty Tarnov ....................................................................................................................7 Calzin, Inc ........................................................................................................................9 Delta BioFuels, Inc. ........................................................................................................12 Imperator .......................................................................................................................15 Borealis Group ...............................................................................................................18 Discrete Manufacturing Meridionale Impianti S.p.a.............................................................................................21 Facilities Management Université de Strasbourg ...............................................................................................25 Food & Beverage Mount Packaging Systems Ltd. .....................................................................................28 Winkler und Dünnebier Süßwarenmaschinen GmbH ....................................................32 Imana Food....................................................................................................................36 SAB ................................................................................................................................40 New Belgium Brewing Company ..................................................................................44 United Dairy ...................................................................................................................48 Greene King ..................................................................................................................51 Graphic Arts CRE-A ............................................................................................................................54 Hydrocarbon Processing Gazprom dobycha Astrakhan, LLC ................................................................................57 Idemitsu Kosan ..............................................................................................................60 Life Sciences Sano Pasteur ................................................................................................................63 Xcellerex ........................................................................................................................66 Metals, Minerals & Mining Hydro Aluminium Extrusion Deutschland Gmbh ...........................................................70 Lonmin Plc .....................................................................................................................74 Ash Grove Cement ........................................................................................................77 Assmang Limited ...........................................................................................................81 Hydro .............................................................................................................................84
Plastics Illinois Precision .............................................................................................................87 Power BC Hydro .......................................................................................................................90 CM European Power Slovakia S.r.o. ..............................................................................93 China Huaneng Group...................................................................................................96 ESKOM ..........................................................................................................................99 Ontario Power Generation ..........................................................................................102 RK Powergen ...............................................................................................................104 Southern Mississippi Electric Power Association .........................................................107 Tucson Electric Power Company .................................................................................109 Vectren Corporation ....................................................................................................112 Endesa .........................................................................................................................116 Pulp & Paper Weldwood of Canada ..................................................................................................121 Semiconductor Texas Instruments ........................................................................................................124 Transportation Ferrocarrils de la Generalitat de Catalunya .................................................................127 SALT – Società Autostrada Ligure Toscana p. a. .........................................................132 Wuxi Transportation Tunnel System ............................................................................136 Water and Wastewater Southern Nevada Water System..................................................................................140 Video Success Stories ............................................................................................................144
Dear Reader, Welcome to the 2011 collection of Invensys Operations Management Success Stories. I would like to thank our customers, partners and employees who contributed to this most impressive collection of stories that all exemplify: Real Collaboration. Real-Time Results. We believe that only through open collaboration with our customers and partners, can we accelerate progress towards our mutual journey of business optimization. Real collaboration requires innovative solutions that empower teams of people and departments to work together in new and different ways - ways that are more agile and productive, and that facilitate the key areas of Operational Excellence: Assets, Control, Environment & Safety, and most importantly People. Real-Time results is all about achieving measurable business results based on real-time, informed decision-making and orchestrated workflow across our client’s organization, systems and equipment. At Invensys, we see our mission as collaborating with you to deliver the right automation and information solutions that enable the success of the entire range of production workers that impact your production operations. In this collection of success stories, you will discover innovative, but proven examples how people are able to do their jobs more successfully in order to achieve impressive business results. The people we can help empower not only include plant and facility operators, but also their supervisors, managers and executives, along with the IT staff that manages the IT systems infrastructure. We can also positively impact quality, safety management, maintenance and engineering staffs. Over 650,000 licenses of Invensys software solutions are in use in over 125,000 locations in over 180 countries in the world. This is an amazing testimony to the widespread applicability of our open, InFusion Enterprise Control System and the underlying ArchestrA System Platform that is helping to integrate, operate and manage manufacturing, infrastructure and process operations. But the numbers only become truly significant when we enable others to innovate for their personal and business success. That is what this book of success stories is all about. We invite you to challenge us, and to collaborate with Invensys and our partners in order to accelerate our mutual efforts towards achieving Real-Time Success.
Vice President, Global Promotional Marketing & Communications Invensys Operations Management
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” Lucjan Knapczyk.A.pl “Using the latest technology and IT solutions to build a telemetry and monitoring system shows that Azoty Tarnów is a modern company that is concerned about high quality and low production costs. the desire to have a safe workplace and a company that is concerned about the environment.o. New Control and Monitoring System at Azoty Tarnow Increases Plant Production Goals • Increase the production effectiveness. 7 .INDUSTRY: CHEMICAL Azoty Tarnow S. z o. traceability and safety by installing a central control and monitoring system Challenges • Very high maintenance costs (energy. methane consumption) Solutions and Products • Wonderware Historian • Wonderware InTouch® • Wonderware Historian Client • Wonderware Information Server Results • Manufacturing costs has been reduced as a result of the new Monitoring System • Access to key media parameters analysis (quality. www.azoty. Technology Specialist at Automatyka Sp. This is reflected in the competitiveness of our products.tarnow. consumption) in real-time resulted in more efficient manufacturing • Improved information flow (delivering actual data to technology engineers) has been achieved.
8 . The monitoring system also included the main and auxiliary plants: • Power and Water Treatment Plants • Medium and High Voltage Electrical Substations . Wonderware Information Server • Pumping stations for drinking and process water • 3rd party Nitrogen generator from AirLiquide. It involves the use of high energy and extreme pressure and temperature ranges in the production floor. All of which is collected in a central database. • Process air compressor station • Air for control . Data Acquisition Information is collected from a large number of 3rd party manufacturers each of which has its own communications standard. The board of Azoty decided to expand to a plant wide monitoring system because of the positive feedback from these existing solutions. Industrial database . Add to this. Azoty Tarnów uses Wonderware InTouch for the local monitoring and control of its plants. Data recorded by the Wonderware Historian has a sampling rate of 3. control and manage the use of methane and steam in the plant as well as operate the water and wastewater plants. store information in a central database and be able to generate reports on quality and plant consumption. Production and Energy Information System • The following are measured in the new Monitoring System: Electricity Air supply • Process water for heating and drinking • Steam Pressure • Water and Wastewater management • Ammonia usage • Methane usage with the ability to forecast consumption and set purchase limits The monitoring system involves the supply and consumption of raw materials.3 ms. There are also drops of RS485 and Ethernet connections to the field devices and local controllers. This provides a central source for historical data. This is important in case of gas leak emergencies so plant personnel know which way the wind blows during evacuations. This required the creation of a system that will monitor all the plants. o. • Uninterruptible power supplies • All production departments. In many cases.drying stations. the Azoty Tarnów engineers had to create their own device drivers for communication. with the ability to monitor efficiency and compute manufacturing costs. Wonderware Historian. The main communication network is composed of a fiber optic ring with a copper “twisted pair” redundant connection. compressed air station and the liquid CO2 plant. z o. This allowed Azoty to collect information on energy usage.. production and manufacturing of final product. the concern of most companies in the chemical industries on matters of safety and compliance to standards: There is thus a need to make sure that key parameters are monitored and controlled in the plant. Wonderware InTouch®. Wonderware Historian Client.o.Chemicals The chemical industry involves the production of a wide variety of products that are toxic. The installation of the telemetry and monitoring system at Azoty Tarnów has been implemented entirely by the Automatyka Sp. The DCS and PLC are connected directly to the System Platform via standard communication system. flammable or are explosive. Aside from the normal process monitoring the Wonderware solution also gets data from the Weather Stations around the plant. z o. and Azoty Tarnow S.A. This document was realized thanks to the support of: Automatyka Sp. Construction of telemetric network The large plant area required that the network architecture be modular and yet integrated.collection and data archiving Data collected from the automation and measurement equipment is collected and sent to the Wonderware Historian.
Inc.” Jeff Blanchard. which assures accurate batch composition every time.INDUSTRY: CHEMICALS Calzin. material costs. Inc. Calzin.com “The Invensys Foxboro solution measures and maintains a predetermined percent solids ratio based on conductivity. and product quality Solutions and Products • Foxboro Electrodeless and Flow-Through Conductivity Sensors Solutions and Products • Foxboro Electrodeless and Flow-Through Conductivity Sensors Results • Ensured consistent product quality with the ease of use in release agents and additives • Reduced labor and material costs and eliminated human error by automating the mixing • Enhanced customer service and supported market leadership position by implementing the Foxboro solution 9 . www. Foxboro conductivity sensing system ensures consistent product quality while reducing labor and material costs Goals • Automate the mixing process to improve product quality and reduce labor and material costs • Develop an automated mixing system to enable customers to determine the exact proportions Challenges • Determining the exact percent of solids ratio in the solution • Reducing the variations in the mixture and the implications on labor. Vice President.calzin.
Calzin. and they in turn dilute it with water for use as needed.” Seeking to help customers make more effective use of his product.. Calzin ships the calcium stearate to customers as a concentrated dispersion.” says Blanchard.. produces a soaplike slurry release agent that inhibits rubber from sticking to itself when folded and stacked. For instance. he hypothesized that conductivity sensing could deliver that information. rubber production can indeed be a sticky situation. Vice President of Calzin. The sensor measures the conductivity and sends a reading to the analyzer. According to Jeff Blanchard. Recently. material costs. Worse yet. a two percent mixture will result in the rubber sticking to itself and may require rework. As an innovator in its field. Inc. Calzin. Inc. which assures accurate batch composition every time. Blanchard met with Foxboro process measurement experts. the software triggers 10 . and electrodeless conductivity sensor. One of the company’s original products is calcium stearate. has produced a measuring system that enables its customers to determine the exact proportions of calcium stearate concentrate and water for their application. customer technicians adjust the flow of water into the premix concentrate until they feel it has the right consistency. Too much calcium stearate and sheets could slide off of palettes and end up in the scrap pile. A four percent ratio can cause rubber sheets to slide off of pallets and possibly result in scrap. His Internet search for authorities on the subject led him to Foxboro® Measurements & Instruments. From there. One of Calzin’s key products is calcium stearate. Blanchard set out to develop an automated mixing system to remove the guess work and help his customers achieve consistent and repeatable release agent mixes. who demonstrated an electrodeless conductivity system with which he could measure and maintain percent solids ratios with high accuracy. Through what has largely been trial and error. which when mixed with water. the excess can become airborne resulting in sever dust problems that endanger workers. “This is far from an exact science. There’s a fine line between hitting and missing the proper ratio. Calzin has developed an innovative concentrate mixing system that ensures the proper mixing of calcium stearate based on conductivity sensing to determine percent solids ratios. U. Too little calcium stearate powder.Chemicals Hampshire.. Foxboro Electrodeless and Flow-Through Conductivity Sensors Demanding Applications Without a properly mixed anti-tack additive.S. creating costly rework to bring them back into spec. Despite the fact that variations in the mixture have tremendous implications for labor. and product quality. The Foxboro system consists of a conductivity analyzer with a tailored custom curve set. is an international supplier of coatings for the rubber industry. rubber producers have had to rely on human judgment to determine which mix was optimal for their production. if your target is a mixture of three percent solids. which is used as an anti-stick agent that keeps rubber from sticking to itself when folded and stacked. the main ingredient of the liquid additive. “The Foxboro solution measures and maintains a predetermined percent solids ratio based on conductivity. and rubber sheets could adhere to each other. Leading Edge Technology Solution After preliminary discussions about his application. however. Figuring that determining the exact percent of solids ratio in the solution would provide a much more accurate and consistent solution.A – Founded in 1952. Inc.
” they add. Foxboro Electrodeless and Flow-Through Conductivity Sensors Expectations Exceeded By automating the release agent mixing process.” This document was realized thanks to the support of: Calzin. Our system totally eliminates the ‘toomany-cooks’ problem through automation. but our solution definitely makes the path better for our customers. Invensys was always there to help. 11 . “The key was converting conductivity measurements into discernable information that technicians could understand. “I was impressed with their availability and level of technical expertise. But Invensys supplied a complete solution. “Conductivity is not the easiest thing to work with.” says Blanchard. Through trial and error I developed a percent ratio chart as a guide for determining percent solids at different temperatures. If I had a question. It can be very temperamental. “We didn’t invent migration. Looking to the BASF philosophy. including technical support that made it possible. “The most significant benefit for our customers is ease of use of our agents. which control a series of valves and pumps that supply the Calzin concentrate and water in proportion to maintain a predetermined target conductivity setting. while assisting customers in reducing labor and material costs. and how to work the data for programming the software. “They love it because we give them a quality concentrate and the capability to automate mixing specifically for their applications. Invensys definitely has educated and talented people. which also reduces waste.” says Blanchard.” says Blanchard. “We don’t make the products. The automated system also reduces labor and material costs for Calzin customers. Calzin has improved the use of its additives. Inc.Chemicals alarms when conductivity setpoints are reached. The Foxboro-based system enables us to better serve our customers and gives us a competitive edge in the market place. “In some cases there have been as many as six people checking and adding to the release agent mixtures.” Invensys provided technical support to decipher the analyzer’s codes and showed Blanchard where and how to link his equipment to the analyzer. says Blanchard. It eliminates human error while enabling customers to use just the right amount of concentrate. we make them better. Matching the Right Partner to the Project Finding the best-suited solution along with a The Invensys team hopes to be a part of ongoing BASF projects.
deltabiofuels. Inc. making it one of the largest biodiesel plants in the country • Using Foxboro FT10.000-gallon reactors and controls the delicate separation process through accurate conductivity measurements • By implementing a reliable and accurate process automation system. Delta BioFuels achieved the production goals of its four 20. Delta BioFuels has been able to eliminate human error and enhance overall product quality 12 .” Scott Nisula.INDUSTRY: CHEMICALS Delta BioFuels. A conductivity measurement system is relatively inexpensive. Chief Technical Officer. Inc. but conductivity sensing is really ideal for this application. Delta BioFuels brought in Invensys to discuss its Foxboro products and we decided these were the solutions we needed. very clean. Delta BioFuels. Foxboro Conductivity Sensing Sparks Automated.com “There are a number of ways to detect phase changes. www. Efficient Biodiesel Fuel Processing Goals • BioFuels required technology that would improve the delicate process of separating by products from the final product at various stages • Improve technology that would enable frequent and accurate monitoring without interrupting production or jeopardizing worker safety Challenges • A solution was required to ensure that the production process of Delta BioFuel’s biodiesel would not be interrupted during the fuel separation process • Sustainable alternative energy sources demands an immediate technology solution that would produce a very pure biodiesel product quickly and efficiently Solutions and Products • Foxboro FT10 Noninvasive. Nonmetallic. and maintenance free. Electrodeless Flow-Through Conductivity Sensor Results • The Foxboro FT10 enables Delta BioFuels to produce between 80-100 million gallons of biodiesel per year.
Electrodeless Flow-Through Conductivity Sensor producer of biodiesel fuel. primarily soybean oil. making it one of the largest biodiesel plants in the country. is a leading private alternative energy company dedicated to producing only the highest-quality biodiesel. including the production of biofuels. called transesterification. However. Delta BioFuels can then easily distribute its final biodiesel products by barge. the company selected Foxboro technology to monitor the delicate biodiesel production process.” Leading-Edge Technology Solution Based on more than 20 years of petroleum and refinery experience. The Delta Biodiesel plant has four 20. The process. Located directly on the Mississippi River. rail or truck. electrodeless flow-through conductivity sensor enables Delta BioFuels to monitor the critical ongoing viability and purity of biodiesel during production process.” said Scott Nisula. “When emptying the reactors we need to know exactly where the interface is between the biodiesel and byproducts. Delta BioFuels. Nonmetallic. nonmetallic. If we pour out biodiesel. we won’t meet product quality standards and have to reprocess the material. Biodiesel production process is done through a chemical reaction that combines vegetable oil or animal fat as a raw stock. “Effective separation is critical to the success of our process and the quality of our product. Delta BioFuels selected the Foxboro FT10 sensor as the preferred instrument for measuring conductivity. If we leave byproducts in the fuel. To complement its state-of-the-art production facility. Chief Technical Officer at Delta BioFuels. The company has achieved best-in-class operations with state-of-the-art equipment coupled with a highly experienced management and technical staff. Mississippi – Little did the scientists in the mid-1800s know that their pioneering work in developing biofuels and diesel engines using vegetable and peanut oils would serve as the foundation for today’s efforts to combat the world’s growing energy demands. Using the Foxboro noninvasive. Biofuel products are made from a variety of feedstocks. positioning the company to serve any market on a global scale. which we take very seriously. these 19th century researchers paved the way for the options that we enjoy today to help balance the need for additional energy resources with choices that are sustainable and reduce the impact on the fragile global environment. Inc. producing biodiesel fuel is a difficult task that requires precise separation at various stages. Delta BioFuels overcame this “separation” anxiety by applying conductivity sensing technology. as well as large field storage tanks used in the delicate separation process. involves chemically converting triglycerides to smaller methyl esters that resemble diesel fuel with extra oxygen atoms that make it oxygenated diesel fuel enabling it to burn cleaner.” said Nisula. meeting or exceeding all industry standards. but conductivity sensing is really ideal for this application. methanol and a catalyst of sodium methylate in proper proportions. “A conductivity Demanding Flow Rates Biodiesel is a safe alternative fuel replacement for traditional petroleum diesel. By spearheading alternatives to fossil fuels. “There are a number of ways to detect phase changes. Congress significantly changed the nation’s energy strategies by providing tax incentives and loan guarantees for energy production of various types. we’re throwing money down the drain. the company’s 60-acre facility can receive its soybean and vegetable oil feedstocks quickly and directly at the production facility. The Delta BioFuels facility has the capacity to produce between 80-100 million gallons per year.S. vegetable oil and animal fat derivatives. Foxboro FT10 Noninvasive. As an innovative 13 .000-gallon reactors and approximately 15 process vessels of various sizes.Chemicals Natchez. The Energy Policy Act of 2005 passed by the U.
reduced material and maintenance costs. Electrodeless Flow-Through Conductivity Sensor Expectations Exceeded Delta BioFuels’ innovative application of Foxboro conductivity sensing technology has resulted in improved production efficiency.000 to 5. The Foxboro probe monitors the conductivity of the fluid passing by and. At this stage. The second application involves removing these components from the biodiesel fuel before it can be released as a final product. glycerin. 14 . and most importantly. Nonmetallic. albeit more than 150 years later. automated phase detection also eliminates loss of valuable biodiesel that might otherwise be disposed of with byproducts.” The early developers of biodiesel fuel probably would be pleased with the evolution of their pioneering chemical experiments and today’s implementation of biofuel technology. At that point what remains is finished biodiesel fuel. “Conductivity sensing technology has proven to be the cornerstone of successfully automating our critical phase separation process. the company needs to separate glycerin.” said Nisula. the interface between end-product biodiesel and waste byproducts is accurately and consistently detected to ensure product quality.” Delta BioFuels is using the Foxboro conductivity probes in three applications. Because wash water has a high conductivity of about 2. Accurate. it immediately detects a dramatic drop in conductivity because the methyl ester phase has a conductivity of less than 20 microsiemen/cm. Inc. approximately 4.500 microsiemen/cm. the biodiesel goes to the final phase where a vacuum dehydrator warms the wet biodiesel and draws out any residual water. The conductivity sensor then triggers a signal to stop the pump and close the valve. This document was realized thanks to the support of: Delta BioFuels. Now. very clean and maintenance free. since there are no moving parts. The remainder of what is in the reactor is methyl ester that contains contaminants including excess methanol. which will further improve production efficiencies and consistent product quality. The initial application is in a batch plant mode where the company has a pump on the bottom of the reactor. catalyst and other impurities. The ongoing development of biofuels as a viable alternative energy source will surely play an important role as the world transitions from its dependence on petroleum to cleaner. as the interface occurs. and then the water is allowed to settle to the bottom of the reactor. The crude biodiesel is mixed with water to scrub out the impurities. “This will promote additional and ongoing process improvements such as automated. I brought Invensys in when discussing the process and the company provided the solution we needed. Directly downstream of that pump is a “T” configuration that houses the Foxboro conductivity sensor. which has a relatively high conductivity. In this third application the Foxboro conductivity sensing probe is used to determine when the appropriate amount of water is removed.000 microsiemen/cm. the Foxboro sensors can immediately detect the interface between methyl ester and wash water. ensured product quality. After the washing. continuous processing. Delta BioFuels has eliminated the possibility of human error. Foxboro FT10 Noninvasive. By automating the phase separation process through Foxboro conductivity sensing technology. soaps.Chemicals measurement system is relatively inexpensive. sustainable energy options.
000 metric tons produced every year • Dialogue facilitated between the formulator and the “machine” technicians using the same man-machine interface 15 . Vincent Duthoit. Wonderware’s InBatch gives us the open technical standard. As for Wonderware. which has a weak culture in automated operations and industrial data processing • Develop a solution that makes it possible to apply the same formulation on different production lines Solutions and Products • ArchestrA System Platform • Wonderware InBatch™ • Wonderware InTouch® • Wonderware Historian Results • Fewer variations in the quality of the greases produced • Production facilities optimized with 16. without using the integrator Challenges • Adapt to the constraints of the company.fr “We have a huge project to automate our 10 batch production lines for lubricating greases. it provides us solid guarantees that it will be able to adapt to information technology developments over time. Imperator’s Manufacturing Manager InBatch optimises the production of lubricating greases Goals • Automate the batch production lines for lubricating greases in order to limit the influence of human factors • Obtain improved regularity in the quality of the grease produced • Increase the production facilities’ efficiency and avoid losses of production lots • Develop a tool that enables Imperator personnel to develop and execute themselves their new formulations. that we were looking for. in compliance with standard S88.imperator.INDUSTRY: CHEMICALS Imperator www.
all while being very precise with the dosage. Consequently. boxes and cartridges) and the quantities to deliver vary substantially from one customer to the next. ArchestrA System Platform. Imperator has to optimize its production resources and cannot afford to lose a production lot due to the unexpected absence of an operator or an error in the execution of the formulation. a recognized and open standard When it came to choosing the technical solution. Like everywhere else. with trained operators who have mastered the process. without requiring the help of the integrator. “The specifications were functional and didn’t impose a technical solution. Imperator is not known to the general public. But the world is changing. small casks. pails. barrels. We wanted an open and upgradeable solution based on a standard software program that met the S88 standard and that let us modify or implement our formulations ourselves. there is an average of 10 ingredients per formula). Like kitchen recipes. 260 formulas According to the definition of the NLGI (National Lubricating Grease Institute). possible errors) and obtain regular production quality. It had participated in a huge study carried out by its parent company (a major industrial group specializing in hydrocarbons and lubricants) to standardize the batch solutions at its different sites. In spite of its leadership position in Europe. the production was done exclusively under the “manual” control of operators. it is in large part thanks to the quality of its employees that Imperator has been able to establish itself. We also wanted flexibility in the execution of formulations. Wonderware Historian the sequence of operations. These are the reasons why Vincent Duthoit decided to automate his production lines in order to obtain increased regularity in production through an improved repeatability of operations. without having to reformulate them when we went from one production line to another. The parent company was also called on to develop the specifications. The company has just entered an important new phase: “We are progressively upgrading and equipping our production lines (at the rate of one line per year) with Wonderware InBatch software. Imperator has 10 production lines. Imperator has 300 active customers around the world. grease is a “solid to semi-fluid product resulting from the dispersion of a gelling agent in a lubricating liquid (oil). with mixtures of components in a cooker. Imperator didn’t start from scratch. and addition of various ingredients at well-defined moments. Until very recently. the production lines operated in manual mode. S88. followed by customers from the iron and steel industry and then in no particular order the nuclear. At Imperator. Other ingredients can be included to provide special properties.Chemicals Baisieux (France) – Created in the 30s.” sums up Bertrand Guille.” Thus it is possible to create specialized greases based on the application. Imperator had also defined a few criteria that the software editor and the integrator had to satisfy. aeronautics. there is increased personnel mobility and it is hard to find specialists. Imperator’s Manufacturing Manager in Baisieux . all assigned to lotbased production. Wonderware InBatch™ Wonderware InTouch®. these products are offered in some 20 types of packaging (bulk tank or container. heating and cooling operations. To further complicate the process. based on 300 base components (in practice. the operator relies on descriptive documents. this resulted in the implementation of 260 different formulas. In light of 300 basic components. the temperature ramp time and 16 . The reason is quite simple: the greases it manufactures are sold under what is called “private brands” Under the name of the company that markets them (major oil companies in particular). Since it involved a long-term commitment. Imperator began producing lubricating greases in 1950. These eliminated de facto in-house software solutions. Since then it has become one of the leaders in this field in Europe.000 metric tons produced every year. irrespective of the circumstances. Automobiles form the first customer segment. public works and related industries. To meet this complex and diversified demand. with more than 16. Until recently. Here as elsewhere. The objective is to reduce the influence of human factors (absences. manager of new automation work. The process is somewhat similar to kitchen recipes.” explains Vincent Duthoit.
This document was realized thanks to the support of: Imperator and Wonderware France Single formulations. the choice of integrator was obvious. the highest level of certification issued by Wonderware. Technord. When one knows the history of the plant’s automation under manual control. activating the heat. to be more flexible in assigning them to the different production lines and in the end. with the assurance of having completely perfected applications. In terms of supervision and batches.) and their sequence have to be described before they are transcribed in PLC language. is one of the best system integrators that specialize in Wonderware products. etc. the operators are freed from numerous tasks and they see to it that the sequences are done correctly (otherwise InBatch forbids certain operations). “The description of the phases and their sequencing (operations in series or in parallel) are done easily using a logical diagram (Graphics).It isn’t necessary to store mountains of reports anymore. but thanks to InBatch and InTouch. Wonderware InBatch™ Wonderware InTouch®. it provided guarantees in terms of life expectancy and services and clearly demonstrated its ability to upgrade its software based on computer standards (especially on the arrival of new operating systems). Wonderware’s InBatch was the obvious choice. You just have to do a query and Historian will search for the useful data and immediately create the requested report. In order to see clearly what happens when the recipe is executed. Imperator’s formulators write or modify the recipe for the grease they want to produce. We don’t disperse ourselves at all. Furthermore. technical services total autonomy. Three InTouch stations provide the operator interface (one for the formulations and two for the operators on the line). there is a PLC (Schneider’s Premium TSX57) and an InBatch/ Historian server with redundancy. things were made very simple. Here. agitator. we focus all of our energy on Wonderware’s product line. recipe execution using the equipment in the elementary phases (opening a valve. irrespective of the production equipment In practical terms. Wonderware Historian all of these parameters.” explains Bertrand Guille. using InBatch. Only some 20 companies can claim such a level around the world. The formulators and the operators use the same explicit displays thereby avoiding misunderstanding. providing Imperator’s 17 . Here again. Another advantage is that several integrators are capable of implementing the Wonderware products. this graphics can be understood just as well by operators without computer experience. one can measure Imperator’s progress brought about by the Wonderware software. Sales Manager at Technord.” contends Rémy Sagot. which when it comes down to it is our basic roles. Our customers are the first to benefit from this expertise. The recipes can be transferred to any production line (as they are all equipped with the Wonderware software). Some ingredient loading operations remain manual. The transcription in PLC language is done automatically. An important point in the choice of InBatch is its ability to adapt to all process sizes. It is easy to find the cause of problems and to do a post-analysis using the data gathered from the Historian. “We are an “Endorsed” certified partner.Chemicals ArchestrA System Platform. We don’t have to intervene on the PLC program that Technord developed for us. We concentrate on formulating the formulation and executing it. In terms of the architecture: For each line. the operators on the line have an InTouch screen with the graphics of the operations sequence with all of the useful information. including small ones (Imperator’s production lines include approximately 150 inputs/outputs). to be much more composed. in addition to being close to Imperator. According to the S88 standard. As for Wonderware. These programs have made it possible for the company to do a much better job of supervising its operators’ work.
That is not more than we would have needed if we had chosen to connect only 10 sensors to our DCS.’ Wouter Verheyden.INDUSTRY: HYDROCARBON PROCESSING Borealis Group www. innovative provider of plastics solutions based on polyethylene (PE) and polypropylene Goal: • Create an automation system that will reduce risk.borealisgroup.000 euro in total. reliability team leader at Borealis Borealis: Leading. we will have earned enough to repay the investment. lower production costs and address all environment and sustainability goals Challenges: • Be able to check static equipment such as piping and pressure vessels Be able to evaluate the functioning of safety systems designed to prevent damage to man and/or the environment Solutions & Products: • Wonderware IntelaTrac • ArchestrA System Platform Results: • An optimal safety systems was completed with less cost that inventing in traditional sensors • Preventive maintenance are scheduled effectively 18 .com “The implementation of the IntelaTracsystem cost less than 100. If the new system will prevent a standstill of only one day of our factory.
Therefore.’ The improvement projects resemble a Six Sigma implementation. This means that critical parts. in which all the preventive maintenance activities are recorded. Anticipating all possible problems is of course not achievable. and prevent and/ or reduce the seriousness of failures. to we are able to speak the same language in every plant. are inspected frequently 3. Evaluate the functioning of safety systems designed to prevent damage to man and/or the environment.’ Changes in the way equipment is maintained are never carried through without an evaluation.’ Wonderware IntelaTrac Archestra System Platform risks for man and environment are of course also evaluated. during which we – together with people from production – investigate if there are possible new risks. Borealis also produces base chemicals like phenol. For example. 2. Using a unique Borstar®-technology. we always form a multidisciplinary team. and permeable packing materials. when a failure occurs. regularly evaluates that schedule. That team will investigate what the root cause was.Borealis uses IP21 of Aspentech – with data originating from Pro-active strategy As part of this pro-active strategy for maintenance and safety. This is called the “Borealis Way”. it produces tailor-made polyethylene and polypropylene pellets. the Safety Integrity Level method is applied. mitigating financial risks often comes first. The focus is on being pro-active. implement and review. which is used by its customers in the production of car bumpers. focus is again on the prevention of problems with the most severe effects. when an unexpected standstill of a plant lasts longer than a day. Another alternative is called predictive care: that is maintenance carried out at the moment the equipment failure threatens to occur. Reliability Centered Maintenance or RCM. cable coverings. An example is an unwanted side-effect of using a new type of lubricant’. because the approach was developed and tailored within and for the company. To execute RCM we developed a matrix. In this case. analyze. Predictive maintenance Planned care is not the only form of preventive maintenance. ‘Like in the two other approaches. the following approaches are combined: 1. ‘The third pro-active method. That is the central idea’. and the project phases are called define. of which failure would have severe consequences. and will try to implement effective countermeasures. we mainly use for rotating equipment’. solve. ‘But. To check static equipment such as piping and pressure vessels. Risk Based Inspection. Risk Based Maintenance Risk Based Maintenance aims to reduce risks in the plant as far as possible. the more preventive measures we take. says Verheyden reliabity team leader at Borealis. analyzing these data it could turn out that carrying out preventive maintenance on a certain redundant pump is more expensive than simply waiting until a failure happens. To trace these situations. the data-historian is an important source of information. if possible you want to prevent that the same problem happens again in the future. but 19 . Besides that. In this database . produces polyethylene and polypropylene products. In that matrix. ‘Our Reliability Task Force. according to Verheyden. Borealis uses historical data from SAP. we systematically map the risk and consequences of possible failure modes.Hydrocarbon Processing Borealis. To do that. ‘The bigger the risk. acetone and melamine. explains Verheyden.’ Management of change The three pro-active strategies are used together to optimize the preventive maintenance planning. ‘We have a management of change process.
That is important information. ‘An added advantage is that operators detect more than all the sensors put together! They are our eyes and ears in the field. ‘On the handhelds runs Wonderware IntelaTrac.’ This document was realized thanks to the support of: Wonderware Benelux and Borealis Group Eyes and ears ‘Therefore we prefer that our operators collect the missing data. The operator will get appropriate recommendations to map the problem in more detail. nor had he or she enough time to enter the data in Excel to perform a trend analysis. during their inspection rounds’. However. and from there to our data historian. but also for the process. However. only the pressure is transmitted to the DCS.000 euro in total. it all becomes pointless.’ The implementation of the IntelaTrac-system costs less than 100. ODR also includes decision support. because vibrations for example turn out to be the root cause of 25% of the machine failures. vibrations and leakages. an effective solution was found. ‘IntelaTrac supports the workflow during the data collection process. On the one hand this is used to verify if certain tasks are completed. ‘That brings along the advantage of realtime measurements. In that case. This makes it possible to determine if for example temperatures or pressures have a tendency to change. When that temperature is for example not within the permitted domain. However. When an operator finishes an 20 . . an operator can make a maintenance order in SAP. or when there is a large difference with the previous reading. but it is an expensive solution. Verheyden continues. The model they use is suited for application in ATEX zone 1. Operators now collect data with three Bartec mobile handheld computers. and to solve it immediately if possible. even from the office. ‘Take for example a compressor’. If the new system will prevent a standstill of only one day of our factory. In addition. Therefore you have to find ways to bring the other data in. there is a problem: No less than 40 to 60% of all measurements are not automatically written to the data historian. rainy weather conditions sometimes made the papers illegible. we create a feeling of ownership and responsibility’ Collecting data is however only half of the solution. ‘We use that name not only for the tools. ‘The handheld mobile computers support barcode scanning. because it is not only about doing measurements. we will have earned enough to repay the investment. that person not always took the appropriate action. or calling in help. In addition. an alarm is given.’ Operator Driven Reliability IntelaTrac was programmed for a number of fixed inspection rounds. everyone can access the information collected in the field with a web browser.’ The collection of maintenance related data by the operators is called Operator Driven Reliability (ODR). operators used paper checklists which they filled in and handed over to their shift supervisor. After that. ‘Until recently. or if the information does not find its way to the right persons. an operator immediately receives feedback if something might be wrong. In addition. explains Verheyden.’ Wonderware IntelaTrac ArchestrA System Platform inspection round. he or she will scan an equipment barcode label to resume inspection.’ Theoretically. ‘That is not more than we would have needed if we had chosen to connect only 10 sensors to our DCS.Hydrocarbon Processing the Distributed Control System (DCS). As a result. the handheld computer indicates what should be measured. he or she places the handheld back into a docking station. If it is not done in a consistent way. the data are automatically uploaded to an IntelaTrac server. ‘Such a machine comes with trimmings like the measurement of the oil temperature. ‘And after for example entering an oil temperature. explains Verheyden. by involving our operators in the maintenance process. all sensors could be connected with the DCS. on the other hand scanning a barcode makes it possible that an operator interrupts an inspection round. There are process variable that they notices like abnormal sounds. The suggestions can vary from adding oil to checking a valve position.’ Wonderware IntelaTrac One year ago. That is convenient because sometimes an operator is called away to solve an urgent problem.’ During an inspection round.
can offer a 20-year warranty on the productivity of a photovoltaic plant Goals • Ensure excellent quality in the production of photovoltaic panels • Real-time action on deviations and negative trends in production Challenges • Constant and accurate control of environmental parameters in photovoltaic panel production areas • Traceability across the manufacturing process • Integration of plant automation systems with enterprise management system (ERP) • Diversified access to manufacturing information at different levels of the organization Wonderware Solutions • ArchestrA System Platform Results • Monitoring of real plant performance to eliminate possible inefficiencies • Reduction of manufacturing waste 21 .merimp.A.” Giovanni Raffa Business Development Manager. www.p.A. With the deployment of ArchestrA System Platform and accurate engineering. Meridionale Impianti S.com “Through the extensive monitoring of manufacturing stages.A. we have significantly reduced wastes that have a negative impact on efficiency and production costs.INDUSTRY: DISCRETE MANUFACTURING Meridionale Impianti S. Meridionale Impianti S.p.p.
“We decided to trace the entire production process . Italy . we started to search the market for a solution that could be quickly customized to our specific requirements. check them against available stocks and provide information about current activities. Raffa has decided to test and certify each component of each panel. Strongly expanding markets are typically addressed by companies that exclusively try to exploit a favorable trend.are assembled under ideal conditions. preventing all contamination risks and obtaining panels with consistently high production efficiency rates. They hardly care about quality and try to maximize their short-term profits. within a range of few kilometers. photovoltaic cells . has been developing its expertise in industrial plants across 30 years. are the result of experience acquired by Meridionale Impianti engineers in hundreds of industrial installations. with no impact on the work of plant staff. pursuing this goal with traditional methods was difficult. The company has entered the photovoltaic panel production business with a truly unconventional approach: bet on the quality of production. a multinational company with manufacturing sites in Sicily. Business Development Manager – we provide customers with a legally binding certification. “To meet these requirements – Orlando continues – we have discarded the idea of developing a software platform ourselves. we must exclusively deliver panels complying with the highest quality standards.Meridionale Impianti.” The system also had to dialog with the ERP system to receive production orders. however. In photovoltaic panel production. In this territory. Furthermore. Meridionale Impianti is among the few companies that execute production in an environment with constantly monitored temperature and air quality. ArchestrA System Platform Perfect control The perfect control of environmental parameters. Scada systems manager . because manual measurements are both slow and arbitrary. and some of them just distribute modules manufactured by others.in order to identify and handle possible causes that may affect the optimal quality of our modules. For this reason.” This requirement cannot be always satisfied with standard solutions from trade. no manufacturing operations can guarantee results that are always ideal. while providing all people involved in the production and management process with extensive information about current and past activities. And to make sure we meet such warranty.says Vincenzo Orlando. over 60 high-tech companies have been established and you can easily find skilled staff in the production of electronic components. Hence the need to find a software platform to automate these activities in an effective and reliable way. in the Etna Valley near Catania. the past few years have seen the rise of a number of Italian and international manufacturers often lacking specific experience. in order to achieve a consistent improvement of production. Meridionale Impianti has decided to invest in high-level expertise and technology to create an offer distinguished by excellent quality. we would have had to check possible bugs. So. Meridionale Impianti decided to leverage its expertise in high-tech plants to produce panels and systems internally. whereby we declare the production capacity of a solar field built with our technology over the next twenty years. who can work inside low-contamination areas and clean rooms. 22 MES screenshot: plant layout . the impossibility to correct possible issues. Despite the most innovative production and automation technology. This means we subscribe a ROI warranty for the customer. So.” However. In this way. To do this.explains Giovanni Raffa. Meridionale Impianti installed new manufacturing facilities in Sicily. acting promptly in case of deviations or negative trends.manufactured to Meridionale Impianti’s Intellectual Property specifications by semiconductor specialists . On the contrary. with the consequent risk of slowing down production or. as it would have taken too much time to write the code.Discrete Manufacturing Catania. in some cases. as well as the optimal management of staff operations. We make our own panels “In a business where nothing is taken for granted . growing into an organization with over 600 employees and 120 million Euro revenues.
ArchestrA System Platform MES screenshot: inventory All the benefits of Mes Using a Mes system as offered by Wonderware. Orlando underlines. support offered by the historical track of all data within the System Platform becomes critical. partnering with Meridionale Impianti for over a decade in the development of Scada systems based on reliable platforms. Simplifying complexity Using Wonderware System Platform to record.” Despite strong attention to quality. Therefore. “Just think that photovoltaic cells represent approximately 70% of the cost of a panel . identifying the possible causes of detected problems and the corresponding production batches. enables the use of information according to the specific requirements of each user. Besides affecting a line’s productivity. “This is also due to the fact that MES is still relatively uncommon in Italy – Orlando continues . The system allows to trace back across the entire production process. process and automatically store all production data. you can no longer perform any action on a panel’s internal components. Also for this reason.” The solution adopted by Meridionale Impianti offers all industrial automation software applications on one single platform: from Scada to Hmi.Raffa explains –. This situation is even more critical if you consider that. but still it is essential to trace back to the roots of the problem. If you have to discard an entire module because one cell is contaminated or damaged.and consequently. All of this was combined with a range of specific training courses for System Platform. after lamination. who can access the system from any location. Furthermore. potential partners turned out to be incompetent. in terms of supply and service. Orlando states: “We have always received direct support. they could reduce waste dramatically. through the automatic collection of all production information. “In this case – Raffa explains – we replace the panel. “we have leveraged the graphical features of the system to create an easy-to-read interface that can generate impact charts to provide an intuitive view of all parameters required for the daily work of plant operators. On the contrary. presented a professional and collaborative approach. and the customer was able to customize. especially during the most critical project stages. lacking the required technical support and demanding very high prices”. taking actions to remove inefficiencies and situations that might affect quality. as designers must interact with operators and understand exactly 23 MES screenshot: work order . These solutions were pre-packaged.Discrete Manufacturing Searching for excellence Even international vendors operating in the Italian market had no effective solution to Meridionale Impianti’s needs. any non-conformity detected during the final quality test results into the elimination of the entire module. the Meridionale Impianti management has been able to measure the real performance of their manufacturing lines.” It is not easy to develop an HMI suitable for the needs of plant staff. the economic impact is significant. Orlando explains. Individual managers at each level can access the same database for more detailed and specific analysis. some noncompliance might still emerge over time. The first impression was then corroborated by facts. For this reason. Wonderware. test and deploy them in just two months. waste has significant economic impact. including supervisory systems and Mes/Emi.
as we keep track of all components picked from the line. We need to act promptly in all situations of abnormal conditions. which require a direct action by skilled staff. our operators are encouraged to perform periodical operations on semifinished parts. we monitor and check the entire production.Discrete Manufacturing how they act and respond to each event. After this activity had been completed. but we also have to keep track of all manipulations. With this operating mode based on total monitoring. “Our production standards – states Raffa – are very high and.A. Being committed to high-quality production. 24 .” ArchestrA System Platform This document was realized thanks to the support of: Meridionale Impianti S. the operating modes to be complied with by each user were defined and standardized. but it is the best solution to optimize the production cycle management. for this reason. leveraging the platform flexibility. we have dramatically reduced waste. both on raw materials and at the end of the manufacturing cycle and during the process. In addition. which not only has a negative impact on productivity.p. but also represents a significant cost in a production process based on expensive photovoltaic cells. Meridionale Impianti technicians often have to pick some panels in order to execute specific operations or customizations. This approach may seem constraining.
INDUSTRY: FACILITIES MANAGEMENT Université de Strasbourg www. Solutions and Products • ArchestrA System Platform • InTouch® for Terminal Server • Wonderware Historian • Historian Client Server Results • Simplified creation of the supervisory system based on the asset data management program • Better visibility and control of installations based on centralized technical data • A functional library and standard graphic created for all of the equipments being controlled • Implementation of a technical software platform capable of meeting future needs 25 . “The originality of this application lies in the automatic transfer of the information entered in an asset data management program to the ArchestrA System Platform. Manager of the Energy Department ArchestrA System Platform provides the building management system for the Université de Strasbourg Goals • Development of a centralized building automation system interacting with heterogeneous equipment • Easily access equipment’s technical data entered in an asset data management program • Exchange data with other application software simply Challenges • The standards for the supervisory application needed to be defined • Importing of the ArchestrA System Platform directory structure for the installations and equipments identified in the asset data management program needs to be executed without any losses.” Damien Bertrand.fr “We chose the ArchestrA System Platform to provide a building management system for the equipment in our 140 buildings.unistra.
“Beyond its site location and the extent of the zone covered. The ArchestrA System Platform automatically obtains this information. Schiltigheim Cronenbourg. compressed air and other technical fluids) : “When a new piece of equipment enters the University.). based on the ArchestrA System Platform. Selestat. Consequently. we begin by assigning it a name and attributes in Abyla. we began by imposing a standard programming software for all of our automatic operations. Definition of need and responses to the specifications Thereafter. in most cases with very detailed arguments. InTouch® for Terminal Server Wonderware Historian. each had its own standards and practices. the Energy Department’s task looked daunting. No re-entry is required. this involved finding a way for us to “appropriate” these facilities. Initially. In practical terms.” These controllers were also selected for their ability to handle natively the Ethernet and IP protocols that the Energy Department had chosen to communicate with its future CMS. this involves making sure that the facilities run smoothly.” explains Damien Bertrand. It specified the information systems architecture. “Of course the controllers for the automatic operations had to be programmable with this software. the maintenance contracts and the commission reports. and with a multitude of suppliers and subcontractors involved.” explains Sébsastien Bahls. the specialised CMS programs. chairs. computers. The Université de Strasbourg also wanted the integrators to make a technical proposal with a maximum degree of independence vis-à-vis their software suppliers. Abyla also manages the technical documents like the asbestos files. To do this. to control their operation. pumps. fans. More generally. the calculations of legal floor areas. Manager of the Energy Department (electricity. France – Its wrought iron gate and its architectural style evoke the private mansions or executive homes of the 19th century’s great industrialists and land owners: it is in this “unlikely” setting that the Université de Strasbourg houses its all new centralised building management system (CMS/BMS). “For the communications. with the task of maintaining the heating. the data structure and how to handle modifications. But it can’t process the technical data reported by the PLC controllers (especially the values provided by the sensors) and it is not suited to real time requirements. The Energy Department was created at this time. The bidding process stretched over a year. thereby ensuring all occupants are comfortable and that continuous service is provided for certain critical facilities (especially for the laboratory animal houses).” continues Damien Bertrand. but there was something more urgent to do. etc. It also specified that the different pieces of equipment to supervise had to first be entered in Abyla. Manager of the Asset Information Department.). we wanted a simple solution and to avoid the multiplication of gateways. etc. “We were impressed by Everything begins with the homogenization of equipment Abyla’s beginnings at the Université de Strasbourg go back to 2004. radiators. were also excluded due to their lack of openness.The project will progressively take charge of the operating equipment for 600.). including the technical equipment (PLC controllers. in this case CoDeSys by 3S-Smart Software Solutions. ArchestrA System Platform. Abyla lists a million entities and draws up an exhaustive inventory of all the premises (walls. Add to the fact that each University site operated with total independence.Facilities Management Strasbourg. electricity and special fluids treatment facilities. “The idea of implementing a Centralised Management System (CMS) became obvious to us quickly. which led us to choose the Wago and Beckhoff solutions. the asset data management program developed by the French company LABEO (based in Toulouse). of net habitable floor area in the University premises. with 10 integrators responding. Guebwiller. divided amongst 140 buildings spread over 60 miles in Strasbourg and other top places in Alsace (Colmar. etc. etc. The specifications submitted to integrators were very explicit. and until then. the way was clear for a standard supervision program. Haguenau. windows and floor coverings) and everything they contain (tables. Historian Client Server When it was created. often proposed by equipment manufacturers. doors. given the size of the stock of heterogeneous equipment. The ArchestrA System Platform won the bidding process. it required that they propose two solutions based on two different programs.000 m2. HVAC. the communication protocols. This criterion led us to eliminate a functionally attractive CMS program that was nevertheless too closed. the application of CMS stands out because of its close links to the University’s asset data management program.” explains Damien Bertrand. 26 .
a premise or an existing piece of equipment (e. The implementation is done in steps: 3.000 additional points will be added soon.” concludes Damien Bertrand. room). its precise physical location or the name of the company in charge of its maintenance).” Thanks to the ArchestrA System Platform.000 points were installed in the first phase and 3.g. The basic supervision application (i. An easy integration between the ArchestrA System Platform and Abyla This interconnection between Abyla and the ArchestrA System Platform is quite obvious when one looks at how the two applications are presented: one finds in them the same tree structure. We initially used the automatically edited reports to raise building operators’ awareness about their consumptions and their change over time. the Wonderware operators often have to work with Abyla both to identify new equipment and to obtain additional information on a building. Other functionalities of the ArchestrA System Platform were especially appreciated at the time of choosing the CMS program. “We are interested in the energy efficiency of facilities. the Energy Department is already prepared to confront new requests.Facilities Management ArchestrA System Platform. Not less than 5 lightweight workstations are connected to these servers. Prog’Time (hourly programming server) and Alert (monitoring of critical alarms and sending SMS and telephone messages to operators on call). thereby providing substantial availability for the application. especially the IP addresses with the PLCs). This helps them do a better job of controlling their expenditures and everything leads us to believe that tomorrow they will be proactive.e. This uniformity is a great advantage.. We have seen that up to now the Université de Strasbourg’s Energy Department has endeavored “to appropriate” the existing technical facilities and control them The ArchestrA System Platform fulfils an essential role at this level. floor. which is presented in the same way (zone. the control of automatic operations) is hosted on two redundant servers. Wonderware contacted the Abyla editor (LABEO) to develop a file conversion solution so data entered in Abyla could be imported in ArchestrA System Platform. A third server hosts the data historization application. The ArchestrA System Platform is installed on three servers. We have installed several meters and the measurements are archived in Trend. Indeed. InTouch® for Terminal Server Wonderware Historian. “We are especially attached to the 100% object concept because it corresponds completely with the formalization work that we had carried out before implementing the CMS.” underlines Damien Bertrand.” explains Damien Bertrand. This document was realized thanks to the support of: Université de Strasbourg and Wonderware France 27 . Historian Client Server the company’s ability to react and the interest it showed in our request. building. “But the department doesn’t intend to stop there. “We also appreciate the ArchestrA System Platform ability to integrate other applications. The time saving is substantial and there are no risks of errors.” This is the case with the following programs: IntraVue (verification of the state of connections..
INDUSTRY: FOOD & BEVERAGE Mount Packaging Systems Ltd. implementing technology that ensures continuous quality enhancements is a key objective for Mount Packaging Challenges • While manufacturers have been largely satisfied with traditional measurement methods. state-ofthe-art filling machinery for a variety of chemical and food industries. When used with viscous fluids like paint.1 pounds (0.5 seconds.004 pounds (2 grams) • Repeatability was achieved well below 0. with a target weight of 30. at 4.1 percent during 64 consecutive batch runs. We can now prevent lost production. www.mountpackaging. which are repeatable to ± 0.” Kevin Beaumont Managing Director Foxboro Coriolis Flowmeter Provides Breakthrough Technology for In-Filling System Measurement and Performance Goals • As a leading supplier of high-quality. The company adjusted its equipment to improve performance and we are getting excellent repeatability with the Foxboro CFT50 Coriolis mass flowmeter.04 kilograms) 28 . to fill 2.64 gallon (10 liter) cans. eliminate inaccurate pricing concerns and avoid excess downtime. in short runs of 0.95 pounds (14.2 seconds. even small levels of gas in liquid (two-phase flow) can skew Coriolis readings Solutions and Products • Foxboro CFT50 digital Coriolis mass flowmeter Results • The trial system provided precise performance with consecutive runs on filling 1.com “Mount Packaging learned to trust the meter. Mount Packaging was concerned because of the limitations in traditional Coriolis technology which often resulted in false readings and measurements • Conventional Coriolis meters lack the ability to respond rapidly to flow changes during the course of short batches.5 kilogram) batches.
Mount Packaging officials experimented with Coriolis flow measurement technology. another conventional measurement technology. The company specializes in providing technical solutions for difficult filling applications for liquids and pastes including paints. Mount Packaging Systems Ltd. conventional Coriolis meters had limitations as well. One of the conventional measurement methods used is volumetric piston filling. trimming the fill size had to be done mechanically.Food & beverage Dewsbury.” said Kevin Beaumont. Mount Packaging was aware of certain limitations of each approach and identified measurement technology as an area for improvement. In addition. even small levels of gas in liquid (two-phase flow) skewed Coriolis readings. in-line filling machinery relies on systems that use precise measurement technology to prevent waste from overfilling and spillage. To overcome these limitations. United Kingdom – Precise measurements for packaging of liquid products is vitally important to companies in the food. but they did not deliver the repeatability we required. Mount Packaging implemented Foxboro mass flowmeter technology to manage the wide range of viscosities. 29 . When used with viscous fluids like paint. which is both time-consuming and causes spillage that can lead to erroneous readings. This technology is considered a “breakthrough” in Coriolis flow measurement for automated filling applications because it uses digital technology to keep flow tubes in constant motion so there is no loss of flow measurement during dynamic flow conditions. Mount Packaging has implemented a variety of methods to help its customers achieve consistent. adhesives and food products. beverage and chemical manufacturing industries. managing director at Mount Packaging. They require trickle or ramping flow at the end of each fill. “While conventional Coriolis meters were very accurate with steady flow in longer batches. However. lubricating oils. temperatures. accurate measurement of the materials that its machines dispense. they lacked the ability to respond rapidly to flow changes during the course of short batches. chemical compatibilities and particulate sizes associated with materials processed by its worldwide customer base.” Foxboro Coriolis Flowmeter Successfully Manages Filling Operations Mount Packaging implemented the Foxboro CFT50 digital Coriolis mass flowmeter from Invensys Operations Management. While volumetric piston filling is considered highly accurate. chemicals. Founded in 1990. To ensure the accurate filling of these products in final packaging. These businesses use in-line filling machinery to ensure uniform product levels for packaging products in various types of containers. Using this approach. which would measure dispensed volume based on flow rate rather than volume. and to ensure volume and weight uniformity. it has a limited turndown ratio of approximately 20:1 and poor repeatability at the bottom end of the range. mobile filling machines to fully automatic turnkey systems. “We tried traditional Coriolis meters. Foxboro CFT50 digital Coriolis mass flowmeter Weigh scales. are limited in a different way. custom designs and manufactures a comprehensive line of in-filling systems ranging from semi-automatic. the Foxboro CFT50 flowmeter re-tunes the drive frequency of the Coriolis flow tubes every half cycle which ensures consistency Conventional Measurement Methods Over the years. While customers have been largely satisfied with traditional measurement methods. which uses a device external to the container to measure the volume of material being dispensed.
95 pounds (14.Food & beverage and reliability. and food/dairy/beverage measurement. the consistency proved itself in full scale production. Combining this with linear velocity defines the Coriolis force. even when the flow tube contains entrained air. Invensys collaborated with researchers at Oxford University in England to develop digital technology for accurate measurement of flow. The Foxboro CFT50 digital Coriolis mass flowmeter can handle the highly accurate measurements. sanitary batching. eliminating loss of production. The rotation produces an angular. Mount Packaging tested the Foxboro CFT50 flowmeter on a 1 1/2-inch (40 mm) flow tube with a nominal flow capacity of 900 pounds/minute. outward acceleration. This is particularly true for difficult-to-meter materials such as slurries and homogeneous fluids. including tanker and truck loading/ unloading. Flowmeters are designed to measure flow of liquids by analyzing changes in Coriolis force of the substance in which the Coriolis force arises from a mass moving within a rotating frame of reference. in short runs of 0. After a few trial runs.5 seconds. and an electronic transmitter that controls the oscillations. pharmaceutical batching. (6. In addition. In addition. “Mount Packaging learned to trust the meter. The second system processes the measurement data from the Coriolis meter. The Foxboro CFT50 Coriolis mass flowmeter achieves high measurement accuracy.1 percent during 64 consecutive batch runs. which ensures precise fluid measurements. and the operational aspects of keeping the Coriolis meter running stably in single-phase or twophase flow conditions. It is able to compensate for common industry problems associated with entrained gases. with a target weight of 30. eliminates downtime and avoids workarounds to help keep profit flowing. Built-in algorithms also compensate digitally for inaccuracies resulting from two-phase flow.5 kilogram) batches. We can now prevent lost production. centrifuge control. Foxboro CFT50 digital Coriolis mass flowmeter provide useful measurements of both mass flow and density.04 kilograms). while other Coriolis flowmeters fail at such precision. This application resulted in the Foxboro flowmeter producing pulses that correlate with product weight. Coriolis meters provide direct measurement of mass flow. Mount Packaging was able to establish new flow profiles for the batch runs. Customers report the CFT50 provides exceptional performance in the world’s most challenging applications. The group developed the Foxboro CFT50 flowmeter which incorporates new signal processing techniques to 30 Impressive and Consistent Results Mount Packaging is now getting consistent results well within target ranges.” said Beaumont. analyzes the results and transmits the information. The trial system provided precise performance with consecutive runs on filling 1. A Coriolis meter’s two main components include an oscillating flow tube equipped with sensors and drivers.” Research & Testing Pays Off Initially. ethylene oxide processing.64 gallon (10 liter) cans. empty tubes or flash-prone fluids. Maintenance and operating costs also can be reduced since the flowmeter can be used in applications with a wide variety of fluids without re-calibration. which demonstrated the considerably improved measurement potential that could be achieved with the Foxboro CFT50 flowmeter. One customer achieved repeatability well below 0. . One processing system controls the meter drive sequence to provide uninterrupted flow tube operation.004 pounds (2 grams). to fill 2. the CFT50 reduces overall cost of ownership since the meter continues to operate uninterrupted.2 seconds. eliminate inaccurate pricing concerns and avoid excess downtime. For example. which is highly desirable in applications requiring precise measurement. at 4.1 pounds (0.8 kilograms/second). “The company adjusted its equipment to improve performance and we are getting excellent repeatability with the Foxboro CFT50 Coriolis mass flowmeter. which are repeatable to ± 0. three pulses per milliliter of flowing liquid are transmitted to a PLC which counts them and is programmed to actuate the shut-off valve when the target fill weight is achieved.
the Foxboro CFT50 flowmeter has provided a significant improvement in flowmeter technology and has huge potential. It maintains a digitally precise process flow measurement while simultaneously re-tuning the drive of the Coriolis flow tube every half-cycle of the drive frequency. Mount Packaging is looking forward to providing this Foxboro CFT50 digital Coriolis mass flowmeter technology in its in-line filling machines for all of its customers. “However. This document was realized thanks to the support of: Mount Packaging Systems Ltd.” said Beaumont. 31 . software-based system that prevents the erratic liquid/gas flow tube vibrations that cause measurement failures. The Foxboro CFT50 flowmeter responds up to 10 times faster than conventional Coriolis flowmeters.” The Foxboro CFT50 digital Coriolis mass flowmeter enables Mount Packaging to measure from liquid to gas and back to liquid without slippage or stoppage.Food & beverage The CFT50 finally does Coriolis flow measurement right with its patented. The company also can achieve accurate measurements with the flow tube starting from empty which is sometimes necessary in certain filling processes. or a start-from-empty condition. or wildly wrong measurement. which is particularly vital for batch measurement to reduce startup time while increasing production throughput and profitability. making accurate process measurement and control impossible. they would exhibit bursts of no measurement. “When traditional Coriolis meters encounter even small bubbles.
INDUSTRY: FOOD & BEVERAGE Winkler und Dünnebier Süßwarenmaschinen GmbH www. while substantially improving standardization”. Bernd Plies.com “By using ArchestrA System Platform. we could cut development cycle time for large visualization and data systems into half.w-u-d. Electric and Automation Technology Manager Setting standards in chocolate production: WDS adopts the innovative and flexible ArchestrA System Platform for plant monitoring Goals • Effective production visualization • Design of complex visualization and data systems • Use of standard templates Challenges • Interfaces to a wide range of systems • Open to suppliers of different systems Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware Historian • Wonderware Industrial Computer Results • 50% reduction of development time • Substantial simplification of plant management • Easy replacement of clients in case of failure 32 .
ArchestrA System Platform. For this reason. So. pectin and fondant candies. this system enables WDS to design. using standardized templates both Requirements Constant development and increasingly tighter interaction between automation systems.and higher-level management systems. for several generations now. WDS has adopted a production strategy based on variants and modularity. continuous data flow between physical plant components .such as a motor or a valve . But as you are dwelling on sweet dreams. Wonderware Industrial Computer Summary To handle these challenges. sweet fruit gums and fruity candies. The benefits of this upgrade include much shorter development cycle time. Germany. commission and efficiently maintain even more complex visualization and data systems. modular plants for the production of fruit gums. In addition. such as marzipan. this generates high expectations and requirements from confectionery producers and equipment manufacturers. With this solution. i. jelly. WDS relies on its ArchestrA System Platform based solution for all product monitoring and visualization operations. Open. object-oriented approach But why has WDS decided to upgrade from the visualization software Wonderware InTouch to ArchestrA System Platform? As a rule. have you ever wondered what kind of complex industry stands behind this sweet temptation? The market demands new creations. Today. 33 . has already become a standard. ERP and quality management systems. for instance. Their product range includes equipment for the production of chocolate (bars or filled pralines).e. These are the challenges faced by Winkler und Dünnebier Süßwarenmaschinen GmbH (WDS). WDS specializes in the development and construction of forming machines for the confectionery industry.Food & Beverage The company Everyone knows the sweet temptations you can find today on the shelves of sweets and candies: seducing chocolate and delicious pralines. the equipment control level. and new taste trends emerge at shorter and shorter intervals. candy casting machines and extruders for high-viscosity mass processing. Combined with constant pressure for cost optimization. as a result of the introduction of an object-oriented development environment. a company that. WDS has adopted a high-performance visualization and management system. Furthermore. IT environment and manufacturing area have resulted into complex and high-performance methods and technologies to help companies approach the market dynamically and deploy effective and flexible production strategies. based in Rengsdorf. Wonderware InTouch® HMI Wonderware Historian. For many years. there are increasing demands for the plant level to be able to exchange data with the production control level. Wonderware InTouch HMI has been used to equip countless single or multiple visualization systems workstations.e. i. WDS develops special machines. This is instrumental for the flexible and efficient management of production orders and the optimal exploitation of equipment production capacity. has been developing intelligent solutions for its high-performance manufacturing plants. several renowned customers in the confectionery industry all around the world have already benefited from WDS’ easy and intuitive visual machine operation systems based on Wonderware InTouch and ArchestrA System Platform. and no machine is identical to a previous model.
This plant is comprised of three casting stations. In this case. leads come from the complete plant or line to each station and then to the corresponding “sensor”. whereby the server retrieves data from the central PLC (Siemens S7-400). The motion control connection to controls and drives (Bosch Rexroth) is also Ethernet-based. each equipped with a panel (Wonderware Touch Panel for Windows CE). Once developed and tested. stored and forwarded by ArchestrA System Platform. the company has obtained a 50% reduction of development time in the design of visualization. is handled. shell weight. filling weight. as if they were placed in a toolbox. This is where the advantages of ArchestrA System Platform emerges: the modular concept. HMI and data management systems. Any sensor. any piece of equipment or any other data element with all its properties is stored as an object. Panel and server communicate via Ethernet. In case of production changeover. The plant was designed for the flexible production of solid chocolate. the entire plant can be monitored and controlled. the new instance of the object is addressed to the corresponding application location within the tree structure. this is one of the biggest praline plants supplied by WDS. In this configuration. Finally. WDS uses this solution for all multi-user HMI (Human Machine Interface) systems. graphically incorporated into the visualization at the corresponding station. Wonderware InTouch® HMI Wonderware Historian. it can be easily integrated into higherlevel system environments and process control systems. such as data coming from the integrated scales that weigh the shells at each processing stage (empty weight. The Wonderware solution also includes efficient recipe management. Furthermore. It is equipped with 100 servo drives that ensure the smooth shell transport and high-precision positioning and dosing processes. built into a Terminal Services Architecture. When a recipe is loaded. “actuator” or other “data object”. ArchestrA System Platform provides all necessary interfaces and functionalities for an enterprise-wide data management system. it is child’s play to reconfigure the system. the development environment runs from a central location and modifications can be distributed quickly and easily to all stations simultaneously. through a tree layout. Through this panel.Food & Beverage ArchestrA System Platform. provided the object is available through the data link both in the PLC and physically. The huge quantity of process information. and consequently. these object templates are then constantly updated. final weight). However. Object templates are produced. The structure is self explanatory and. the central node is located on a server in the switch cabinet. This solution was also used as foundation for a forming plant (or chocolate shell moulding plant) manufactured for company Brandt ZwiebackSchokoladen. the entire plant 34 . so that it can be used directly. the Terminal Services clients operate within a connection session to the fully protected server. Wonderware Industrial Computer in hardware design and in software development. An object is taken from a template. Stepping up from the traditional Wonderware InTouch solution to a modular platform approach. With a length of approximately 80 meters. and declared to the PLC by its name and address. This approach is particularly effective when you leverage one of the key features of ArchestrA System Platform: the layout of a model structure. used and stored.
This document was created in collaboration with: Winkler und Dünnebier Süßwarenmaschinen GmbH 35 . the Web interface can also be used by the customer himself. WDS can constantly monitor and maintain the plant. who can “peep” into the production plant from external working places to check status notifications and production statistics. the shell weights are tracked based on the shell codes and analyzed for plausibility and limit values. Each chocolate shell is provided with a tag for correct identification at each reading station. Collected data can be used for statistic and process optimization purposes. for instance. Unlimited possibilities This system based on Wonderware software offers many more capabilities and features. The expandability and flexibility of System Platform represent a milestone for large plants typical of the confectionery industry. WDS relies on modern technology for product optimization Brandt-Schokoladen has also implemented an RFID (Radio Frequency Identification) product monitoring system. Wonderware Industrial Computer Always up to date Through a VPN (Virtual Private Network) connection. the plant operator gets the plant fully parameterized for a new selected product. The shells whose weight is out of tolerance are marked and discarded. WDS relies on this software and additionally develops new approaches in order to add even more color and taste to the production world of sweets and candies. Wonderware InTouch® HMI Wonderware Historian. This process is partially reproduced in the visualization and can be constantly monitored. cycle times and limit values. So.Food & Beverage is adjusted accordingly as relates to temperature values. Of course. In less than a minute. ArchestrA System Platform. motor rotation speeds.
Paul Alcock.INDUSTRY: FOOD & BEVERAGE Imana Foods Ltd www. Imana Foods Imana Foods get HACCP accreditation with help from Wonderware Goals • Full traceability of all materials entering and leaving the Savoury Powders blending process • Visibility into the blending process • Production data to be linked in to the company’s ERP system • Gain HACCP certification • Improve the quality of finished goods • Reduce inventory discrepancies Challenges • Tracking of all incoming raw materials used in more than 150 recipes Solutions and Products • ArchestrA System Platform • Wonderware Historian • Wonderware MES • Wonderware InTouch® Results • HACCP certification achieved within three months of going live • Better insight into the blending operation in the factory • Improved raw material stock control • Real-time blend closure in the ERP system • Factory procedural deviations are highlighted • More consistent product quality from following recipes exactly • Improved management of the physical blending process • Proper temperature control of sensitive blends 36 . MD. imana.za “Imana Foods would not have achieved HACCP accreditation without this solution in place“.co.
Bags of work in progress from the blenders needed to be individually weighed and tagged with bar-coded labels for tracking through to the packing lines. On the ingredient side. the availability of the MES is core to the solution. Imana Foods’ MD also believed that Wonderware’s technology was a very good match for the company’s future goals. Full traceability would then be achieved by ink jet coding the packed product. while every effort was made to stick to a first-in-firstout transfer of raw material. “that was not however the deciding factor for solution selection. This would need to be done for all materials used in the more than 150 recipes in Imana Foods’ range of products. Historian and Information Server). ArchestrA System Platform. All incoming raw materials needed to be lotmanaged and scanned into their storage locations. “This meant that the work schedules depended on the reliability of a printer and the recipe integrity on the reliability of the operator. faced with an expanding marketplace demanding increased food safety focus.Food & Beverage Imana Foods is a member of the Kwaden Investments group and is supported in systems development by a sister company. MES and enterprise integration initiatives that would place Imana Foods in control of their existing production and ready to meet future business and operational challenges. Wonderware InTouch® would still be responsible for the queuing and prioritising of work orders. Imana Foods would rely on a scalable system design where there was to be minimal data duplication between the ERP and production systems. The decision was made to go with Wonderware and the purchase of all the other Wonderware solutions necessary to this project (System Platform. Project Engineer at IT Dynamics.” says Irvine. Project goals For the Imana Foods’ leadership team. Historian Client. Background Prior to this project. “Blenders worked from instructions printed manually from the ERP system. They would then be tracked into the blenders. IT Dynamics. there was a need to review its production operations. team leaders had no clear visibility of the blending operations. this was not always guaranteed and stock discrepancies were identified at the end of every month. Paul Alcock. which was tasked with providing a systems solution for product traceability. so that printed instructions would no longer be necessary. For Wonderware. One of the most important requirements of the system was that it must guide operators “what to do when”. This led to the launching of a blender project with the following goals: 1 Full traceability of all materials entering and leaving the Savoury Powders blending process 2 Visibility into the blending process 3 Production data (from Wonderware) to be linked in to the company’s ERP system for the automation of real-time work order administration 4 Gain HACCP certification 5 Improve the quality of finished goods 6 Reduce inventory discrepancies The scope of the project was to include SCADA. The ERP system Figure 1: Mobile computer and printer from Intermec 37 .” says Murray Irvine. Wonderware Historian Wonderware MES. “The SCADA system would verify all transactions and would be the source of daily shift reports. monitoring PLCs in the factory.” says Irvine. There was no real traceability”. Solution selection “A small ‘InTouch’ application was already in use.” Wonderware MES enables users to record production events into a standard database and Solution requirements To achieve the expressed goals.
network administrators and technical support personnel. For wireless networking with the mobile computers and printers.” On the handheld units (figure 3). Wonderware InTouch® Implementation Because of the scope of the project. “The most important item of information supplied by the system is the raw material lot tracking data as fed into the blenders. The Sequencer object exposes a comprehensive set of attributes that allows users to create SmartSymbols and regular InTouch animations to monitor and control the Sequencer operation. The ERP system is sent the resultant blending process information in order to close the loop and monitor stock levels and any accounting variance anomalies. The Sequencer Object coordinates tasks that must be executed in a certain sequence or order of operation. PEM. broadband was chosen because narrowband could not cope with the InTouch-based operator interface even though graphics and complex displays were eliminated. equipment and production events. the blender operators are shown the recipe details as well as an ingredient by ingredient breakdown Figure 2: System topology 38 . instrumentation technicians. The office computers are connected via the Wonderware Information Server portal to allow viewing of custom reports. business analysts. Figure 2 shows the system topology. engineers. On the technology front. FMM and Sequencer are now all part of Wonderware’s Equipment Operations Module Mobile computers for use by the operators and mobile label printers were both sourced from Intermec due to good service levels. The handheld PCs are running a managed InTouch application through Microsoft Terminal Services which resides on the Application Object Server. Imana Foods chose barcodes over an RFID solution. ArchestrA System Platform. In addition. The Sequencer object is used to sequence the blend process. The objects store acknowledged data from the operators and provide the traceability for lot-tracked raw materials as well as for finished goods. The system is fully integrated with the company’s ERP system which passes the recipe information to the Formula Manager which is queried for each ingredient on a bag-by-bag basis in order to load the blender. many disciplines and skills would be required including a project manager. software developers. network engineers. Wonderware Historian Wonderware MES. The blending area was set up for a wireless infrastructure with handheld PCs and wireless label printers. It is designed to configure. Users can also report forward and backward genealogy of materials. custom reports calculate equipment utilisation from time data captured in the Wonderware production database.” says Irvine.Food & Beverage to know the exact process conditions at a certain step. This decision was based on price and the fact that RFID as a technology is not yet mature enough to give an easy. pricing as well as being the only supplier that could support both narrowband and broadband. execute and manipulate a sequence of operations associated with attributes from multiple application objects running within an Industrial Application. resulting in 22 PLC nodes being connected to the Wonderware system. The MPI network was expanded to include the blenders. viable solution. “This is giving Imana Foods a far greater level of control than previously.
Project Engineer at sister company IT Dynamics who did the implementation 39 . There are built-in timers that capture the total blend time as well as any additional mixing times that may be required. Wonderware InTouch® Benefits • HACCP certification was achieved within three months of going live • Better insight into the blending operation in the factory from a material usage variance point of view • Improved raw material stock control • Real-time blend closure in the ERP system • Factory procedural deviations are highlighted • More consistent product quality from following recipes exactly • Improved management of the physical blending process • Proper temperature control of sensitive blends Figure 3: Examples of handheld unit displays of what they have to scan or acknowledge as having been fed into the blender. platform scales underneath the blenders register the weight of the offloaded bag and this data is captured by the objects.Food & Beverage ArchestrA System Platform. Conclusion Imana Foods has achieved all its initial project goals and has ambitious plans for expanding and extending the capabilities of the system. This document was realised thanks to the support of Paul Alcock. The blender is on load cells which register its weight increase as it is loaded. This was made possible through the use of a flexible platform in the hands of a very capable project team which amply demonstrated that technology is no longer a barrier to achieving business and operational objectives. MD of Imana Foods and Murray Irvine. When being unloaded. Wonderware Historian Wonderware MES.
SAB Ltd. • Cross-regional analysis highlights trends and areas to focus on for development or support. • Cross platform comparison and analysis facilitates decision making. we were able to roll out the project to the rest of the sites and commission within 2 months! This is a reflection on the power of the underlying ArchestrA technology. Business Analyst.za “After the testing and development phase. The time saved with the project roll-out had a direct impact on the cost and we were able to finish within budget.sablimited. Early detection of issues that impact system performance. interpreted and viewed from a divisional level at head office. 40 . • Current historian performance to remain unaffected Solutions and Products • Wonderware Intelligence • ArchestrA System Platform • Wonderware Historian Results • Risk reduction.co. System Platform and MES hardware and software systems for all seven beer manufacturing regions • Present the information in dashboard format so that it could be easily read. Wonderware Historian.INDUSTRY: FOOD & BEVERAGE The South African Breweries Limited www.” Hein du Toit. Then there’s the matter of cost. Challenges • Collating data from a wide and disparate number of sources from seven breweries nation-wide. The South African Breweries Limited manage the big picture with help from Wonderware Intelligence Goals • Provide a centralised system for the early detection and warning of mission-critical problems • Implement a centralised data repository for analysis purposes • Identify key KPIs for PLCs.
Project objectives Project Dash (short for the dashboard view it was to provide into the individual and collated production facilities of SAB) was started and it had to plug some important information holes by: • Providing a centralised system for the early detection and warning of mission-critical problems • Implementing a centralised data repository for analysis purposes • Identifying key KPIs for PLCs. there were limited facilities to proactively monitor critical systems in SAB’s beer manufacturing systems department and this led to the requirement for the implementation of a centralised monitoring system that would detect and warn about mission-critical manufacturing systems within SAB that were in difficulty with respect to meeting their KPIs. ArchestrA System Platform Wonderware Historian Solution selection “We selected Wonderware Intelligence because not only would it provide the functionality we were looking for but it would also fit into SAB’s strategic architecture and alignment with our standardising on the Wonderware Application Server (System Platform). While this may sound challenging enough for the management of a single brewery. the expert use of the ArchestrA Application Introduction Before this project. SAB chose system integrator Advansys for the implementation. data aggregation as well as roll-up and drill-down functionality.Food & Beverage The South African Breweries Limited (SAB) is a vast. Wonderware Historian. it really does make creating dashboards easy. “Buying into suite-based products gives long term value and it also gave us seamless access to time-based Wonderware Historian production data. Figure 1: Required regional system architecture 41 . Business Analyst at SAB Limited.” says Hein du Toit. unified and comprehensive view of KPIs was best done with help from an application known as Enterprise Manufacturing Intelligence or EMI. Wonderware Intelligence. It also allowed us to plug into MS SQL databases for MES and other applications. It is an extremely powerful tool. In addition. Although distributed in nature. interpreted and viewed from a divisional level at head office. which is our quality/MES system. manufacturing enterprises such as SAB still need to operate as unified entities with respect to meeting their business objectives and it is in this regard that the company looked for a solution that would provide a collated picture of its production facilities and that made the best use of its existing information assets while providing the least change to operators and users.” Since it’s an SAB rule that all system integrator work done on the System Platform be performed by ArchestrA-Certified SIs.” says du Toit. But this information is less than helpful if it can’t be displayed in a format that is easy to define and understand.” says du Toit.” One of the main functions of any EMI application such as Wonderware Intelligence is to collate data from a wide and often disparate number of sources and to provide data warehousing. geographically-distributed network of breweries involved with complex production processes that have to satisfy the demands of millions of discerning customers in real-time. drag-and-drop dashboarding functionality. if any custom development had to be done. Tableau Server. “Wonderware Intelligence provides user-friendly. coordinating the efforts of seven manufacturing regions so as to provide an in-depth. “Advansys’ specific advantage is knowledge of not only the beer making process but also the manufacturing system architecture that we use such as our eQMS. “Once you have explored the Dashboarding tool. The company has a good knowledge of the Food and Beverage industry in general and the brewing industry in particular. System Platform and MES hardware and software systems for all seven beer manufacturing regions • Presenting the information in dashboard format so that it could be easily read.
Food & Beverage Wonderware Intelligence. unprocessed SQL messages and many more. we wanted to make use of the existing infrastructure at the regions and did not want to introduce anything that would affect the performance of the historians. I/O Server Figure 2: Required national system architecture Object Toolkit was important. etc. In other words. memory usage. This would include everything from the PLC. Server Platform. Systems engineers are familiar with its IDE and the System Platform provides builtin change propagation and object derivation. “Lastly. out-ofthe-box alarm and history primitives and compile editors for easy configuration. the process and the ArchestrA engine to the I/O Server. as well as SAB’s requirement to use ArchestrA. The project team drew up the required regional system architecture shown in figure 1 which collates KPIs from the PLCs as well as the Historians and MES servers for storage in the regional data warehouse from which it can be extracted and viewed in dashboard form according to the needs of users. Wonderware Intelligence is a Business Intelligence tool and Advansys’ knowledge of data warehousing was important to understand and implement the project on a tight timeline. traffic volumes. application object servers or even the PLCs. This regional architecture was replicated seven times for each of the regions and connected to the central data warehouse at head office as shown in figure 2 where the dashboard views not only represent an aggregated picture but also allow drilling down to the views of each region independently. This gives the ability for any custom development to conform with SAB’s architecture and standards while making it easy for the engineers at regional level to understand and maintain the system. This all meant that no scripting was required for engineers to configure the data retrieval objects. providing centralised change management.). a deployment installation model as well as an integral security model.” says Advansys Director Graeme Welton.” . disc space availability.” concludes du Toit. message status (MSMQ). ArchestrA System Platform Wonderware Historian configuration. most of which comes from operating system diagnostics. the file system. Microsoft Message Queue and any SQL database (MES). The main reasons for this were that SAB didn’t want another system to maintain and ArchestrA is already the standard system control platform at all the breweries. “SAB stipulated that we make use of the existing ArchestrA System Platform install-base. CPU usage. change propagation and it’s user-friendly Integrated Development Environment (IDE) for all data retrieval 42 Figure 3: Final regional architecture item counts (total. scan times. This phase of project Dash focused on collecting and collating diagnostic data with respect to system performance. we decided to use the ArchestrA Object Toolkit which gave us full use of the ArchestrA Object Framework and access to low-level C#. “This approach also allowed us to use standard. everything was in place to allow Advansys to focus on the Intelligence application and not spend engineering time on fundamentals.” says du Toit. “Because of the nature of this data.Net coding.” says Welton. Implementation “Starting at the regional level. active.
we were able to roll out the project to the rest of the sites and commission within 2 months! This is a reflection on the power of the underlying ArchestrA technology. time. With an immediate view of the status of each system. we are only using a tiny fraction of the power of Wonderware Intelligence.” With Wonderware Intelligence. eQMS.” • One immediate benefit was risk reduction. “The next step is Manufacturing Intelligence at every level of production and we have no doubt that the product’s ability to connect easily to different data sources and reporting flexibility will be of real value in the real-time production arena. Galaxy Repository and Historian servers at all breweries This document was realized thanks to the support of: The South African Breweries Limited 43 .” Conclusion “At the moment.” says du Toit. the “islands of information” of a decade ago have vanished and companies can become the unified entities they were always meant to be. “First of all. “This is rather different to traditional Business Intelligence tools that require large IT teams to support and develop. The time saved with the project roll-out had a direct impact on the cost and we were able to finish within budget. Then there’s the matter of cost. The third point is the exceptional quality of the work delivered by Advansys. Welton believes that the dashboard development tool is much more than it appears at first and that Wonderware have produced a solution whereby almost anyone with some basic training can collect and collate information from virtually any combination of sources to suit their needs. ArchestrA System Platform Wonderware Historian Benefits “I feel I should comment on three important aspects of the project. engineers were able to detect issues that impact performance of the various systems under scrutiny. • Cross-regional analysis shows trends and areas to focus on for development or where support should be given. Figure 5: Drill-down status determination of the status of the Application Object. after the testing and development phase. Figure 4: Final national architecture showing the addition of another instance of Wonderware Intelligence at head office and an identical structure to that found at the regional level.” says du Toit. • Cross platform comparison and analysis makes decision making easy when deciding on deployment of areas.Food & Beverage Wonderware Intelligence.
” Jennifer V.INDUSTRY: FOOD & BEVERAGE New Belgium Brewing Company www.000 barrels (18 million gallons) of beer annually • The methane rich biogas byproduct from the wastewater plant is now captured and converted into electricity. brewery to acquire 100% of its purchased operating electricity from wind power 44 . New Belgium Brewing was concerned about maintaining high manufacturing standards • In order to meet stringent environmental and sustainability goals. the company had to ensure that it would continue to produce the high quality products expected by its loyal customers Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware Historian • Wonderware ActiveFactory Results • The Invensys solution helped in the efficient and sustainable production of more than 600. Orgolini Director of Sustainability and Strategic Development New Belgium Brews Up Sustainable Manufacturing Goals • Minimize impact on the environment by transitioning from fossil fuel-based sources to total renewable energy options • New Belgium Brewing has set an ambitious objective to reduce its wastewater impact by increasing its waste diversion rate (sans spent grain and sludge) from 73% in 2007 to 95% by 2015 • By 2015.com “One of New Belgium Brewing’s core values is to honor nature at every turn. The health of our community and of our business depends upon the health of the natural environment. the company plans to decrease the water use per barrel of beer produced by 10% and curtail greenhouse gas emissions by 25% Challenges • With the reduction in energy usage and materials consumption.newbelgium. producing 15% of New Belgium’s operating power requirements • The solar photovoltaic panels installed on the roof of the bottling plant are able to produce up to 200 KW • New Belgium Brewing is the first US.
encouraging a shift toward sustainable technologies with other businesses throughout the community. The Production Events Module enables the recording of production events that help New Belgium Brewing understand product and production history. The brewery’s manufacturing intelligence system uses Wonderware software to provide extensive “track and trace” capabilities in order to adhere to New Belgium’s conservation and performance goals. and now is a major microbrewery with devoted legions of beer aficionados. Wonderware InTouch provides an intuitive graphical interface to help managers run overall plant operations.S. also.. InBatch manages batching operations and Wonderware Historian is the brewery’s archive of real-time and historical production data. Orgolini. the company has proven to be a stellar example of sustainable manufacturing. equipment usage.” Alternatively empowered means making business decisions based on minimizing environmental impact. our energy consumption.” New Belgium Brewing is the third largest “craft brewery” in the U. “One of New Belgium Brewing’s core values is to honor nature at every turn. produces millions of gallons of beer annually to appreciative customers across the nation. the Invensys technology enables the brewery to track any bottle or tank of beer back to all of its ingredients and processes within 30 minutes. Within the company. Regardless of its size. based in Fort Collins. As winner of the Environment and Safety Excellence Award from Invensys Operations Management. but.Food & Beverage Fort Collins. The level of monitoring is at the very highest levels of plant vigilance. Wonderware InTouch® HMI Wonderware Historian. Chief Electrical and Automations Engineer. It captures and distributes information related to the genealogy of materials.000 barrels (18 million gallons) of beer annually.” said Igor Valuyev. we think of the environment first. New Belgium Brewing has increased its recycled paperboard usage from 44 to 88 percent. so we try to design our equipment around not just our processes and our beer production. For example. and continues to balance business objectives with efforts to reduce waste and minimize its impact on the environment. “The health of our community and our business depends upon the health of the natural environment. New Belgium Brewing strives to maintain an environmentally. managers refer to the energy policy as “alternatively empowered.” said Jennifer V. 45 . It started with a bucolic bicycle trip through Belgium and an amber ale called Fat Tire. It is a recognized leader in sustainable manufacturing practices. events and which personnel were utilized during production activities.” New Belgium Brewing strives to act as a role model at every opportunity. brewery to obtain all of its purchased electricity through wind power. Wonderware ActiveFactory ArchestrA System Platform serves as the foundation for managing the complex network of product production and energy management systems. Along with its emphasis on brewing world-class beer. It strives to serve as an industry influencer. Sustainable Technology Goes Down Smooth “Every project that we design. Colorado – New Belgium Brewing Company. New Belgium Brewing’s notable environmental accomplishments have been achieved with the help of solutions from Invensys Operations Management. Director of Sustainability and Strategic Development at New Belgium Brewing. Additionally. That’s where Wonderware was able to offer the additional benefit of managing operations and helping us achieve high levels of sustainability. Colorado. socially and economically conscious business. encouraging the growth of its employee owners and being a socially responsible contributor to the community.S. “Brewery operations can be very material and energy consuming. New Belgium Brewing also understands the importance of a sustainable relationship with the environment and has invested in environmental stewardship from its first days of operation. New Belgium Brewing still managed to be the first U. ArchestrA System Platform. producing more than 600.
Wonderware InTouch HMI plays a key role in visualizing. an Invensys partner and system integrator. while also maintaining a two-way communication with the local power company. In 1999. New Belgium Brewing was among the first to harness the power of the wind.Food & Beverage “Alternatively empowered encompasses everything we do here at the brewery.” said Orgolini. ” With the help of Wonderware West. Wonderware ActiveFactory software is deployed throughout New Belgium Brewing’s operations so that managers can analyze and optimize all energy usage. the company started purchasing power from a neighboring wind farm in Wyoming. These solar photovoltaic panels are able to produce up to 200 KW. with sensors that can dim or turn off lights in areas where no workers are present. This engine produces up to 15 percent of New Belgium Brewing’s electricity needs. New Belgium Brewing has recently incorporated the “Smart Grid” to manage its technologies and equipment. turning a waste stream into a power source. ArchestrA System Platform. most facilities will be nodes on an intelligent energy supply chain network and managing the cost of energy will produce a competitive advantage over plants unable to leverage the opportunities offered by demand response. dispatchable distributed generation and real-time market pricing for energy. or intentionally engineered electrical power outages. self generation. For example. Even the accountants use ActiveFactory to monitor batch data and product alcohol content to meet government reporting and taxation requirements. All three of these efforts to maintain a sustainable business have effectively worked to reduce waste and protect natural resources. the Invensys solutions control the entire lighting system for the brewery operation. the company is able to monitor total production of kilowatt hours generated on a real-time basis as well as track historical power production records to optimize operations based on seasonal solar energy patterns. A Smart Approach to Energy Management With high energy costs. significantly increasing its sourcing of renewable energy. “That makes us different and gives us the energy for our success. With the Invensys technology. 46 . At its on-site process water treatment plant. Wonderware InTouch® HMI Wonderware Historian. Wonderware ActiveFactory Finally. the brewery uses microbes to clean all of its production wastewater. Steam. The Wonderware software plays an integral role in New Belgium Brewing’s energy conservation efforts. from monitoring power production to tuning operations to maximize its renewable energy sources. The water treatment results in a methane-rich biogas. New Belgium Brewing has used Invensys solutions to make its environmental and sustainability projects succeed. This allows for load shedding. water and electricity consumption is tracked continuously through the brewery and every effort is made to minimize energy demands. Panels have been placed on the roof of New Belgium’s packaging hall. ActiveFactory monitors every detail. New Belgium Brewing has also employed photovoltaic technology to produce electricity from the sun. The excess methane is then captured and converted into electricity. the energy component of production cost is critical to any business. when the strain on the municipal power grid is too high. In the future. Invensys has had a long-time commitment to sustainability so it has been a great asset in our business mission to minimize our footprint on the environment. from room temperatures to facility usage to cleaning requirements. New Belgium Brewing has directly implemented three technologies to reduce waste and maintain a sustainable business. optimizing and controlling the entire wastewater treatment process so that New Belgium Brewing can manage its biogas production and leverage the energy power return on its water treatment process. The historical records also are key to helping the company determine exact solar panel upgrade requirements for business growth resulting in higher electrical demand.
That’s where our data is being extracted from. Focusing on sustainability and the environment gives New Belgium Brewing the strength to grow its business.” said Orgolini. was finely tuned by Wonderware West to help New Belgium Brewing maximize its Smart Grid initiatives. Wonderware InTouch® HMI Wonderware Historian. Wonderware ActiveFactory “Every Wonderware system is what our operators pretty much use. New Belgium Brewing protects the environment while maintaining a safe and sustainable business. “We’ve been utilizing InTouch for 10 years plus for extended period of time.” said Valuyev. “The Wonderware software helps us communicate with our local utility to inform them immediately what we are using and communicate with us when we need to shed load. We unify our plant information through Wonderware. ArchestrA System Platform. We’re pretty happy with this system. with a little help from Invensys. “The Smart Grid provides the internal metering that lets us know how much energy we are using throughout the process. New Belgium Brewing is continuing to improve its carbon footprint and hopes to reduce greenhouse emissions by 25 percent by the year 2015. so it kind of unites all of the systems together. Wonderware software.” What started with a pastoral bike trip through the fertile valleys.” Using the Smart Grid gives New Belgium the strength to grow its business and improve the welfare of its employees while helping to protect the environment in a cost efficient manner. improve the welfare of its workers and help protect Mother Earth. The journey toward sustainable operations is never ending.Food & Beverage The Smart Grid delivers tangible benefits to both the brewery and the community. This document was realized thanks to the support of: New Belgium Brewing Company 47 . sandy plains and thickly forested hills and plateaus of the Ardennes has become a major employee-owned microbrewery with a dedication to protecting the world’s natural resources. With the help of Invensys. which is optimized for energy management.
2 percent • Cost accountability during custody transfers has been greatly improved • Maintenance costs have been reduced since the Foxboro CFT50 Digital Coriolis Mass Flowmeter has no moving parts in the stream. indisputable measurement of the milk we are receiving. And the system has paid for itself within 60 days.INDUSTRY: FOOD & BEVERAGE United Dairy www.uniteddairy. which has resulted in substantial savings. Highly Accurate Custody Transfer Solution from Invensys Goals • A measurement solution that would comply with stringent federal standards in operations ranging from procuring raw resources to delivering the final product • Implement a solution that would lower initial capital costs.” Tom McCombs Director of Milk Procurement Leading National Dairy Implements Low-Cost.com “The Invensys custody transfer solution proved to be just what we needed.000 pounds • Accurate accountability of raw materials is critical to the business because of the variances in volumes from one truckload to the next Solutions and Products • Foxboro CFT50 Digital Coriolis Mass Flowmeter Results • Enhanced accuracy of truck unloading applications with a demonstrated accuracy of ±0. requiring little or no maintenance 48 . be inexpensive to maintain and provide highly accurate measurement data Challenges • The current industry solution of using scales for custody transfer has significant drawbacks including high initial capital costs. We now have reliable.000 and 54. expensive maintenance and inaccurate reporting of data • Effectively measure 15 to 20 truckloads of unprocessed milk daily that is between 24.
United Dairy needs accurate accountability of raw materials. Coriolis meters have emerged as the instrument of choice for custody transfer in other industries. Director of Milk Procurement at United Dairy. But conventional Coriolis meters are not suitable for measuring two-phase fluid flow. “We continually look for ways to improve operations while maintaining our high quality standards. we needed a custody transfer measurement system that establishes a recognized standard for accuracy and reliability. and thus provide a lowmaintenance solution. Ohio – From the dairy farm to the kitchen table. the distribution of milk and milk products have evolved tremendously. a common condition when transferring milk. More than a hundred years ago. and are now being accepted for milk custody transfer applications.” the cow out in a family’s pasture. “Given that the cost of raw materials has a direct impact on our profitability. To keep up with the country’s demand for milk and milk by-products.000 pounds. Coriolis mass flowmeters have no moving parts in the stream. Custody transfer of raw products from milk suppliers is vital to United Dairy profitability.” Foxboro CFT50 Digital Coriolis Mass Flowmeter Conventional Custody Transfer Methods Unusable – Invensys is Key Solution United Dairy receives 15 to 20 trucks of unprocessed milk daily that is between 24. milk processing plants have had no standard for custody transfer systems. however these measurement devices have a high initial capital cost. Some of the larger dairy processors have used scales. United Dairy was established nearly 50 years ago with a single plant and has grown to be one of the largest family owned dairies in America. United Dairy has employed a custody transfer solution by applying advanced flow measurement technology to reduce costs and improve material accountability. The system.” said McCombs.Food & beverage Martins Ferry.” 49 . historically. Dairy processors must comply with a host of stringent standards in operations ranging from procuring raw resources to delivering final product. While a number of conventional custody transfer measurement methods have been tried through the years. West Virginia and Uniontown.000 commercial dairies operate in the United States and these dairies produce 80 percent of the nation’s milk. the company provides a full line of dairy products throughout the Northeast. Today more than 100.” said Tom McCombs. “This is particularly critical in our business because of the variances in volumes from one truckload to the next. However. provided an almost immediate return on the company’s investment. The company turns this raw product into a full line of dairy products ranging from skim milk to cottage cheese to ice cream. and like any other business. United Dairy has remained focused on consistently improving operations to provide customers with quality products. Pennsylvania. based on Invensys technology. dairies and dairy processing facilities must employ the latest technology to maintain efficient production and distribution processes. Ohio. Charleston. many Americans received their milk from “Bessie. all have significant drawbacks. “Milk is the basis of our business. and is easy and inexpensive to use. Over the years. are expensive to maintain and have proven inaccurate. With plants located in Martins Ferry.000 and 54.
Thanks to the Invensys solution. In addition. With the dairy industry evolving from the local farm to large cooperatives in just 100 years. The heart of the Invensys custody transfer solution is the Foxboro CFT50 Coriolis transmitter. Having proven itself in United Dairy’s Charleston facility. The average American consumes almost 25 gallons. Because the Invensys solution provides a high-level of accuracy in calculating the amount of the actual product being transferred. United Dairy also is saving considerable maintenance costs previously spent on calibrating scales because the Invensys Coriolis Mass Flowmeter requires little or no maintenance.S. and can operate up to a year without calibration. The custody transfer indicator then communicates with the printer to produce a ticket that accurately documents the total mass of milk transferred during the operation. United Dairy has gained additional revenue by avoiding overpayments due to the trapped air issue. the CFT50 transmitter provides accurate measurement from the beginning to the end of a custody transfer batch and has no moving parts to wear out or internal mechanisms to replace. or 400 glasses a year. with a demonstrated accuracy of ±0. with 99 percent of all U. This implementation achieved equal success. Developed collaboratively by Invensys and Oxford University in the United Kingdom. the Invensys custody transfer system was subsequently installed at the company’s headquarters facility in Martins Ferry. so miscalculations of actual product occur frequently.” At United Dairy.S. the Invensys system has proven to be ideal for fast and accurate custody transfer of milk from tank trucks.2 percent. households purchasing milk today. Ohio. which employs patented digital technology that compensates for variations in the amount of gas or liquid in a flow.2 percent at the well site. This document was realized thanks to the support of: United Dairy 50 . “United Dairy now has reliable. The Foxboro CFT50 Coriolis transmitter sends pulses to the indicator to start the batch count. In addition to surpassing the reliability and accuracy requirement. the American public’s demand for milk products has dramatically increased. United Dairy can maintain its pledge to provide customers with quality products by continually improving operations with innovative technology solutions. West Virginia facility and the accuracy requirements were ±0.” said McCombs.Food & beverage Invensys Digital Coriolis Mass Flowmeter Key to Controlling Costs United Dairy chose to implement the Invensys custody transfer solution which requires little or no maintenance and is certified internationally for accurate fiscal metering of milk. which has resulted in substantial savings – the system has paid for itself within 60 days. The Invensys Digital Coriolis Mass Flowmeter was first installed at United Dairy’s Charleston. indisputable measurement of the milk it’s receiving. consumption of milk is declining. Foxboro CFT50 Digital Coriolis Mass Flowmeter “The Invensys custody transfer solution proved to be just what the dairy needed to improve operations and control costs. the Invensys Digital Coriolis Mass Flowmeter custody transfer solution includes a transfer indicator with a printer interface. A high volume of air from the bottom of the trucks accompanies the liquid. the Invensys custody transfer solution includes seal out hardware enabling a local inspector to verify and protect the flowmeter from tampering after the certification procedure is complete. and there are no signs that U.
this allows operational staff to be deployed more flexibly across the business as they quickly feel familiar with the process interfaceHistorian is proving to provide reliable information in high fidelity. everything is consistent. Greene King Automation Engineering Manager.co. Challenges • To be able to extend a standard SCADA solution to all parts of the brewery • To enable automatic data gathering and improve plant production Solutions and Products • Wonderware InTouch® HMI • Wonderware InTouch Compact Edition • Wonderware Historian Results • Single plant wide standard . week in and week out.” Roy Matchwick. missing nothing that needs to be seen and working continuously as the plant runs. product uniformity and repeatability.all displays are now recognisably similar across the current systems.greeneking.INDUSTRY: FOOD & BEVERAGE Greene King www. assisting us in getting it right first time. Greene King PLC Maintaining Brewing Excellence at Greene King Goals • To make sure that within the Brewery. stays under control and everything is executed at the right time.uk “Wonderware delivers consistency. 51 .
fermentation and bottling operations and will in the next phase be deployed in the kegging and casking operations. The new system obtains its tag information from a dual redundant tag server. This was primarily because of an accruing business risk in their increasingly legacy systems combined with the need to make other improvements which would require more functionality. At Greene King it was decided that a phased upgrade of controllers and supervisory systems was required. It is crucial in modern brewery control that everything stays under control and everything is executed at the right time. thus the selection of an appropriate solution was critical as one has to live with the decisions that are taken at the outset. Modern manufacturing information and control is now usually undertaken on a modular. Roy Matchwick. bump-less swap over should a problem occur. inverters. There were many reasons for this. InTouch is now in use throughout the brewing. it was its object oriented approach that made the difference by delivering sustainable engineering and operational advantages that benefit Greene King’s business. such as its large installed base and significant functional benefits. Greene King Automation Engineering Manager. the standardisation of objects allows Greene King’s engineering department to specify work undertaken by external integrators to be better detailed and to meet with their requirements exactly.” Reliability System reliability is vital for effective production and for achieving on time delivery in full. in historic Bury St Edmunds. alongside the full InTouch stations. Furthermore. more importantly. Doing this delivers engineering savings and design standards which ease maintenance and use when troubleshooting. All systems there use a mix of InTouch and PLC objects (the latter being as standard function blocks at the Omron PLC level).Food and Beverage For over two hundred years. projects are undertaken faster and meet with the detail of the Greene King specification. They recently completely refurbished their brewing and ancillary control systems using Wonderware InTouch and Historian. the broader business benefit is that all displays are now recognisably similar across the current 12 and later to be 17 InTouch systems. 52 Greene King Brewhouse . PID loops and pump control. Wonderware Historian Standardisation It is standardisation which has underpinned the successful use of Wonderware technology at Greene King. However. measured by the principle KPI of ‘on A Plant-Wide Solution Greene King’s engineering department selected Wonderware technology as its new standard. this uses the latest Wonderware InTouch functionality to provide ease of setting this up and. To achieve this one requires reliable controllers and supervisory systems. “Standard Wonderware objects and PLC function blocks allows the SI to have a detailed set of tools to undertake work. The whole benefit of which is fundamental to the metrics of OEE and Schedule Adherence. where they have been making beer since the time of the doomsday book. However Greene King has also to stay abreast of the times as they have many of today’s business challenges that are faced by other manufacturers. This allows the site standard to be deployed cost effectively across the whole operation. however. As is often the case not all the requirements in the kegging and casking operations require complex functionality and here InTouch Compact Edition will be used which runs on low cost CE panels. ‘object-driven’ basis. Wonderware InTouch® HMI. Also the data within controllers can provide a rich source of manufacturing information. malted just two miles from the brewery. regardless of complexity. This involves standard faceplates for valve control. Water is still drawn from the chalk aquifer beneath the brewery the same that Benjamin Greene and Frederick King used when they first started making beer 200 years ago. this allows operational staff to be deployed more flexibly across the business as they quickly feel familiar with the process interface. They use the country’s finest locally grown barley from the bread basket of England. the master brewers of Greene King have been brewing fine ales in the heart of Suffolk. Wonderware InTouch Compact Edition.
it should not be assumed that the brewing process is now simply an automated process.” Summary As Roy puts it. this is supplemented by the are for planning to be able to automatically take controlled addition of acid. It also ensures that the Brewer has time to constantly ensure that Greene King ales have the product uniformity and consistency that their customers expect. Historian is proving to provide reliable information in high fidelity. This is a multistranded approach which involves the use of Wonderware Historian data from the plant being used to produce highly detailed trend displays to determine ‘what happened. week in and week out. Wonderware technology allows us to proceed with this confidently. Initially this will be done with scripting to demonstrate a ‘proof Greene King abstracts water from a chalk aquifer of concept’ – as was the case prior to installing beneath the brewery. this is the allocation of budget and developing detailed neutralised initially with slightly acidic by-product requirements specifications. abstraction is metered to Historian. carefully monitored by into account production realities and events and InTouch and a record maintained in Historian. Roy Matchwick.Food and Beverage time delivery in full’. measurable and sustainable business benefits. this allows the Brewer to ensure that all is well and that production is on target. assisting us in getting it right first time. Initial requirements and. Wonderware InTouch Compact Edition. missing nothing that needs to be seen and working continuously as the plant runs. This approach ensures that all involved comply with the Environmental agency license. it is Brewhouse Copper Mimic now working on the integration of this directly with production using the data Environment within Wonderware Historian. when needed. “Wonderware delivers consistency. with a little help from Wonderware! This document was realized thanks to the support of: Greene King 53 . At Greene King the Brewer can readily see what is happening by using various automation interfaces to all parts of the process. Wonderware InTouch® HMI. these activities are undertaken at Greene King on a basis of Continuous Improvement. Wonderware Historian Integration Greene King utilises advanced scheduling software in its planning process.” However. to thereby make changes accordingly. ensure that Greene King’s environmental credentials “The integration of our systems will produce are always high. parties can see planned extra functionality before Brewery effluent is typically alkaline. product uniformity and repeatability. how can we improve’ information through scripted reports.
which was already achieving extremely high levels of efficiency Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware Historian Software Results • Total integration of information at both the production process level and with the company’s business system. CRE-A now has useful. one of the main challenges of the company. • To integrate information from each of the production areas between each other and also link information from the presses with the company’s ERP system. 54 . head of industrial computers at SICMA 21 CRE-A Imppresiones de Catalunya improves production on using Invensys Wonderware Technology Goals • To provide one of Europe’s most modern printing plants with a control architecture that is able to maximise plant efficiency. reliable and timely information available of its production process. • To achieve production excellence in a pioneering facility of its kind.INDUSTRY: GRAPHIC ARTS CRE-A Impresiones de Catalunya www. Challenges • To ensure communication between the wide variety of existing plant machinery regardless of the communication protocols to be used.grupogodo.” José Ramírez.com “Thanks to the full integration of production equipment. which has facilitated the implementation of a work methodology based on the philosophy of ‘lean manufacturing’. • CRE-A is today implementing better production planning and more efficient production management.
Maximum Information The complexity of each of the tasks performed in the printing plant obliged the team involved in the project to study the best option to begin 55 .” explains José Ramírez. three major challenges were established at the beginning of the project: to integrate the different machinery of the production system into a single management system.” In general terms. distribution − while ensuring the soundness of the data collected individually in each of these areas.Graphic Arts ArchestrA System Platform. printing. Divided into four production sections − warehouse. Inaugurated in 2007 with an investment of 120 million euros. Maximum Connection. as well as other specific additional publications such as La Vanguardia Dossier or El Magazine. Therefore. printing. Wonderware InTouch® HMI. the use of the machinery’s capacity was sufficient. “Our main objective.” Wonderware software’s ability to communicate with the various existing latest generation machinery and the ease of deployment led to management opting for its technology to ensure a qualitative leap in terms of the efficiency sought by the printing plant. “The plant had first-rate machinery. the CRE-A printing plant in Barcelona is today a pioneering facility with an average monthly print run of 22 million copies.” explains Oscar Mateu. through an internal audit in which overall equipment effectiveness (OEE) indicators were used to measure current production efficiency. it could still be optimised further. to control Advanced Control System for Pioneer Facility The renewal of the Grupo Godo presses was from the outset seen as an opportunity to maintain leadership in the holding’s offer of news and information. but there was as many islands of information as operational units. the systems integrator responsible for the project. Wonderware Historian Software Barcelona. converting it into one of Europe’s most modern printing plant of its kind. With production already underway and motivated by a pursuit of excellence and continuous improvement. Spain. it was found that while plant information in real time (it was hitherto obtained with a slight delay that made in situ decision-making difficult) and to integrate data with the company’s ERP system to provide reliable information for proper cost management. “was to obtain realtime information of our activity in order to establish appropriate operational indicators to help us with decision-making during the production process of the presses and other related activities. packaging. CRE-A Impresiones de Catalunya is a Grupo Godo company and one of the major publishing holdings in Spain. the investment involved printing press machinery equipped with the latest technology to help publish the group’s newspapers at quality and speed levels never before achieved by automating each of the tasks performed in the plant. packaging and distribution – the plant performs the entire cycle of its publishing production in a fully automated manner. the company’s management accepted the challenge of optimising the performance of its facilities. It is responsible for printing. head of industrial computers at SICMA 21. This lack of consolidated data meant that the facility had still not reached its full potential and level of production. collating and distributing the newspapers published by the group: La Vanguardia. Avui and El Mundo Deportivo. a reference general news daily in Catalonia and one of the most prestigious in Spain. Therefore. “The need was identified to correlate the information generated between the different sections − warehouse. technical director of CRE-A.
The modular capabilities of the software have also opened new avenues for improvements in several areas that go beyond production. packaging and distribution.” explains Jose Ramirez. the advantages of working with Wonderware derive mainly from its open architecture: “It is now possible to have communication within a complex facility. Wonderware software adapted perfectly to the various existing units regardless of origin or the technological language used.” explains Oscar Mateu. Following a “very satisfactory” evaluation of the improvement process by CRE-A.” sums up Ramírez. such as an optimal human resources policy. because it is where the least amount of information is handled. “The decision was made to start with the packaging area. Wonderware Historian Software Operational Excellence with Wonderware Extensive analytical work by SICMA 21 prior to the deployment of Wonderware technology has helped to ensure to a large extent that the new control system will provide the expected results. full connection was guaranteed between each of the units involved in the production process. ArchestrA System Platform.” The greatest overall benefit of the new technology architecture is determined by the integration of information at both the production process level and with the business system of the company. managing to create a single language that tells us what is happening at each moment and why. Thanks to this ability to adapt. the three types of existing clients responsible for installation – area manager. Once the information is collected. therefore. In terms of development. adding that this first deployment represented a “litmus test” for the project “because it would show if data collection could actually be improved and a new level of excellence achieved for operations at the plant. This document was realized thanks to the support of: CRE-A and Wonderware Spain 56 . CRE-A will in the near future embark on a modernisation process of the control system of the building housing the facility. more efficient predictive maintenance of facilities and streamlining the document management process. After a year and a half of work. As explained by the system integrator. the prospects for the future are to implement Wonderware solutions on off-site issues. the possibilities of Wonderware to replicate objectives helped the deployment of control technology in each of the sections after the initial test made in packaging. during which the other production areas of the press replicated this development model. The dynamics through which the project was structured were similar for all sections of the plant. Wonderware InTouch® HMI. After this process. The first stage began with the mapping of data. “The plant information that Wonderware helps us to collect and analyse has led to important business decisions. the last stage of each of these micro-projects involved the full connection of the data on two levels: first. In order to meet an energy-efficient approach of its activity. in which the printed material is packed for delivery. it is now easier for the company to create process improvement teams aimed at fulfilling established indicators. As a result. between each of the sections in order to provide maximum continuity and efficiency to the processes of printing. technical director and operator – can access it according to their privileges through InTouch to see real-time production behaviour. At a technological level for José Ramírez. This was how the technological architecture of the CRE-A plant was configured in a modular manner. “Wonderware allows us to make an objective assessment of production activity based on real information. involving an extensive analysis of the information collected thus far to confirm the soundness of the information. Each area has a data server connected via Ethernet to the database of objects. and second. where there are various types of machines with different technological features. thus helping to begin implementation with full guarantees. allowing for in-depth analysis to help move closer every day to the model of production efficiency sought by the company. and once the main needs in the pilot packaging section of the project had been defined. between the plant and the company’s ERP system to ensure maximum consistency between production events and management decisions. In addition.” points out José Ramírez. “CRE-A is today able to implement better production planning and. the system was configured with the parameters that would provide a full picture of what was actually happening in the plant in real time. plant information is stored through Historian.Graphic Arts implementation.” One of the main challenges faced was related to the diversity of communication protocols incorporated in the different machines that worked the different sections of the plant. more efficient management of production costs. and it also plans to launch a monitoring and system optimisation project for wastewater treatment to decrease the volume of waste generated at the plant by 80%.
INDUSTRY: HYDROCARBON PROCESSING Gazprom dobycha Astrakhan. Challenges • The environment is hostile with the hydrogen sulfide content of the formation fluid up to 25% • The manufacturing process is complex with pressures of more than 600 atmospheres and temperatures of up to 110 degrees Celsius. • Increase productivity.I/A Series® • Triconex Critical and Safety Systems Results • Overall all improvement in the safety and control system of the plant • In 2010 increase in separated gas and condensate production 57 .com “In addition to improving the control and safety system.” Invensys helps Astrakhan Gas Processing Plant achieve Operational Excellence Goals • Improve safety and minimize environmental impact through modernization of control system. Solutions and Products • Foxboro Distributed Control System .gazprom. LLC www. the solution achieved outstanding performance results in separated gas and condensate production.
4. condensate and sulfur. solid and prilled sulfur • R&D. 6. the executive management decided to modernize the control system by replacing the legacy system into a modern. fuel oil as well as liquid. Due to the high complexity of technological processes during gas processing. The Astrakhan gas and condensate field was launched on December 31. It also involves the storage. shipping and transportation of critical products that are highly explosive and are potential fire and gas hazards. gasoline. one of the largest energy companies in the world. The main activities of the company involve the following: • The exploration of hydrocarbon deposits • Production of sour hydrocarbons. LLC . This involves oil. Increase in company’s profit by increasing technical capability and making efficient use of use of raw materials. Be able to solve production problems by analyzing historical information Improved environmental safety and production efficiency Astrakhan gas condensate field is unique in Russia. auxiliary facilities and energy. preparation.Hydrocarbon Processing Gazprom dobycha Astrakhan. The project required a phased reconstruction. A number of processes take place at high pressures (over 600 atmospheres) and at high temperatures Choosing the right solution and partner The automation and process control system modernization was entrusted to the Russia office of Invensys Operations Management because of its experience in completing similar projects. It has an extremely high content of hydrogen sulfide in the formation fluid (25%). Improve the working conditions of plant operations personnel by creating a central control room with easy display of plant information 3.I/A Series® Triconex Critical and Safety Systems The Foxboro I/A Series DCS and Triconex Tricon Safety System use of the state-of-art technologies and architectural solutions that meet the operational requirements of Gazprom dobycha Astrakhan. with an 81% share of all the sulfur produced in Russia and about 10% of the world’s total production. a major sulfur producer in the former USSR. modernization and expansion of the gas processing plant so that it meets the current and future European requirements. high-speed. Currently. microprocessor-based system. 2. The goals of the automation and control system include: 1. it is very deep (4000 . The Characteristics of the process The control of the Astrakhan GPP plant is characterized by a variety of a complex and continuous batching process that involves control of gas. exploration and design work. 58 . 5. Gazprom dobycha Astrakhan is the world leader in the production of sulfur. gas and condensate processing resulting in production of dry and liquefied gases. it has high reservoir temperature (110 degrees Celsius) and pressure (more than 600 atmospheres). The entire plant is a complex that embraces 19 subdivisions within a unified process chain involving the Astrakhan gas processing plant. 1986 with the comissioning of the Astrakhan gas complex. Russia is a subsidiary of Gazprom. Because of these goals. diesel fuel. condensate and mined products. Increase productivity by increasing the production of separated gas. Have the ability to edit the supervisory and control functions and improve display screens. Enabling remote monitoring while being able to control and manage the entire plant from a central control room.4100 m). processing. Improve safety and meet its environmental goals by upgrading the control system and try to avoid erroneous operator actions during unit start-ups and shut downs. 7. gas and gas condensate processing. Foxboro Distributed Control System . the primary goal of the company is to improve environmental safety.
storage. planned maintenance shutdowns 5. without component failure • The Control System should be spread out and distributed so that the operations personnel is not present in the dangerous product areas. Invensys is proud to have been part of this endeavor and is prouder to be part of the team that helped its customer record operating results that are above expectations. Invensys. (110 degrees Celsius). Installation at end user site 4. 7) with the existing process control system without shutdown 6. despite the complexity of the processes.I/A Series® Triconex Critical and Safety Systems The Invensys solutions at Gazprom dobycha Astrakhan Invensys installed a control system that includes a Foxboro I/A Distributed Control Systems (DCS) and a Triconex Tricon Safety for seven processing units. Russia plant modernization at the Astrakhan gas processing plant that included the following: 1. This document was realized thanks to the support of: Gazprom dobycha Astrakhan. Installation. Detailed engineering of the process control system including. There was effective communication and full cooperation with the entire team and this contributed to the project’s success. Furthermore. the solution achieved outstanding performance results in separated gas and condensate production. The works was carried out within schedule. This required Gazprom dobycha Astrakhan to specifically ask for a control solution that will be able to meet the following requirements: • The Control System should be able to operate in the limits of the hazardous environment prescribed above. shipment. transportation are closely interrelated and require clear central control. • The Control System should be redundant and provide a high operational tolerance (that is. the faults and failures of individual components will not lead to the failure of the whole system). multi-level hierarchical solution that is easy to maintain and upgrade. The environment inside the plant is also hazardous because the hydrogen sulfide concentration in the formation fluid is 25%. the possible mixture of hydrogen sulfide with hydrocarbons is a real danger to the equipment. testing and commissioning according to a clear project schedule that took into consideration. also makes the raw materials toxic. This results in a lot of corrosion and if unchecked. Supply of all equipment 3. Achieved results and Business Metrics In addition to improving the control and safety system. Training of engineering and operations personnel. LLC 59 .Hydrocarbon Processing Foxboro Distributed Control System . documentation and development 2. Integration of new subsystems (nodes 6. All processes of gas processing. • The Control System should be built as an integrated.
com “The Invensys solution has met all of Sanofi Pasteur’s expectations by providing easy migration with the existing system. resulting in operators being sent incorrect hardware and network failure information • Only manual written records could be produced and these were prone to operator mistakes resulting in data entry errors Solutions and Products • Foxboro Programmable Automation Controller (PAC) System Results • Sanofi Pasteur has achieved an estimated 30 percent increase in overall equipment effectiveness (OEE) • The stability of the Invensys architecture and its object-oriented technology enabled Sanofi Pasteur to achieve a 15 percent reduction in time and engineering costs • Maintenance operations have significantly improved with the ability to immediately address issues on the line when operators are notified by the Foxboro PAC System alarms and alert information 63 .INDUSTRY: LIFE SCIENCES Sanofi Pasteur www. high availability and a secure architecture to store and manage all the facility’s technical data.” Christian Colin Life Sciences & Systems Business Manager Invensys Operations Management © Sanofi Pasteur Invensys Helps Sanofi Pasteur Achieve 30 Percent Increase in Overall Equipment Effectiveness Goals • Sanofi Pasteur needed to implement a solution that would enable the company to continually gather information and monitor its manufacturing processes • The company required a system that could be easily integrated into a pharmaceutical validation system Challenges • Sanofi Pasteur was limited in the flexibility and expandability of its previous proprietary system • The instability of the former system triggered numerous false alarms.sanofipasteur.
Sanofi Pasteur was limited in the flexibility and expandability of its manufacturing operations. The system experienced numerous hardware and network failures which also contributed to unacceptable downtime events. Life Sciences and Business Systems Manager at Invensys.” Colin said. the previous system was unable to provide electronic data reporting. the company produced 1. This required Sanofi Pasteur to enter into costly service contracts with the developer in order to keep the manufacturing facility running. Moreover. Sanofi Pasteur is the largest company entirely dedicated to vaccines. the company implemented the Foxboro Programmable Automation Controller (PAC) System from Invensys Operations Management to operate its facility in Val de Reuil.” Because of continued production downtime. Sanofi Pasteur was forced to find a more reliable and productive solution. In addition. the company began researching various technologies that could not only address Sanofi Pasteur’s requirements for today.Life Sciences Val de Reuil. It is an The Importance of Quality in Vaccine Manufacturing As the world’s largest company entirely dedicated to producing vaccines that immunize the public from more than 20 infectious diseases. “Because of the proprietary nature of the former system. The prior system was unable to manage this manufacturing requirement because the technology was obsolete and built on a specific proprietary hardware platform that could only be maintained by the company that developed the system. Increased Reliability and Cost-Effective Redundancy Options After completing an intensive evaluation process. Sanofi Pasteur recently expanded its manufacturing operations to fulfil the ever-growing demand for its products. The Foxboro PAC System is a high-performance hybrid automation controller system. could rapidly produce large quantities of vaccines to accommodate the high volume of anticipated demand. Foxboro Programmable Automation Controller (PAC) System meet various regulatory requirements. France – Protecting the health of people around the world is Sanofi Pasteur’s primary focus and concern.6 billion doses of vaccines to immunize more than 500 million people across the globe. The company experiences less downtime and has more confidence in the integrity of the reports provided by the Invensys system. the proprietary system had several instability issues. Recently. That means the company’s manufacturing operations have to maintain the highest level of control and accuracy to meet the health needs of the public with a reliable supply of vaccines. The new production facility was designed as a highly advanced and rapid production operation which. new international regulations for product quality control and increasing market demands for its vaccines worldwide. Sanofi Pasteur Implements Foxboro PAC System to Provide High Performance.” The Foxboro PAC System provides Sanofi Pasteur with an estimated 30 percent increase in reliability of its manufacturing operations. Alarms were triggered erroneously. As the world’s leading producer of vaccines to safeguard the world’s population from infectious diseases. causing the production line to halt and resulting in significant downtime and lost revenues.” said Christian Colin. instead Sanofi Pasteur had to rely on paper reports to complete production audit trails to 64 © Sanofi Pasteur . France. “The reliability and redundancy features provided by the Foxboro PAC System and data servers ensure that Sanofi Pasteur operators and management receive a continuous flow of information. in the event of a global influenza pandemic. “The Invensys solution offers high availability architecture at all operations levels. “After reviewing the manufacturing requirements that were not being met by the original system. Conforming to strict quality and regulatory requirements is a constant challenge for Sanofi Pasteur. but provide the scalability to meet expansion needs in the future. Sanofi Pasteur selected the Foxboro PAC System from Invensys Operations Management. To ensure that its production of vaccines complies with strict international regulations for quality and efficacy.
Reduction in Operating Costs Ensures High ROI The ArchestrA technology built into the Foxboro PAC System provides Sanofi Pasteur the ability to create custom objects that can be quickly replicated at other plant sites. “The power of the Foxboro PAC System has been a key element in the success of the company’s strategy to revamp its vaccines manufacturing operations. the Foxboro PAC System will store the information and then send it to the appropriate locations once network connectivity and operations are restored. “Sanofi Pasteur’s selection of the comprehensive Invensys solution has met all expectations by providing an easy migration path with the existing system. native high availability and a secure architecture to store and manage all the technical data across the manufacturing operation.” Colin said. Invensys is making a significant impact on Sanofi Pasteur’s ability to protect the world from deadly diseases that can impact the world’s population. The Foxboro PAC System is designed to store vital information collected during the production process and is managed locally within the device and then forwarded to the appropriate business system via the network.” With more than 50 percent of its staff dedicated to the company’s industrial operations. The savings in production cost and production time is an invaluable feature of the Foxboro PAC System.” Colin said. In the event of a network failure. Sanofi Pasteur is able to better manage production at its facility in France to effectively meet these ever-changing requirements and world demand. logic and sequential control. Invensys is assisting the company to ensure that everyone has access to vaccines to prevent disease no matter where they live.” This document was realized thanks to the support of: Sanofi Pasteur 65 © Sanofi Pasteur . “To constantly improve their customer satisfaction and meet regulatory demands. Not only can the company better monitor and adjust quantity production. This feature has resulted in more than a 15 percent decrease in engineering costs. the Foxboro PAC System collection of features is designed to maximize Sanofi Pasteur’s return on investment. Its control unit and I/O system form the basis of a complete distributed control and recording environment capable of continuous analog. “The data storage feature of the Foxboro PAC System is vitally important to Sanofi Pasteur operations. With the use of the Foxboro PAC System. a batch can be scrapped and the production cycle must be done all over again – wasting time and money. A production batch of vaccines can result in significant revenue for the company. “Together they define quality policies and guidelines to ensure that processes correspond to good manufacturing practices.” Colin said. while keeping the business highly competitive. Use of the comprehensive Foxboro PAC System enables Sanofi Pasteur to effectively meet these business objectives. Combined with secure data recording for accurate manufacturing measurement parameters. The Foxboro PAC System offers data record integrity which is critically important in regulated industries such as pharmaceutical manufacturing.Life Sciences extremely reliable technology featuring high I/O densities with cost-effective redundancy options. “If the company was to lose the process data due to a hiccup in the connectivity of their network. they would be looking at a tremendous loss in revenue because production batch could potentially be thrown away and they would have to start all over again. An important element in the pharmaceutical business is the ability to anticipate specific vaccines and quantities that will be needed by the world’s population.” Foxboro Programmable Automation Controller (PAC) System Invensys Helps Make Vaccines Available to Everyone Working closely with Sanofi Pasteur. Sanofi Pasteur is focused on ensuring that its manufacturing processes employ the most advanced technology that enables the company to continue to be the leading supplier of vaccines in the world. However if accurate records on the production cycle are not maintained properly. the Sanofi Pasteur quality teams work closely with operations managers at its manufacturing facilities. Sanofi Pasteur can now address quality control issues with use of the Foxboro PAC System.
INDUSTRY: LIFE SCIENCES Xcellerex www. including a capital investment reduction that can exceed 60 percent • The solution decreases the facility space required by 40 percent. Chickosky Chief Commercial Officer and President. and lowers the overall cost of finished products by 32 percent • FlexFactory reduces deployment time from three to five years to 12 to 18 months. controlled environment modules. lessens water usage and waste by 85 percent. which enables the production of high value products two to four years sooner than traditional technology • The solution achieves an overall reduction in development time of nearly 60 percent. with an estimated 80 percent saving in rework time. Biosystems Invensys Enables Xcellerex to Achieve Significant Reductions in Overall Operating Costs and Accelerates Time to Market Goals • Address the growing demands in the biomedical market space for more effective biopharmaceutical manufacturing processes • Develop a solution that would define a model for improving how biopharmaceuticals. This results in huge implementation savings and the ability to begin producing high value product 2 to 4 years sooner than traditional technology. This directly impacts customers with reduced costs and shorter time to market. In fact. Xcellerex has been able to deploy FlexFactory® manufacturing capacity. vaccines and other therapeutics are developed. very quickly. we’ve been able to reduce deployment time from 3-5 years to an amazing 12-18 months. manufactured and commercialized Challenges • Integrating complex technology with ultrahigh levels of functionality was considered the greatest challenge in creating a biomanufacturing platform that employs a single-use technology.com “With the integration of Wonderware’s software. process automation and electronic batch records Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware InBatch™ • Wonderware Historian Results • Xcellerex’s FlexFactory enables companies to achieve significant cost savings in several areas. resulting in an overall reduction in development time of nearly 60%.xcellerex.” John A. which reduces costs and shortens time to market 66 .
process automation and electronic batch records into its FlexFactory platform. During the development stages of this pharmaceutical production solution. This results in significant implementation savings and the ability to begin producing high-value products two to four years sooner than what was achievable using conventional technology. reducing on average from several years to only several months.” said Darren Kline. lessen water usage and waste by 85 percent and lowers the cost of goods sold by 32 percent. a manufacturing platform designed to enhance production of these critical biopharmaceutical products. Chickosky. Wonderware Historian Examining a Changing Market The biomanufacturing market is currently undergoing enormous growth and change. “FlexFactory has tremendously accelerated the time of building a plant. Director of Marketing and Business Development at Wonderware North. manufactured and commercialized with the development of FlexFactory. Massachusetts – Xcellerex is revolutionizing the way biopharmaceuticals and vaccines are developed. highly functional biomanufacturing technology platform. Instead. Chief Commercial Officer and President of Biosystems at Xcellerex. This required a manufacturing facility to invest $100 to $300 million and spend three to five years in the validation process before a single product could be developed for commercial sale. Xcellerex quickly identified the need to integrate single-use technology. Years of single-use biomanufacturing experience enabled Xcellerex to design and integrate a solution offering an efficient. The integration of Wonderware software components has enabled Xcellerex to offer customers significant improvements in production processes. “FlexFactory from Xcellerex enables customers to reduce capital investment by more than 60 percent. Wonderware InBatch™ to provide effective batching operations and Wonderware Historian to serve as the system’s powerful application to maintain historical production data. Xcellerex selected ArchestrA System Platform as the backbone of the complete biopharmaceutical automation software application. Wonderware InTouch® HMI. “Xcellerex advances in developing innovative manufacturing solutions has revolutionized the way companies are starting to manufacture the drugs that we use.” said John A.” 67 . Working with Invensys Operations Management solutions in past product development. much of the cost came from the need to maintain clean. In the old business model. Previous manufacturing models can no longer address the expectations and standards of this evolving industry. innovative manufacturing technology platform. including 70 percent faster deployment. sterile conditions in process vessels as well as to preserve air quality in large-scale manufacturing suites. Xcellerex identified Invesys Wonderware software as ideal for integrating with this new.Life Sciences Marlborough.” ArchestrA System Platform. companies such as Xcellerex chose to re-evaluate the biomanufacturing process and develop strategies designed to greatly improve overall efficiencies. Other Invensys solutions included Wonderware InTouch® as the HMI. Wonderware InBatch™. “FlexFactory is able to decrease the actual space needed to build a manufacturing facility by 40 percent. deployment time has been reduced to a remarkable eight to twelve months. 75 percent reduced capital investment and an unmatched level of flexibility. With the single-use technology from Invensys. controlled environment modules.
” ArchestrA System Platform.” Users of FlexFactory are able to create application standards via ArchestrA System Platform with the development of templates for re-use in any application with similar functionality. The Invensys solution allows for reusable object-based technology. Xcellerex has proven to be a leader in operational excellence while remaining both efficient and innovative. Wonderware InTouch is designed to maximize productivity. It also features Wonderware Historian. “This feature adds tremendous value to Xcellerex and its customers by providing a unified architecture across all different types of process designs. which enables a reduction in time to test. Xcellerex has developed an operations approach totally different from most manufacturing solutions while remaining on the leading edge of manufacturing technology development. FlexFactory provides a single. “The biggest benefit for Xcellerex is the Invensys solution’s comprehensive object architecture functionality. as well as bundling them with Invensys software. Wonderware InBatch™. Xcellerex’s application of Invensys solutions also features Wonderware InTouch. scalable software solution for all the SCADA. which provides advanced graphic visualization.Life Sciences Excelling Toward a More Efficient Future Xcellerex utilizes patented process equipment in conjunction with Wonderware software from Invensys to achieve a highly productive and profitable manufacturing process to bring pharmaceutical products to market. This software component enables process and performance decisions to be evaluated and made by management in real time. validate and debug the system throughout a customer’s facility. Wonderware InTouch® HMI. Xcellerex was awarded the Grand Pinnacle Award during the Invensys Operations Management Open contest. They looked at what is feasible and moved forward to completely reverse the way manufacturing is done in the biotech industry for the better. a highperformance real-time database for historical information. “The company has an innovative group of engineers that come together to review what needs to be addressed to improve the biomanufacturing industry and they are not afraid to change the rules. precision-driven real-time biomanufacturing environments. Wonderware software gives Xcellerex a more efficient technology framework. Peter Martin. Wonderware Historian biomedical industry automation and information personnel. The Solution for Winning – Wonderware Software from Invensys To achieve significant implementation savings and accelerated production.” said Martin. in a field of 40 competing entries. a powerful historian server and an easy-to-use information server. while ensuring the highest quality in biomanufacturing. ArchestrA System Platform offers unparalleled connectivity for demanding. ArchestrA System Platform enables the creation of standardized templates resulting in reduced training time and lower costs while driving consistency and quality across the enterprise. In 2010. optimize user effectiveness. Vice President of Business Value Generation at Invensys Operations Management. FlexFactory is strategically integrated with Wonderware software. increase quality and lower development. resulting in a system designed to provide a business benefit in the shortest period possible. With ArchestrA System Platform. “By developing innovative designs and approaches. “Xcellerex is a strong proponent of operations excellence but from a very different angle than what we normally see. maintenance and operational costs by featuring custom graphical views of realtime industrial processes.” said David Mills. supervisory HMI and MES needs of 68 .” said Dr. Senior Director of MES and Automation at Xcellerex. By featuring an industrialized application server.
and related objects are fixed across all instances saving us an additional 80 percent in rework time. This document was realized thanks to the support of: Xcellerex 69 . This achievement directly impacts the customer’s bottom line with substantially lower manufacturing costs and shorter time to market. stringent security. “To make any system changes. Wonderware InTouch® HMI. which enables users to deploy batch functions that adhere to the ISA S88 flexible batching standard. Wonderware InBatch™. operators simply modify the object template once. Invensys solutions used in FlexFactory from Xcellerex have enabled biomanufacturing companies to achieve a significant overall reduction in development time of nearly 60 percent. material genealogy. comprehensive solution for Xcellerex and its FlexFactory technology.” said Mills. This type of forward thinking is the cornerstone of operations excellence.” ArchestrA System Platform.Life Sciences The Invensys solution also includes Wonderware InBatch. “The Invensys system is an excellent. InBatch software offers comprehensive batch execution and equipment history. Web-based reporting and the ability to facilitate the design and implementation of systems that are compliant with FDA 21 CFR Part 11 regulations. Wonderware Historian Operational Excellence at its Finest With the innovative strategies implemented by Xcellerex in its FlexFactory platform. the company has developed a solution that revolutionizes the way pharmaceutical companies manufacture products vital to the health and well-being of the world’s population.
hydro.INDUSTRY: METALS. Software Department Manager. ArchestrA System Platform turned out to be the ideal solution thanks to simple object creation.” Oliver Houbé. MINERALS AND MINING Hydro Aluminium Extrusion Deutschland GmbH www.com “We were looking for an easy-to-use configurable system. EMP Planungsgesellschaft für Prozeßautomation mbH More efficient energy management and optimized building automation at Hydro Goals • Reduction of energy costs through the accurate management of peak loads to prevent expensive consumption peaks effectively • Counter measures by optionally switching off users and/or switching on power generators • Unified visualization of existing building automation/control systems Challenges • High availability • System openness • Standardized interfaces • Integration of existing systems • Centralized data collection and analysis • Easy management Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware Historian • Wonderware Historian Clients • Wonderware Device Integration Server Results • Centralized monitoring of consumption • Reduction of peak loads by complying with fixed load limits • Possibility of counter measures before peak load limits are achieved • Quicker ROI by avoiding incalculable costs and/or reducing calculable costs • Short project deployment time • Limited training requirements as a result of easy management 70 . configurationand inheritance properties.
existing building control systems from different vendors offer no standard and unified visualization. 71 . The performance price on the other hand. as the main site for rolling operations. Peak load management contributes to the reduction of energy costs based on the maximum annual 15-minute load peak. It is one of the world’s leading factories for the production of high-value aluminum belt. Such complex requirements could not be handled with the existing systems (ABB. For both activities. ArchestrA System Platform. modular.with just limited training . has a long record in aluminum production. With a century-long tradition. Electricity prices for big consumers are basically made up of an operating price and a capacity price.Metals. the key task was to provide a unified user interface.to modify and expand the system as required and without specific programming knowledge. a major supplier of aluminum and aluminum products. Hydro Aluminium has high energy consumption levels. Hydro Aluminium Extrusion Deutschland GmbH employs 19. The Grevenbroich factory (between Cologne and Düsseldorf. Goals and challenges The project goal was to implement an integrated solution for peak load management and building automation. partners and the entire community.000 people in 40 countries. Another requirement was the integration of process-near components. film products and for value-added aluminum processing. EMP recognized that the functions and capabilities of ArchestrA System Platform would be perfectly fitting for this application. The company looked for an open. Wonderware Historian Clients. the capacity price in the following invoicing period (normally one year) increases proportionally to the achieved annual peak load. as well as interacting with the building process control system. The operating price corresponds to the cost per kilowatt-hour (KWh) of power consumption. Minerals and Mining Germany is among the world’s biggest users and producers of aluminum. Hydro. The application of an easy interface concept should make future expansions simpler and consequently more costeffective. Just like many manufacturers. The related costs represent a significant share of production costs. Wonderware Device Integration Server In the building automation sphere. Another request by Hydro was to enable employees . Kieback & Peter) due to their proprietary nature. This factory has been part of Hydro since 2002. Hydro relies on its capacity to create added value and future-ready solutions for its customers. Wonderware InTouch® HMI. The key task of peak load management is predicting the current 15-minute interval based on current consumption levels and the targeted switching-off of single users based on preconfigured rules. is based on the capacity offered by the utility company: the peak load. Wonderware Historian.950 employees. provides most of the metal for this industry. in Germany) is the biggest site of the Hydro Group with 1. future- proof solution capable of gathering and displaying data and information from all buildings/plants. Therefore. the efficient management of peak loads is a necessary measure for cost reduction. These costs can only be cut by reducing consumption. If the prescribed peak load is exceeded (15-minutes average value). This enables Hydro to reduce the annual peak load and/or to avoid exceeding the prescribed peak load.
An intensive consulting phase involving Hydro and the longstanding Wonderware partner and system integrator EMP quickly resulted into the development of a workable solution. employees at Hydro Aluminium Extrusion Deutschland GmbH can execute the modifications themselves after a short training session. including building automation devices and energy users and peak load management rules. Based on measured values. Wonderware Historian Clients. Wonderware InTouch® HMI. the operator may be required to take action. Then. depending on the downstream process. a comprehensive template library was developed. through instances and configuration. Benefits and results Within just a few months. while incalculable costs like extra charges for exceeding peak load have been effectively avoided. like rolling mills for instance. calculable costs like electricity have been reduced. Wonderware Device Integration Server plant expansions can normally be carried out quickly and easily by employees who do not have specific programming knowledge. a consumption prediction is made every 15 minutes. ArchestrA System Platform turned out to be the ideal solution thanks to simple object creation and configuration. visualize and evaluate them. If the predicted level exceeds the nominal value. Implementation The implementation process for this peak load monitoring and management system had to be tested in the aluminum film department at the Grevenbroich site.Metals. that complies with all submitted requirements. the peak load management system generates the corresponding control signals. the peak load management system was put in place and it is now an integral part of site operations. Wonderware Historian. future 72 . a totally object-oriented approach was the basic condition for a futureoriented solution. First. Hydro can now collect an extensive set of energy consumption data. these signals may trigger switching operations. Minerals and Mining ArchestrA System Platform. or alternatively. For EMP. Easy configuration based on the ArchestrA System Platform have enabled the quick deployment of the project and will support future expansions in the system. a model of the plant was created. “Energy-hungry” users. users are switched off or generators are switched on. As properties and methods are already programmed in the templates. Peak load management is carried out in two ways. start only when forecasts indicate that the nominal value in the current 15-minute interval is not going to be exceeded. In Grevenbroich. use them to prevent additional costs. and when necessary. Since the introduction of the system. Furthermore. Then.
engineers and technicians) in four sites in Berlin. EMP is also proficient in the deployment of solutions from the other Invensys Operations Management brands.The Wonderware Partner: EMP Planungsgesellschaft für Prozeßautomation mbH EMP is an engineering company specializing in process automation in the pharmaceutical. EMP GmbH was established in 1984 in Leverkusen and currently employs 130 people (IT. Users from the plant now have the ability. ArchestrA System Platform. the Wonderware system integrator EMP also considered the usefulness of a Web-based representation of collected data and their analysis. Triconex and Avantis. Bottrop. Wonderware InTouch® HMI. EMP has been a partner of Wonderware GmbH. Minerals and Mining Conclusion While developing this energy management solution. Wonderware Device Integration Server Ecosystem . Leverkusen and Frankfurt. to review reports for peak load analysis. This document was realized thanks to the support of: Hydro Aluminium Extrusion Deutschland GmbH 73 . chemical and metal working industries. through Wonderware Information Server. energy and power stations. including Foxboro. Wonderware Historian. via the Internet or corporate Intranet.Metals. Wonderware Historian Clients. Since 1996. industrial equipment. acquiring significant experience in the successful implementation of projects using Wonderware Software.
• Improve system performance Challenges • The upgrade would have to be done live during full production but with no plant downtime or loss of production. engineering and configuration time is sliced in half.” Johan Louw. Automation Specialist.INDUSTRY: METALS.0 to release 3.lonmin. Lonmin Major real-time SCADA upgrade at Lonmin – and who knew it was happening? Goals • Upgrade of System Platform 3.com “What impressed us most is that.1 involving all 7 concentrators and a large SCADA infrastructure. with ArchestrA. • Operators to have visibility into the plant at all times Solutions and Products • ArchestrA System Platform • Wonderware InTouch™ • Wonderware Historian • Wonderware Historian Client Results • Major system upgrade with no downtime and no loss of visibility into the plant • Improved system performance • Development of a risk-free method for implementing future upgrades • Improved user confidence in the capabilities of the system and its upgradeability 74 . MINERALS AND MINING Lonmin Plc www.
1: The Concentrator “shop floor” at Lonmin’s Marikana complex (map by Google Earth) . • Get buy-in from users – It’s not unusual for system changes to be viewed with some degree of scepticism and the success of the project would largely depend on empowering users to take ownership of the new solutions.) (figure 2). “This was a project involving the upgrade of System Platform 3.1 involving all the concentrators. The Historian is also standardised for each concentrator. a smelter and a base metals refinery. ArchestrA System Platform. Background Lonmin’s Marikana operation spans an area of 33 X 13 kms near Rustenburg in the North-West province of South Africa and is in the business of mining and processing platinum group metals on a 24/7/365 basis.” says Lonmin’s Automation Specialist Johan Louw. 43 ArchestrA Object Servers (AOS). The next step was to upgrade the view station and the IDE. The Marikana operation uses 5 ArchestrA Galaxy Repository (GR) servers. 42 view stations and 14 Wonderware Historian servers. Upgrading its extensive process control operations which. We then upgraded the backup AOS servers. This makes each Concentrator a self-contained production unit with a standardised architecture but individual control. was no casual exercise which demanded guaranteed results and zero downtime. • Operators to have visibility into the plant at all times – Once again. services. Wonderware InTouch™ Wonderware Historian. The rest of the system is used for the shafts.” explains Louw. 7 concentrators. has a DMZ which isolates the control VLAN (PLC connection) from the production VLAN (viewing. How it was done “Fortunately the sites were designed to each run 2 AOS servers (1 backup – see figure 2) and this architecture supported what we wanted to do. the Concentrator Galaxy (figure 1) consists of 16 AOS.” Concentrator architecture Lonmin has defined an operating environment for its concentrators which. this precluded any system downtime.0 to release 3. smelter and metal accounting. in this case affected all seven of its concentrators. This could still be done with no downtime. “While upgrades are normally routine affairs. we introduced an additional upgraded Galaxy Repository (GR) Server to form a parallel galaxy. Wonderware Historian Client schedule making it impossible to arrange for a full concentrator shutdown. 75 Fig. Of this. this one bears mention because each of the concentrators involved operates individually and has its own shutdown Challenges • Implement upgrade with no plant downtime – Production stoppages would not be tolerated yet any upgrade normally requires installing new software and restarting the system. 16 view stations and 9 Integrated Development Environment (IDE) stations monitoring nearly a quarter million tags across 68 PLCs. development. The upgrade would have to be done live during full production but with no plant downtime or loss of production. for security purposes. etc. The complex consists of 14 shafts. • Improve system performance – The magnitude of the concentrator complex demands highly optimised approaches if system performance is to be improved. Minerals and Mining Lonmin’s Marikana complex is one of the largest and most significant platinum mining and processing operations in the world. So a way had to be found to work around this problem. A viewing station and its backup are included as well as an ArchestrA IDE station. “With the help of Wonderware Southern Africa.Metals.
Benefits Figure 2: Concentrator architecture so that two view stations were running the same applications on two parallel galaxies. Another notable feature is the ability to manage the software from a central point.” • The ability to enable redundancy on critical areas. “This also gave us time to implement best practices and to validate our existing GRs. After all the sites were done. with ArchestrA.) in the Concentrator galaxy alone and to have this continue in real-time during a plant-wide system upgrade with nobody noticing and without missing a beat is impressive for two reasons: it’s a great example of merging inventiveness with technology and it’s now become routine rather than a career-defining moment. it took about 3 months. Marikana’s six Historians log 350 million readings a day (4050/sec.not to stop it dead in its tracks for a routine software upgrade. Once each IDE was upgraded. users could start doing development on the new galaxy. “What impressed us most is that.Metals. control and improve production .” Since the rollout wasn’t done on a full-time basis and was interlaced within normal day-to-day activities.and that’s how it should be. the old GR was decommissioned and prepared for the next upgrade. This reduces downtime in the event of hardware failure. The result was a major system upgrade with no downtime and no loss of visibility into the plant. This document was realised thanks to the support of Johan Louw. Any new development on the old galaxy would at this stage be lost. as well as enforcing standards across the business. Systems are there to help monitor.” • Major system upgrade with no downtime and no loss of visibility into the plant • Improved system performance • Development of a risk-free method for implementing future upgrades • Improved user confidence in the capabilities of the system and its upgradeability Conclusion A seamless upgrade of this magnitude goes to show what can be done with modern technologies and ingenuity . Wonderware Historian Client According to Louw. engineering and configuration time is sliced in half. • Distributed architecture which simplifies the process of backups and restore. The next step was to change over the Historian and finally the old AOS. “We were able to do load sharing on areas where a lot of processing power was required.” says Louw. Wonderware InTouch™ Wonderware Historian. Minerals and Mining ArchestrA System Platform. Automation Specialist at Lonmin 76 . the most impressive aspects of the system architecture include: • Scalability.
maintaining between $2 million to $12 million in inventory • Compliance with the Federal Environmental Protection Agency (EPA) regulation called the Portland Cement Maximum Achievable Control Technology (PC MACT) • Minimizes the potential loss of $3. MINERALS & MINING Ash Grove Cement www.INDUSTRY: METALS. while maintaining production Solutions and Products • Avantis. we have reduced inventory by at least $2 million in the last few years.000 items at each plant. Scheduling and Compliance Management for Ash Grove Cement Goals • Automate maintenance data collection at each facility for a well-defined enterprise asset management process to support equipment performance reliability Challenges • Improve the availability and utilization balance of production assets and develop a standardized solution for each of its nine separate production facilities.000 per hour for every hour the kiln is offline 77 . as many as 8.PRO® • Avantis VIP Advanced Scheduling Results • A $2 million first year inventory reduction • Improved ability to manage inventory.com “By closely monitoring and managing what we use. and parts and materials pricing. This is a significant contribution to keeping our prices competitive in the marketplace.ashgrove.EAM® • Avantis.” Mike Ralls Plant Systems Administrator Avantis Solution provides solid Enterprise Planning. reorder activities.
we can lose as much as $3. covering several square miles of quarries and the cement production plant. As the fifth largest U. which gives us a limited window of opportunity to do major overhauls. “Our long-term goal was to automate maintenance data collection at each of our facilities for a well-defined enterprise asset management process to support equipment performance reliability while interfacing with our financial software. but maximizing profit in a highly cost-competitive market requires continuous innovation. Avantis. Company headquarters are in Overland Park. Kansas. transportation. Ash Grove set out to improve equipment reliability and cost savings further by tapping EAM functionality for enterprise planning and scheduling. commercial and industrial complexes.EAM®. silica. regulatory compliance.” With the global rollout underway. and autonomous mining. residential homes.S. production.” This challenge was compounded by having to develop a standardized solution that worked for each of its nine separate production facilities. and iron components into the base “cement clinker” is the heart of the operation. The Portland and masonry cements produced at these plants are used in the construction of highways. JD Edwards One World. Ralls explained. who is going to do it. document management. All are in constant use and need regular maintenance. Avantis. states. the Ash Grove Cement Company is the fifth largest cement manufacturer in the United States. but usually we get a 2-4 week period once a year based on kiln outage. Mike Ralls. “We’re sold out all year long and that’s just the way we want it. which makes the kiln one of our top maintenance priorities. Avantis VIP Advanced Scheduling and reach temperatures as high as 3000 degrees Fahrenheit. we were pretty excited.” said Bernard Sherin.PRO®. We needed a system that we could implement to improve operations. Maximizing profit in a highly costcompetitive market Cement producers can pretty much sell as much cement as they can make. To make most efficient use of that maintenance window. “It’s a challenge to schedule maintenance work when you run 24 hours a day. According to Ryan Farr. “Our original need was maintenance functionality and some cost tracking information. alumina. Ash Grove automated all data collection on kiln-related maintenance activity at one plant and extended it to remaining facilities in the following year. the Ash Grove enterprise includes management.” said Farr. with the scalability to contribute to sustainable development. Maintenance Manager at the Durkee plant. Typically.S. Kansas – Founded in 1882. Minerals & Mining Overland Park. We need to tightly manage what has to be done. with an annual production capacity of more than 8 million tons per year.” While all phases of production are important. finance. and inventory management.000 an hour. geographically separated operations. and what is needed to get the job done most efficiently for ongoing reliable operation. Kansas. The Ash Grove kilns are large ovens that rotate at about 3. the kiln drives our maintenance outages. We must continually find better ways to balance both availability and utilization of our production assets. “If the kiln goes down. bridges. the high temperature kiln. mostly a data capture and get it into the system so we don’t lose it’ type of solution. But when we saw that Avantis could also help us sort and interpret this data. said. Plant Systems Administrator. cement manufacturer. and numerous other applications. which converts calcium. and administration functions at headquarters in Overland Park.Metals. and distribution facilities in nine U. but we don’t have the luxury of non-production time.S. with production facilities located throughout the U.5 RPM Analyze failure causes and histories and take action accordingly The expanded Avantis functionality enables Ash Grove management to share maintenance data from diverse. It is a computerized maintenance management system (CMMS) that uses an “entity” concept to enable tracking of cost and 78 . Corporate Reliability Manager. The scope of the equipment at these facilities ranges from capital expense drilling and excavating systems to motors and power transmission belts.
easier compliance with environmental regulations. all of which can be easily reviewed and analyzed. and any special instructions for the job. and improved inventory management. Sharon McGuire. and the planner coordinates with other related departments to determine the most efficient remedy. The system then notifies the operator that the job is complete and to submit a review and comment. Ash Grove has an open access policy to relevant information by all Avantis users throughout the enterprise from maintenance to management. For instance. which are given to technicians at the beginning of each day. Minerals & Mining maintenance activity. To help all maintenance teams stay on top of required maintenance. Avantis. Technicians can review work backlogs easily. our top priority is minimizing downtime of revenue-producing equipment.PRO®. for regular review and reprioritization. The system automatically issues work orders to technicians. Avantis VIP Advanced Scheduling To enhance the scheduling and planning efficiency further. This is particularly useful for managing work requests. materials. The system then generates the work order automatically. as needed. Planner/Scheduler at the Durkee facility. Electronic Documentation The Avantis. but requires facilitywide coordination. “Parent-child” relationships can be set up easily to build detailed hierarchies for cost rollups and operating statistics. especially when dealing with large numbers of unique and low-unit-value items that can often be subject to unpredictable demand. the technician generates an emergency work order through the PDA. The work orders can include information on labor. Equipment statistics include hours of operation. Ash Grove has added Avantis VIP Advanced Scheduling software. With proper cost justification. and that is one area where the Avantis software has proven to be particularly helpful. and labor and material changes. which goes to the planner as a high priority. so planned outages of this equipment drive our planning. Planners download work orders to PDAs. the equipment operator can enter a work request from his station. they go ahead and do it.” This detailed history of equipment information enables supervisors to analyze failure histories. tools. In addition to improved maintenance efficiency. The VIP software helps schedule maintenance and measures schedule compliance. “We can look at historical data and trend it to evaluate whether we need to spend more or less effort in a particular area. and define the most efficient procedures. and determine appropriate maintenance procedures by studying the equipment history. “Following safety. The software also supports contingency planning for unanticipated equipment failures. Proper planning gives us more control over the situation. adjust work schedules. cause and frequency of downtime. and take action accordingly.Metals. Technicians record status electronically during the day and update the central database by docking the PDAs in the evening.” said Farr. Workflow can be better planned and purchasing and procurement functions can be tied directly into planned outage maintenance programs. drawings. if a guard on a piece of rotating equipment needs to be replaced. The advanced planning and scheduling software also improves processing of emergency work orders.PRO software builds a detailed history of equipment information based on day-to-day maintenance activities. without further coordination. These are closely monitored. including better documentation of all maintenance activities. Avantis. It’s given us an easy way to determine whether a particular piece of equipment has had an inordinate amount of work done on it. Pre-entered coding helps technicians determine which equipment must be shut down during the maintenance and which can continue running. inaccuracy. Ash Grove has benefited from eliminating the cost. track failure causes. Maintenance parts inventories can be better managed. we can judge whether we should replace any equipment that’s costing too much to maintain. It enables better employee work utilization and facilitates changes in plans and schedules.EAM®. which manages availability of all project resources. 79 . and time-consuming aspects of paper processing. and places it in a backlog. Ash Grove uses Avantis VIP in conjunction with handheld personal data assistants (PDAs). For more involved procedures that cannot be handled right then. who replace the guard and enter details into the system. Planners and schedulers in another office will review the work request. schedule the repair. said. If technicians encounter situations that can be corrected immediately.
it is critical that all required parts be available for that outage. “One critical requirement in the PC MACT program is to have preventive maintenance schedules set up and documented. With the Avantis planning and scheduling functionality. Inventory management gains are in reduced inventory size. the Avantis software stores and simplifies retrieval of vendor information such as pricing. so purchasing can prepare to replenish these parts most efficiently by researching price. Avantis VIP Advanced Scheduling Inventory Management To help Ash Grove manage procurement. By increasing kiln usage. and overall maintenance costs savings. and uses this data to drive automatic replenishment and tracking of inventory items. Inventory warehouse managers pull parts and have them ready for the technicians. This document was realized thank to the support of: Ash Grove Cement 80 . we could face serious fines.EAM®. Without this. and delivery of these items. They want to know what time the incident occurred. what we did about it. availability. We rely on Avantis to maintain our history of all operations to meet these new requirements. and what time the emissions were abated. Visible emissions can generate complaints. lead times. Avantis. and manufacturers’ cross-references. Ash Grove minimizes the potential loss of $3. resulting in a visit from Department of Environmental Quality (DEQ) inspectors. kiln uptime. At the same time. and automates ordering so that it is there when needed. including standard operating procedures that demonstrate that we’ve followed these procedures. Minerals & Mining Documenting Environmental Compliance The Federal Environmental Protection Agency (EPA) regulation called the Portland Cement Maximum Achievable Control Technology (PC MACT) requires all cement plants to follow an approved plan for continuous compliance with environmental regulations and provides for regular monitoring of adherence to that plan. Gains in inventory management Expanding the scope and functionality of the enterprise asset management system has contributed to gains in inventory management.000 per hour for every hour the kiln is offline. “By law we are required to document these incidents and the inspectors want to see it. Avantis. Included with every work order is a list of parts required to complete tasks. Avantis tracks items coming out of and going into inventory.” said Farr.Metals. Farr commented that.” This is particularly critical for visible emissions monitoring. Because most maintenance must be done during planned outages. Avantis provides this documentation to validate our actions. the system now predicts what parts will be needed at the time of the outage.PRO®.
” Johann Pienaar.assmang.co. quickly and to the benefit of our clients. Iritron director ASSMANG’s Khumani mine turns to Iritron and Wonderware for its expansion project Goals • Expand the original SCADA installation by 50% using the same tools and technology Challenges • The expansion project is large and critical in nature but it needed a rapid completion schedule Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware Historian Software Results • Re-use of templates developed during the initial project phase greatly reduced development time (10% of the initial time for a 50% expansion) • Proof that system components will rapidly cope with increasing mine demands 81 .za “We are thankful for the Invensys ArchestrA technology because its developers obviously understood our very real needs and built an environment that allows us to grow painlessly.INDUSTRY: METALS AND MINING ASSMANG Limited www.
“All that was required was to create new instances of the existing templates (motors. Khumani is well on the way to becoming a principal player in the global and competitive world of primary metal production. the effort put in during the definition and development of the standards and templates during the initial project finally paid off. Iritron is a certified ArchestrA System Platform integrator and has a long track record with ASSMANG and extensive knowledge of their standards and requirements. The Khumani deposits are among the best iron ore resources in the country in terms of quality and quantity. conveyors. seeing as these templates had already been thoroughly tested. the existing System Platform was expanded by adding an additional pair of redundant Application Object Servers and six additional InTouch View Nodes in the new plant sections – King Primary Crushing. 2nd Load-Out Station and the Jig Plant Extension. “In this case. “One of the main advantages of System Platform is its scalability. Wonderware InTouch® HMI. The same applied to the PLC programmes. the standards and templates that were developed during the initial phase of the project could be re-used for all the new plant sections. No other hardware additions were required – the existing servers and networks had more than sufficient spare capacity in terms of processing power and licensing. a new mine producing 8.) for each piece of equipment that had to be added. ArchestrA System Platform. To date. “No testing and integration was required. Wonderware Historian Software In terms of hardware. Iritron is also actively involved in the Beta and systems testing of current and future releases of System Platform. valves. screens.” says Iritron director Johann Pienaar. etc. flexibility and ease of expansion once standards and templates have been developed for a specific implementation.Metals and Mining ASSMANG’s Khumani iron ore mine is situated in the Northern Cape Province of South Africa and close to Sishen. Iritron has successfully implemented five large ArchestrA projects ranging from the Northern Cape to the United States and the company is currently busy with another four projects. Completed in just two years from a foundation of Kalahari sand.” 82 . Expansion project For the mine’s expansion Project.4 million tons annually would have a life in excess of 40 years and at double that capacity. crushers. System Integrator Iritron was contracted by DRA Mineral Projects (Pty) Ltd during the initial (2008 greenfields) ASSMANG Khumani project to take responsibility for the implementation of the overall SCADA (Supervisory. Based on current reserves. ASSMANG’s Khumani iron ore mine is an ambitious undertaking by any definition. a life in excess of about 25 years. ASSMANG again appointed DRA Mineral Projects as the Managing Contractor for the project and Iritron was again contracted by DRA to implement the extensions to the already-installed System Platform. Control and Data Acquisition) system using the ArchestrA System Platform.” In terms of software development.” says Pienaar.
“We are thankful for Invensys ArchestrA technology because its developers obviously understood our very real needs and built an environment that allows us to grow painlessly. flexibility and ease of expansion the project required Conclusion Proof positive that the bottom line is impacted positively when industrial production solutions “understand” the long-term view rather than cater for the immediate fix. Through design. The savings in time will be even more pronounced during commissioning. quickly and to the benefit of our clients.” concludes Pienaar. Wonderware Historian Software • Using standards developed during the initial phase of the project greatly reduced engineering time • Thoroughly tested existing templates could be redeployed with confidence • The System Platform provided all the necessary scalability. After all is said and done. it’s predictable that Khumani will continue to expand and continue to hone its production processes to maximise profits. it’s results that count – not promises. but the SCADA development took less than 10% of the original development thanks to the standards enforcement of the underlying ArchestrA technology. the solutions now in place “understand” that this is the norm of today’s industrial marketplace and will continue to deliver results that keep pace with the inventiveness and ingenuity of their owners. The size of the Khumani Expansion Project is about 50% of the original project. ArchestrA System Platform.Metals and Mining Once the object instances had been created (exports from the FDES instrumentation design software and CSV imports were used to automate this process in both System Platform and in RSLogix5000). Wonderware InTouch® HMI. Based on soaring world demand. the new mimics were created by dragging and dropping the associated object graphics on to the mimic pages and adding the static detail. Benefits This document was realized thank to the support of: ASSMANG LIMITED 83 . so no additional configuration or testing was required. The graphics and animation form part of the object templates.
we can melt 50 percent more cold aluminum in the same amount of time as we did previously. Linde Gas has enabled Hydro to increase its aluminum cold metal melting capacity by more than 50 percent • The company was able to reduce dross to less than 2% and fuel consumption by 50% • A significant reduction in carbon dioxide and nitrogen oxide emissions also was achieved to maintain the company’s commitment to reducing its impact on the environment • The Linde Gas Low Temperature Oxyfuel technology. now enables the continuous production of 125.hydro. using The Foxboro PAC System.000 tons of foundry alloys annually 84 . MINERALS & MINING Hydro www. the technology needed to provide both cost savings in production as well as assist in minimizing the company’s environmental impact Solutions and Products • Foxboro Programmable Automation Controller (PAC) System Results • By utilizing the key features of the the Foxboro PAC System.INDUSTRY: METALS. In addition the propane consumption and carbon dioxide emissions have been cut in half which also is very positive.” Wenche Eldegard Cast House Manager © Norsk Hydro Invensys Helps Hydro to Significantly Increase its Aluminum Cold Melting Capacity as well as Reduce Waste and Emissions Goals • The company required a solution that would enable it to achieve increased melting capacity and reduce waste • The technology needed to not only increase production efficiency but also reduce production costs and increase energy savings Challenges • The aluminum manufacturer needed to accurately control combustion operations and enable the smooth transition of various metallurgical processes • Optimizing energy output during the aluminum melting cycle was vital to achieving overall production efficiency • To maintain profitability.com “By using the lowtemperature Oxyfuel method.
a more effective process had to be found. Combined with secure data recording for accurate manufacturing measurement parameters. Hydro now effectively manages these risks by employing lowtemperature Oxyfuel technology combined with the Foxboro PAC System intelligent burner control solution. with capacity up 50% while dross is less than 2%. the Foxboro PAC System’s collection of features is designed to maximize Hydro’s return on investment. the Foxboro PAC System delivers higher melt rates with reduced oxidation. Norway – In 1957 the tin can made a significant leap in design and functionality by incorporating the most abundant metal in the Earth’s crust -. Foxboro Programmable Automation Controller (PAC) System The challenge at Hydro was to optimize the amount of energy required in the manufacturing process when producing its more than 125. Using the Foxboro Process Automation Controller (PAC) System. With the risk of creating hot spots due to overheating the aluminum surface. which is a mass of solid impurities found floating on molten metal such as aluminum. it became cheaper to produce and reduced the possibility of lead poisoning associated with solder used to seal tin containers.Metals. The Foxboro PAC System is a high-performance hybrid automation controller which offers high performance. The whole System reduces Hydro’s engineering costs and provides high availability of data. packaging and consumer goods. The re-melt capacity has now been increased. machine vision and motion control. Although Oxyfuel is accepted as state-of-the-art for rotary furnaces. The low density. More Than Just Aluminum Foil Working in conjunction with Linde Gas. enabling it to be manufactured in a wider array of shapes and sizes. Its control unit and I/O system form the basis of a complete distributed control and recording environment capable of continuous analog.000 tons of foundry alloys each year. Hydro employs intelligent burner control solutions for low-temperature Oxyfuel control. 85 . logic and sequential control. The use of Oxyfuel combustion substantially increases the thermal efficiency of the production facility’s furnace operations because the radiant heat transfer of furnace gases produced are significantly more efficient than those created from air-fuel processes. Though the new aluminum container still had to be opened with a knife. aluminum manufacturing has made various evolutionary leaps in processes and materials thanks to the development of new production technologies. During the last decade. data acquisition. the aluminum industry has been more cautious to adopt the technology in reverberatory furnaces. reliability and high I/O densities with cost-effective redundancy options. Hydro is one of the world’s leading producers of aluminum and is a supplier to a wide range of industries spanning automotive and transportation to building supplies.aluminum. a leading gases and engineering company. Invensys Operations Management installed the Foxboro PAC System for process control. lower fuel consumption and ultra-low nitrogen oxide emissions. Combined with the lowtemperature Oxyfuel technology. maximizing the company’s process uptime. corrosion-resistant metal also offered greater malleability. remote equipment monitoring. To provide top-quality and cost-effective aluminum products. minerals & mining Ardal. in conjunction with Linde Gas Oxyfuel burners has resulted in significant economic savings and supports Hydro’s commitment to reducing greenhouse emissions and dross.
000 tons of liquid aluminum by re-melting cold metal. all files from the primary processor are copied to allow a secondary processor to mirror and monitor the primary processor. logic and sequential control all combined with secure data recording at point of measurement to maximize ROI. the process included the mixing of 8 tons of cold metal and 22 tons of liquid metal which had a high production cost factor.Metals. Project Manager at Invensys Operations Management.” said Constantine Lau. Now the mix is 13 tons cold and 17 tons liquid metal. The two production lines for primary foundry alloys were converted to the low temperature Oxyfuel and Foxboro PAC System process resulting in a 50% increase in re-melting capacity. power supplies. “The key element Hydro needed was increased capacity on melting cold metal. Hydro can replace 20. reducing overall operations costs. As aluminum has demonstrated its ability to be used in a multiplicity of products with myriad business and consumer applications. Previously. The Oxyfuel process and Foxboro PAC System technology has enabled the company to increase its overall average re-melting capacity by more than 50% for the four furnaces at the cast house. The controller/recorder redundancy is automatically commissioned by simply plugging the additional processor module into the redundant base and initiating the E-Sync technology with a single button press on the front of the unit. minerals & mining Oxyfuel and Foxboro PAC Technology By using the low temperature Oxyfuel technology. During the E-Sync process. Hydro has been a leader in advancing improvements to the metallurgical processing of this extremely abundant metal. With the help of Invensys. Hydro has implemented redundant capabilities that maximize process uptime in its aluminum melting process. overall productivity is increased while at the same time saving on fuel costs and reducing carbon dioxide and nitrogen oxide emissions. this provides a high degree of fault-tolerance at a very low cost. the solution gives them that alongside large energy savings. the Foxboro PAC System provides a high-performance solution that offers extremely cost-effective redundancy options. No special cabling or engineering is required to configure a secondary processor. Combined with optional controller redundancy. it will continue to control the process even if a network link is lost. Director of Product Marketing for Control and Safety Products at Invensys Operations Management. Foxboro Programmable Automation Controller (PAC) System at a process unit and can be easily configured using Invensys technology. multiloop process control capability to be deployed right This document was realized thanks to the support of: Hydro 86 . The control unit and I/O system form the basis of a complete distributed control and recording environment capable of continuous analog. Combining the low-temperature Oxyfuel burner for aluminum melting with the Foxboro PAC System. the Foxboro PAC System enables redundancy of processors. cost-effective process automation controller also uniquely provides secure data recording with dual-redundancy at point of measurement. recording and networks. Integrating the Foxboro PAC System with the plant’s PLCs enable Hydro to maximize Return on Investment (ROI) by offering automatic dualredundancy options to guarantee process efficiencies and protect against controller or communications failures.” Foxboro Combines PLC Architecture and DCS Functionality In addition. Hydro has taken a significant step toward enabling more efficient re-melting of aluminum in reverberatory furnaces. With the E-Sync technology. Thanks to improved thermal efficiency and increased heating/melting rates. “The Foxboro PAC System allows low-cost.” said Lars Goran Elfgren. It was vital to provide accurate combustion control and a smooth transition between all aspects of the cycle while optimizing the melting cycle and applying the maximum energy when the thermal efficiency is highest. resulting in lower engineering costs and a reduced impact on the environment. This powerful. “While the Foxboro PAC System can be easily integrated into a control or plant network.
especially medical products • Standardizing the control application of its medical press machines was a primary objective for the company • Illinois Precision wanted to offer its OEM customers improved operations and streamlined manufacturing processes Challenges • The company needed to identify technology that could provide more precise process control • The competitive marketplace demanded an expansion of company leadership in the medical molding market space • Transitioning from an open-loop process to a closed-loop process required a technology that could provide a more precise and repeatable process for medical injection-molding applications Solutions and Products • Eurotherm MACO Compact Control System Results • The Eurotherm MACO Compact control system integrates more precise control of injection-molding processes for the medical industry • Illinois Precision has made the Eurotherm MACO Compact standard for all brands of its presses • The company’s presses can better meet environmental requirements because the Eurotherm MACO Compact provides a more precise material processing application reducing scrap and improving overall operating efficiency 87 .illprec. setup storage and maintaining a complete history of the overall molding process. mold storage.com “The Eurotherm MACO Compact control system manages a wide range of variables which are needed for the successful implementation of medical molding processes such as repeatability.” Steve Schroeder Business Development Manager Invensys Operations Management Invensys Eurotherm MACO Compact Control System Enables Illinois Precision to Expand Business into Medical Industry Goals • Illinois Precision wanted to increase its market share by expanding into other industries.INDUSTRY: PLASTICS Illinois Precision www.
linear-positioning control of machine or auxiliary functions. Eurotherm MACO Compact Control System systems and blood collection sets. Some of the medical products manufactured via the injection-molding process include oxygen masks and airway management systems. from bottle caps and pipe fittings to eating utensils and surgical tubing. The production process of these mass produced injection-mold products must not vary. Illinois Precision recognized the need for its presses to continuously perform at peak levels. “However. IV 88 .” In a closed-loop process. This process may involve many variables which can affect the finished product. Business Development Manager of Plastics at Invensys. and built-in timing and counting. a sensor monitors the system output and relays that data to a controller which then adjusts the process for the optimal control of the system. as well as infusion. Its operator interface is designed to support maximum flexibility enabling IPC to run the system using its preferred interface design. so a closed-loop system must be used in production. tracheal and feeding tubes. The Eurotherm MACO Compact supports the precise manufacturing requirements demanded by the medical field. which demands extremely precise manufacturing standards. with a display that supports in-depth process data trending. Each batch produced must be exactly the same. The MACO Compact control system offers several keyboard options. the machinery must maintain precise calibrations in order to produce products that meet the stringent medical industry manufacturing requirements for quality and consistency. Machinery designed and developed by the company has been used in the production of products for a variety of industries such as electronics. “Many injection-molding methods use the simple open-loop process which is a low-cost. IPC selected the Eurotherm MACO Compact control system from Invensys Operations Management as standard technology to be incorporated in both its regular line of Echo presses and its new Echo MD line designed specifically for the medical industry. from touchscreen to full numeric keypad functionality. To successfully compete in this market space. nonerror controlling approach commonly used when reporting of production data is not critical. text displays. The process of injection molding for medical product manufacturing requires specialized tooling in the form of an injection mold and an injection-molding press. alarm messages and control standards charts. The MACO Compact offers a full range of features including closed-loop process control. Illinois Precision Corporation (IPC) has been in the business of developing injection-molding equipment since 1970. appliances and sports. in the production of plastic medical products. The technology incorporated into the injectionmolding machinery has a significant impact on how quickly manufacturers can produce large volumes of product to meet customer needs as well as reduce overall production costs. Indiana – Injection-molding processes are key to the manufacturing of consumer and industrial plastic items used every day. These features and benefits make the MACO Compact control system a reliable. pressure/flow control. cost-effective solution for any injection-molding operation. This is done throughout the manufacturing process to maintain the exact system production criteria and ensure that the exact output specifications are met. Therefore. auto-tuned temperature control. precise measurement and manufacturing statistics must be adhered to exactly. IPC selected the Eurotherm MACO Compact to provide more precise machine control functions. custom machine graphics. The process melts plastic in a heated cylinder which is then injected into the mold to form specific parts or components.” said Steve Schroeder. the company identified the medical industry as an area for expansion and realized that a closed-loop system is required for this market segment. catheters.Plastics Bicknell. Critical Medical Manufacturing Processes Expand IPC Market Reach With a strong business commitment to improving and expanding its line of injection-molding equipment for the medical industry. Recently. clamp control. flushing and drainage kits. All of which has a direct impact on the availability and price the customer pays for finished products. automotive. sequential machine control. The process involves melting plastic pellets and transferring the molten material to molds to create products for a wide array of applications.
“The Eurotherm MACO Compact control system has enabled IPC to expand its offerings of machinery to the medical market since the Invensys technology provides required repeatability. IPC can now offer its OEM customers improved manufacturing operations and standardized processes. This document was realized thanks to the support of: Illinois Precision. The Invensys solution enables IPC’s injection-molding machines to manage a wide range of manufacturing variables. “For medical molding processes. provides storage mold design and setup specifications and maintains a complete historical database of molding operations.” said Schroeder. efficiency and repeatability. ensuring reproducible product specifications. With the implementation of the Eurotherm MACO Compact control system. and complete molding historical data. but especially in medical injection-molding manufacturing. By standardizing the control application of its medical press machines on Invensys technology. because the Invensys technology is a comprehensive packaged solution it can be used to retrofit other IPC machine designs. 89 . IPC has achieved a milestone in the design and functionality of its injection-molding machinery. “Illinois Precision has gone from the basic ‘push and squirt’ process characteristic of an open-loop system to a closed-loop system for more accurate measurement and control of the injection process.” The Eurotherm MACO Compact was also selected for its enhanced processing features and ease of operation. these new tables provide smoother movements and braking to ensure faster and more accurate production of injection-molded plastics items. In addition.” said Schroeder. Illinois Precision is positioned to successfully increase its market share in the medical injection-molding industry segment. IPC is able to achieve a more precise shot control during the injection process. Because process reliability is critical in medical injection molding. and such needed features as mold and setup storage. The servo-electric rotary table enables operators to have more control of the injection process.” Eurotherm MACO Compact Control System Eurotherm MACO Compact Control System Offers More Precise Shot Control Illinois Precision’s new Echo MD Press with the Eurotherm MACO Compact control system features a new servo-electric rotary table that can pivot 90 degrees in one second. With the Eurotherm MACO Compact.Plastics “With all types of molding. IPC machinery has to deliver an extremely precise and repeatable process which is inherent in closedloop process control and statistical process control applications. with greater precision. precise and repeatable processes are very important.
bchydro.com “Our BMS migration from Bailey Symphony to the Foxboro I/A Series Distributed Control System went very smoothly. Checkout of the new BMS was substantially complete within three days.6 million customers • Decreased maintenance time/effort. Burner Management System checkout was reduced from three weeks to three days • Reduced upgrade costs by half and shortened downtime from weeks to days 90 . and improve process control Challenges • Continue delivering reliable power with the least possible environmental impact to its growing base of commercial and residential customers Solutions and Products • Foxboro® Distributed Control System .INDUSTRY: POWER BC Hydro www.I/A Series® • Foxboro Measurement & Instruments Results • Provides clean energy to more than 1.” Huitt Manering Principal Engineer and Task Manager BC Hydro gets upgrade from aging Bailey control system to Foxboro I/A Series Distributed Control System Goals • Replace obsolete Bailey control system to increase efficiency and reliability of power generation • Improve and optimize unit heat rates • Centralize plant controls in one room • Provide a real-time focus for plant operation.
It also jeopardized operation of the selective cathodic reduction (SCR) technology installed in 2000 to reduce nitrogen oxide emissions by 90%. on Vancouver Harbor.I/A Series® Foxboro Measurement & Instruments Upgrade and easy migration to a Foxboro I/A Series Distributed Control System After comparing proposals from Bailey. Foxboro® Distributed Control System . Rather than “bulldoze” the existing infrastructure — a costly and highly disruptive alternative — BC Hydro was able to implement the Foxboro I/A Series Distributed Control System on its legacy racks. British Columbians enjoy some of the lowest electricity rates in the world. and improving process control. In addition.Power British Columbia. and Invensys Operations Management. Due to this efficient. Besides repairing these deficiencies.6 million customers in a socially responsible way. Invensys handled the upgrading of Foxboro intelligent field transmitters and intelligent valve positioners. Invensys also provided the BMS design and the boiler/generator coordinated controls. Most of the actual migration then involved simply substituting the repackaged I/A Series I/O modules for those from Bailey. reliable power to fuel economic growth and development throughout Canada’s British Columbia province. Burrard is one of two thermal plants that supply critical base load support to the electrical grid in years of low water run-off or during maintenance outages. BC Hydro has constructed a world-class integrated hydroelectric system of close to 11. and seamless integration with data from new safety systems and other on-site third-party systems. Requirements also included a burner management system (BMS) and upgraded boilers. Fisher. reliable system. BC Hydro’s Challenge To continue delivering reliable power with the least possible environmental impact to its growing base of commercial and residential customers. The Foxboro migration solution simply replaced the Bailey I/O modules with I/A Series electronics packaged in the exact same form factor. without rewiring. Canada – BC Hydro provides high-value. centralizing plant controls in one room.500 megawatts of generating capacity — over 87% of which is hydroelectric. balancing its users’ energy needs with environmental concerns. BC Hydro determined that a Foxboro® plug-in migration solution would provide the greatest reliability and performance at the lowest cost with the least interruption of service. Supplementing the utility’s 32 hydroelectric facilities. providing a real-time focus for plant operation. other upgrade objectives included improving and optimizing unit heat rates. 91 . sustaining required availability. This unique approach reduced upgrade costs by almost half and shortened downtime from weeks to days. The utility provides energy solutions to more than 1. as well as balance-of-plant (BOP) controls. its obsolete Bailey control system was becoming increasingly difficult to maintain. However. A vital element: migration to a modern digital control system at the utility’s Burrard Generating Station in Port Moody. The station’s six gas-fired CE boilers generate 155 MW each of electric power. BC Hydro implemented an ambitious environmental improvement and plant modernization initiative.
Their new system delivers a major leap in functionality and ease of use in startup. This document was realized thanks to the support of: BC Hydro 92 . and the result was a well-designed card that was delivered on time for our first installation. “Invensys developed a new discrete I/O module to meet our requirements.” Foxboro® Distributed Control System .Power Delivering higher levels of control and efficiency The migration enabled Burrard’s system engineers to retain existing field wiring terminations. said. runup. Principal Engineer and Task Manager. Checkout of the new BMS was substantially complete within three days — as compared to approximately three weeks for the initial Bailey BMS commissioning.I/A Series® Foxboro Measurement & Instruments Burrard operations personnel report the new I/A Series System is delivering levels of control and efficiency higher than they have ever experienced before. system enclosures and power supplies. Huitt Manering. Our BMS migration from Bailey Symphony to the Foxboro I/A Series Distributed Control System went very smoothly. rundown and runback sequences.
4.r.cmep. www.sk An industrial power plant upgraded to face new market challenges.o.INDUSTRY: POWER CM European Power Slovakia s. I/A series® Version 8.3 Results • Heating capacity increased by 30% • Hi-availability • Power generation increase 40% • Sulphur dioxide emissions reduced by 70% • Flue gas emissions kept below the limits • Real-time production data available non-stop for evaluation 93 . • Increase of the installed capacity of the heating plant from the 114 MW to 169 MW • Reduction of sulphur dioxide emissions of approximately 70% Challenges • Power supply demand growth by 40% • High availability request to secure continuous processes in refining and petrochemical production • New environmental project: Flue gas desulphurization unit Solutions and Products • Foxboro Distributed Control System. efficiency and environmental standards Goals • Power plant modernization with construction of two new boilers and construction of a new circulation centre for cooling water and related activities.
With Slovakia joining the EU and Slovnaft becoming an integral part of the MOL Group in 2004. a new boiler of 350 t/h performance was built instead of 2 old boilers. By the time the modernization project started in 2009. The power plant is built on the premises of the MOL Group Refinery Slovnaft in Bratislava. the management was facing a new challenge of a much larger and more sophisticated market combined with growing ambitions of a new corporate owner.o.s. K2. At that moment the Power Plant was equipped with 5 boilers. As this solution was not flexible enough. project management decided to install the I/A DCS system on all reconstructed boilers and other equipment. is a power generation and heating plant owned by the Czech energy corporation CEZ. With ongoing time. providing steam and electricity to the refinery and supplying its production surpluses to the outside grid. wholesale. step by step.r. Invensys suggested the customer to go for the new I/A Distributed Control System (DCS). each with an overall steam output of 160 t/h. they were equipped with new burners and flue gas dust emission was resolved by installing electrostatic precipitators. retail sales and distribution of fuels and other products of hydrocarbon processing. Slovnaft Power Plant was built in several phases to feed the refinery with heat and electricity.. with total capacity 740 ton per hour(t/h) and 4 generators with a total power supply of 114 MW. SLOVNAFT a. Along with standard oils and natural gas also non-standard heavy oils were burnt in the plant. Let the modernization begin The project begun with an overall assessment of requirements placed on the control system to be installed.3 and construction of a new circulation centre for cooling water and related activities. In the next phases of the power plant modernization project. In 1997. To cover this demand Czech energy ˇ firm CEZ was invited to join a strategic partnership on the power plant modernization project. with its numerous local Control Rooms. Slovakia.Power CM European Power Slovakia s. based in Bratislava is a refinery with annual processing capacity of 5. The DCS was continuously extended Redefining demand for industrial power generation From the start of its operation in 1957 the Slovnaft refinery had to go undergo several makeovers having an immediate influence on its power supply. The old pneumatic panel in the Control Room was decommissioned and the entire plant control. Foxboro Distributed Control System. Other boilers (K1. The demand for reliable power supply grew significantly. outdated analog electronic system included. all boilers were revamped. each producing 120 t/h of steam. The Slovnaft company’s core business is production. K7 and K8) followed.s. Projected budget allowed control system modernization on the first two revamped boilers – K7 and K8.5 – 6 million ton. First considerations dealt with combining Foxboro’s modern electronic controllers with Expert Adaptive Control Tuning (EXACT). The measurement and control system in 1986 was pneumatic and had many constraints. a new 60 MW turbogenerator 94 . was moved to one single Central Control Room. Due to new circumstances – higher emission standards and the skyrocketing energy resource prices. The installed capacity of the heating plant should thus increase from the current 114 MW to 169 MW and the generated power should fully cover Slovnaft’s energy consumption. The plan also included a sulphur recovery unit to secure reduction of sulphur dioxide emissions by approximately 70 %. The Power plant modernization plan projected construction of two new boilers.4. CM European Power Internation BV and Slovnaft a. the ineffective energy generation presented a serious threat to the business. warehousing. I/A series® Version 8.
Delivered. In the near future.a total shut down. Invensys Operations Management provided maintenance support and ongoing service.o. The installed I/A system had approximately 5000 I/Os and the PLCs had over 15000 I/Os. New issues can be easily traced and evaluated. The system is entirely integrated with all components supplied by different OEM manufacturers and the corporate IT infrastructure.r. HIMA. The modernization project resulted in the system growing further and to fitting a few more thousands I/Os in addition to 25000 existing ones. In 2009. The system was upgraded to MESH and I/A version 8. Real-time production data is available non-stop to ERP and business intelligence systems for evaluation.4. Operators can proactively maintain and improve the power plant operation. Slovnaft refinery is supplied with energy a power plant running on a robust and stable system. the heat and energy generation effectiveness continuously improved and emissions further reduced. one new turbo generator and new cooling water circulation centre). which was then ready to be improved with the implementation of new technology. This was all possible due to the previous successful upgrade of the system. fully integrated. I/A series® Version 8. Allan Bradley and Siemens PLC systems were all running under the I/A system. 95 . This document was realized thanks to the support of: CM European Power Slovakia s.2. Foxboro Distributed Control System.3 Shift to a new era. which took several years to finish.4.Power throughout the entire duration of the project. The new Central Control Room became the heart of the power plant enabling our customer to employ fewer operators. Invensys participated on the “Flue Gas Desulphurization Unit” project and TPP Revamp (two new boilers. a Triconex Emergency Shutdown (ESD) system will be implemented to resolve the last maintenance constraint . The burning process is optimized and all flue gas emissions are below the allowed limits.
INDUSTRY: POWER China Huaneng Group www. • The digital control system reliably monitors and controls the power plant’s 19. • Connect thousands of stations at data speeds up to 1GB between switches. offering us a cost-effective process control solution and has helped to sharpen our competitive edge.I/A Series® • Foxboro Mesh Network Results • The plant reduced the power shortage risks in the Anhui Province and has helped accelerate the development of its economy. Jinjian Operations China Huaneng Group Powers up for Growth Goals • Build a power plant in the Anhui Province to service its high commercial and industrial energy demands. Challenges • In light of China’s rapid economic growth. resulting in shortages. Solutions and Products • Foxboro Distributed Control System . there has been inadequate construction of power plants.com.” Mr. • The more advanced control system improved equipment and unit performance 96 .000 I/O points.cn “Invensys Operations Management has been an important partner. Rapid expansion in capacity is required to service demands and avoid additional shortages. • The fault-tolerant system design provides continuous and reliable power to the province.chng. production and process optimization.
CHNG is accelerating its market expansion plans.000 Megawatts (MW) to reach 622. Unfortunately. technologically advanced. With power plants in 23 provinces. and fuel optimization. China – In 1978. digital power plant that is specially designed to house four supercritical generating units. the highest demand for power. the growth in power demand is expected to remain strong. In accordance with the national economic development plan. business operations and enterprise performance. therefore. To meet the ever-growing power needs in China. Economic growth and the changing demographic of the Chinese worker have gone a long way to create unprecedented demand for power and electricity. As a global technology.Power Chaohu. Foxboro Distributed Control System . Looking ahead. software and consulting firm leading significant change in process manufacturing. CHNG is still expanding extensively. the government of China embarked on a successful program of economic reform.000MW of electricity by 2007. it will increase its generation capacity to 80 Gigawatts (GW). In order to achieve these goals. CHNG required a partner who could effectively implement an automation solution under an aggressive timeframe while keeping an eye on safety. energy. a 20. after years of state control. Overcoming Obstacles More than just a product-provider. plant optimization. Invensys was a strategic partner to CHNG. power plant construction rates have been unable to keep pace with the growing demand for electricity. CHNG forged a mutually beneficial and strategic relationship with Invensys. China’s electricity demand grew by 14% over the previous year. Invensys supplied CHNG an integrated automation consulting service backed by critical technical support and training. China’s industry policies and the market demand. one of the world’s leading names in the automation industry to provide a range of advanced control and safety solutions services. CHNG has identified its development strategy that by the year 2010. while installed capacity increased by approximately 100. the Chinese workforce slowly began to evolve. The new Huaneng Chaohu power plant is its first digitally automated plant. The 97 . A Bright Road Ahead CHNG’s Huaneng Chaohu power plant is a new. making it the largest power generator in China.000 MW. To do so. Anhui province. by 1994. With a market share of 10% of national installed capacity. China Huaneng Group (CHNG) had already supplied more than 70. The goal of this new plant is to not only reduce the risk of power shortages.3% increase over the previous year. Foxboro Mesh Network construction is divided into two phases with the first two units completed in 2008. becoming one of the world’s top 500 power companies. The plant is located in Chaohu City. the ratio was one in two. Prior to the 1978 reforms. advanced technology and customer-centric solution proved to be a perfect fit. In 2006. Invensys’ critical insight helped CHNG to maximize their return of assets through balancing the availability and utilization of equipment. Invensys’ consultative service. Invensys provides a reliable and advanced automation solution that enables a real-time convergence of plant operations and enterprise performance. but to facilitate the economic growth of the province. each with a capacity of 600 MW. This region is enjoying the most vigorous economic growth in China and. As China’s economy grew. CHNG has chosen Invensys Operations Management. nearly four in five Chinese worked in agriculture.I/A Series®.
I/A Series®.” said Mr.Power “We are very pleased with Invensys’ successful process control implementation as this is the first digital power plant for CHNG.” This solution included an advanced Foxboro I/A Series Distributed Control System of more than 19. It was used to control the new plant’s boilers. offering us a costeffective process control solution and has helped to sharpen our competitive edge. Invensys provided a fault-tolerant system design which extended unit availability. This document was realized thanks to the support of: China Huaneng Group 98 . Jinjian from CHNG’s Operations Department. A Brighter Future By the end of August 2008. Feed Water Pump Mechanical ElectroHydraulic (MEH) control system. The success of Phase I has been applauded by CHNG. delivered and serviced its clients. Foxboro I/A Series Distributed Control System used a 1 Gigabyte (GB) Mesh network that provided highavailability and self-healing network performance. Moreover.000 I/O points. This open system revolutionized how Invensys sold. exceeding even CHNG’s automation and information needs. Working together. “The fast data communication in real-time and the system’s open architecture helps to preserve CHNG’s original investment. advanced control that improved equipment and unit performance and control optimization that improved unit and station performance. reliable and accurate information was implemented enterprise-wide. and Environmental Control Systems (ECS). Invensys and CHNG are paving the way to a brighter future for China. Subsystem applications included Data Acquisition System (DAS). Profibus and Hart protocol. Foxboro Mesh Network This best-in-class approach involving superior technology. Furnace Safety Supervisory System (FSSS). This resounding success demonstrated the ease and reliability of the Invensys solution. Invensys supplied a general interface. Foxboro Distributed Control System . Dedicated to digital communication effectiveness. Invensys’ highperformance culture coupled with the unified project implementation team resulted in the successful implementation. Invensys has been an important partner. Turbine Digital Electro-Hydraulic (DEH) control system. which could communicate with other systems equipped with Modbus. Boiler and Turbine Sequence Control System (SCS). Overall installation costs were reduced and the open architecture preserved CHNG’s initial hardware investment. Phase I of this power plant project had passed successfully through 168 stringent tests. The results are impressive. turbines and generators.
INDUSTRY: POWER ESKOM www.za “Our primary decision was that we wanted the new system to be based on Wonderware’s Historian and InTouch HMI/SCADA . the choice of other elements in the implementation would be influenced by their degree of compatibility with that platform. maintenance and engineering • Enhanced in-house skill set • Ability to implement any enhancements requested after the upgrade 99 .eskom.co.” Abdul Gaffaar Hoosain... Senior Advisor for ESKOM Peaking Generation Eskom Peaking’s power stations now more ready than ever with a little help from Invensys Goals • Upgrade control systems of peak-demand power stations to the latest technology • Rapid determination of the root cause of failures • Remote control of stations from head office Challenges • Uninterrupted operation in mission-critical support of national grid Solutions and Products • Wonderware InTouch® HMI • Wonderware Historian Software • Wonderware Historian Client Results • Successful upgrading of mission-critical power stations • Enthusiastic response from operations.
Wonderware InTouch® HMI. an important licensing requirement. The result is that each of these stations can generate a total of 171MW that can be channelled to the national grid at a moment’s notice. so it carries a huge responsibility. it was during the 2010 World Cup held in the heart of a South African winter. Acacia also provides line stabilisation but its most important role is as off-site back-up electrical supply to Koeberg Nuclear Power Station.Power Acacia Power Station is situated on the outskirts of Cape Town in the Western Cape and Port Rex power station at East London in the Eastern Cape. but are not repeated in the future. as possible and. Each station has three 57MW gas turbine generator units where each unit is a “twin-pack” FT4 Pratt and Whitney Gas Generator Set incorporating turbines that are similar to Boeing 707 engines. Koeberg has to be shut down. To this end. The Port Rex power station is at the end of a very long transmission line and its main purpose is to stabilise the voltage on that line by running in what is known as synchronous condenser mode for most of the time and only switching over to its generating mode on demand. SCADA systems can contribute enormously to our knowledge of the cause of incidents. ESKOM’s Acacia and Port Rex gas turbine power stations were ready for action well ahead of schedule thanks to a rigorous upgrade programme. If Acacia does not have sufficient generating capacity and redundancy available. If there was ever a time to be ready for peak power demands. coupled with the very limited availability of expert knowledge to keep them running as well as the absence of historical plant information (i. which often needs to happen in just a couple of minutes (in fact. How it was done “We contacted the OEMs that installed the original system and they indicated that they were able to implement what we wanted and offered solutions based on a number of alternative options.e. Since their commissioning in 1976. Thankfully.” The obsolescence of the control systems. for troubleshooting) and the impossibility of remote engineering support prompted ESKOM to review its options and in 2007. the company decided that an upgrade of these critical resources was in order. However. the control systems for Acacia and Port Rex had remained largely untouched and consisted of hardwired relay logic and analogue power governors which had since become obsolete. Electrical protection was implemented through electromechanical relays and this was simply no longer good enough as Senior Advisor for ESKOM Peaking Generation. when a plant is brought on-line.” says Hoosain. 100 . it takes just 4 ½ minutes for either power station to reach full-load power) – it is vital to avoid trips or mode-change failures as this would defeat the rapid response requirement. Wonderware Historian Software. if the system does fail. more importantly. Both Acacia and Port Rex can be operated by remote control from Eskom’s National Control Centre in Germiston to provide back-up and black-start capability (the ability to start operating without the need for external power). “Our primary decision was that we wanted the new system to be based on Wonderware’s “For example. it is vital that we determine the root cause of that failure as soon Figure 1: System overview of one of the power stations as seen on an InTouch display. Wonderware Historian Client make sure that the conditions which caused it are not only understood. Abdul Gaffaar Hoosain explains.
“The adoption of the IEC-61850 OPC interface software standard (figure 2) allowed us to have far more control over the information we wanted and all The supplied HMI application was based on an old version of InTouch and this was immediately upgraded to the current InTouch version.” adds Hoosain. in Acacia’s case.Power Wonderware InTouch® HMI. Benefits • Successful upgrading of mission-critical power stations through the installation of the most up-todate SCADA facilities without interruption to service or the black start capabilities of either site • Enthusiastic response from operations.” The implementation of the new system came complete with its own set of challenges ranging from getting operator buy-in to the fact that. implementation would be parties involved in this project collaborated to help influenced by their degree of us achieve our information goals. compatibility with that platform. The fault-tolerant ring network (shown in blue) will continue operating should any of its segments fail thereby maintaining communications between the InTouch HMI and other segments of the network. Our good relationship and experiences with Wonderware as well as the excellent level of support and training we have received in the past meant that we had adopted a specific platform and the choice Figure 3: InTouch screens showing the operational overview. Wonderware Historian Software. then it better be applied with great care. “This meant removing all the hard-coded unit-specific details and creating a standardised environment that would accommodate all the individual units in both Acacia and Port Rex. protection relays. ESKOM’s Acacia and Port Rex power stations. which involved creating new graphics and implementing standards. ESKOM would also provide Wonderware software support during commissioning and would be responsible for the installation of the entire delivered system. PLCs.” The OEM was appointed as the responsible party for the building and factory testing the entire control system which was initially implemented at their facility in Colorado.” says Hoosain. controllers. when compared to their coal and nuclear colleagues. Figure 1 shows an overview of the system at any one of the power stations where the switches. The OEM was also to supply ESKOM with a commissioning engineer during the installation phase of the project. Wonderware Historian Client Historian and InTouch HMI. This document was realized thanks to the support of: ESKOM 101 Figure 2: The migration from a proprietary to an open approach of information delivery helped put ESKOM in control of its own information needs . ESKOM’s responsibilities included the design and installation of the Ethernet Network and time synchronisation system as well as the design of the protection system and implementing the historian. “Perhaps the most important development was making the application unitindependent. electrical mimic and the vibration of other elements in the monitoring system. only one unit was allowed to be unavailable at any time without jeopardising Koeberg’s status. maintenance and engineering • Enhanced in-house skill set • Ability to implement any enhancements requested after the upgrade Conclusion Information is obviously the key to improved control and when that control can influence the way of life of millions. InTouch HMIs and the Historian all get their timing information from the TimeSync Server (top right). are diminutive but equally vital to contributing to a way of life that none of us can do without. vibration monitors.
Ontario Power Generation
“By choosing to go with Invensys, we made the decision to utilize their products for future modifications or upgrades... We expect that it will also ensure a high degree of reliability in the future.”
Mike Considine Project Leader
Invensys Operations Management solution helps Ontario Power Generation revitalize Nanticoke plant
Goals • Complete a controls integration and performance improvement project to help the plant meet the energy demands of its customers today—and position it to meet future demands Challenges • Improve energy efficiency, lower product costs, and ensure cleaner electricity production while meeting customer’s energy demands Solutions and Products • Foxboro® Distributed Control System - I/A Series® Results • Assist in providing continuous power, producing 20 to 24 billion kilowatt-hours (kWh) of energy to run nearly 2.5 million households for a full year. • Increase boiler efficiency and responsiveness • Reduce maintenance and fuel costs • Reduce emissions through the use of advanced control • Provide the responsiveness to market demands that Ontario Power Generation needs to compete effectively in its competitive environment • Position OPG to meet future demands
Ontario, Canada – Ontario Power Generation
(OPG) is a major North American electricity generating company, based in Ontario, Canada, that operates a fleet of nuclear, hydroelectric, and fossil generating facilities. Each of these facilities — along with its expanding portfolio of green power sources — plays a unique role in meeting its customers’ energy needs. OPG’s goal is to be a premier North American energy company, providing customers with reliable, clean, and competitively priced power while operating in a safe, open, and environmentally responsible manner. OPG supplies about 85 percent of all electricity consumed in Ontario through a portfolio of 80 efficient and relatively low cost generating stations. As electricity demands grow worldwide, energy providers must maintain highly efficient and modern facilities that can produce the energy their customers require—or risk losing the competitive battle. That explains why OPG focuses on continually improving its plants to improve energy efficiency, lower product costs and ensure cleaner electricity production. That focus has resulted in a recent revitalization project at its Nanticoke Generating Station in Ontario, Canada. OPG’s Nanticoke Generating Station is one of the largest coal-burning stations in North America. Its eight generating units annually produce approximately 20 to 24 billion kilowatt-hours (kWh), which represents enough electricity to run nearly 2.5 million households for a full year. In 2000, legacy management turned to Invensys to help them complete a controls integration and performance improvement project that would help the plant meet the energy demands of its customers today—and position it to meet future demands. Mike Considine, Project Leader, said, “The legacy control systems at Nanticoke were designed and installed in the early 1970s and were no longer supported by the vendor, which was a great concern to us. In addition, the control systems had limited or no expansion capability. We began experiencing deterioration in reliability, and we had limited diagnostics capabilities, which delayed our ability to make necessary repairs. So we knew we had to make significant improvements in our control systems.”
Foxboro® Distributed Control System - I/A Series®
Hydro. But with this project, Invensys went a step further— signing a corporate alliance agreement that ensures OPG will receive the support it needs to cost-effectively complete the control integration and performance improvement project, which will be phased in over a five-year period. “We originally requested quotes from a few vendors, with the intent of choosing the vendor that offered hardware maturity, reliability, backward compatibility, and a mature and proven software design. We visited other utilities that used Foxboro® control systems and were impressed with their excellent track record,” said Considine. Invensys is moving forward aggressively on this project, which will entail replacing the plant’s current control systems with a Foxboro I/A Series Distributed Control System on all eight units. In fact, Invensys delivered and installed 4,000 points of control in a nine-month period — an accomplishment that is virtually unheard of in the industry. Invensys also supplied new operator control interfaces, advanced control packages, engineering, integration, installation, and commissioning services. Considine said, “While this project was justified as a sustaining effort to deal with obsolescence, we also wanted to provide a solid base for future technological/operating improvements like artificial intelligence, optimized soot blowing and smart annunciation. By choosing to go with Invensys, we made the decision to utilize their products for future modifications or upgrades that will allow us to avoid a mix of technologies and ‘black box’ interfaces with different systems. This will simplify our training and help us avoid the need for employing a host of experts that understand different systems. We expect that it will also ensure a high degree of reliability in the future.”
Addressing Future Needs
When completed, the project improvements are expected to help increase boiler efficiency and responsiveness, enhance productivity, reduce maintenance and fuel costs, and reduce emissions using advanced controls. This will provide the responsiveness to market demands that OPG needs to compete effectively in its competitive environment.
This document was realized thanks to the support of: Ontario Power Generation 103
Delivering a Cost-Effective Solution
For 40 years, Invensys has provided solutions to OPG and its predecessor company, Ontario
“The Foxboro PAC System is perfect for RK Powergen because it provides the power plant with a distributed solution that is effective, redundant and just the right size and price for its control requirement.”
Terry Minns Director PAC Systems Portfolio Invensys Operations Management
Invensys Solution Helps Provide Clean, Reliable Electricity in India
Goals • Support a biomass power plant that would generate clean power in an area that previously had limited and unreliable electricity • Automate plant operations to maximize efficiency and productivity while reducing downtime • Facilitate accurate control and monitoring of plant equipment to ensure consistent output as well as safety and security. • Provide a solution that can be easily expanded as energy demands increase Challenges • The plant had to meet strict requirements for sustainability, environmental monitoring and safety while conserving operating costs • The solution had to integrate various processes into one control solution that would encompass the entire plant • Operators needed real-time data to accurately control power generation, steam production and chilled water distribution Solutions and Products • Foxboro Programmable Automation Controller (PAC) System Results • The plant provides electricity to area residents and has improved local agricultural and industrial opportunities • Sustainability goals such as decreased air pollution, water conservation and optimized fuel consumption are being met through the solution’s monitoring and control capabilities • Operators can now view plant-wide processes in real-time, so they can react immediately and make changes to maintain power output and plan for maintenance • The Foxboro PAC System simplifies the rapid addition of new devices through preconfigured and tested applications and plug-in modules
Unique Sustainability Opportunities Several features of the project were central to meeting RK Powergen’s multiple goals. Another fundamental requirement is redundancy to ensure both high availability and safety. the system compiles data and provides management with both real-time and historical information. Data from the boiler. ensuring control. Foxboro Programmable Automation Controller (PAC) System World-Class Process Control In all energy-generation activities. Water-cooled condensers are more typical for facilities of this type because they are initially less expensive. Director PAC Systems Portfolio at Invensys Operations Management. The first was that biomass fuel is considered a zero-emissions power source. Foxboro Programmable Automation Controller (PAC) System. so the plant would not generate greenhouse gases. Next. Local wasteland trees like the mesquite tree and shrubs as well as husks such as tamarind. quality steam output. These abundant solid waste resources were unused before the power plant was built. sunflower stalks and other trimmings would be burned to generate steam. Without it. the plant would not be able to provide reliable power.Power Chennai. “The biomass power plant not only supplies clean power to the southern regional grid of India. choosing the right technology was critical. it was more important for this project to reduce environmental impact. collecting and selling them has become a reliable business and has enhanced local agricultural and industrial activities. but it also provides substantial employment to the local population and increases the income levels of the people. safety and compliance is paramount. Tamil Nadu.” said Terry Minns. conserving it for the use of the residents as well as for irrigation. plant supervisors can make equipment and personnel adjustments to increase efficiency and productivity while reducing downtime. Accurate control of these processes results in consistent. yet flexible. it created new sources of work and income for local residents. the power plant benefits from a distributed control system that enables accurate monitoring and control. But now. But even more importantly. tank farm and other control points is transmitted from plant subsystems to the PAC. With these reports. However. With the Foxboro PAC System. India – When RK Powergen won the contract to build a new power plant in an area of India where the residents previously had very little electricity. The air-cooled condensers use 93% less water. which optimizes fuel consumption. Additionally. Operators can perform live replacement of processor modules within the Foxboro PAC System so that there is little or no interruption of plant operation. That’s why RK Powergen partnered with Invensys Operations Management to configure and install the powerful. the company committed to sustainability goals and to improving the social and economic well being in the region.Mesquite 105 . Biomass Fuel Source . Additionally. the plant uses air-cooled condensers rather than relying on water cooling.
they get a complete picture of the power plant. Industrial customers will require it. Foxboro Programmable Automation Controller (PAC) System Biomass Fuel Source .” said Minns. Fortunately. steam. turbine.Power Operator Ease Engineers appreciate the Foxboro PAC System’s superb visualization components (HMI) with high resolution graphics that enables the engineers to control the plant better. and it also will be essential for all residents to have access to power. Operators can make changes quickly and no training is needed when they move from one system to another. clean and environmentally sensitive power. With it. These additions are integrated into the solution so that This document was realized thanks to the support of: RK Powergen 106 . the need for more electricity will grow. Planning for More Power The solution also makes configuration and development for plant expansions rapid and easy. When applications are added. fuel and air systems with standardized graphics that are easy to learn and intuitive to understand. On-screen views show boiler. while continuing to generate reliable. but the historian and visualization components also provide capabilities that allow the plant operators to perform better. As development continues in southern India. This makes the plant more productive. “The Foxboro PAC System not only gives a redundant and efficient control system.Tamarind Husks it continues to provide one source for all plant data. The live data and historical reports that come from the Foxboro PAC System enables operators to schedule maintenance as well as to recognize possible problem situations and correct them before they impact productivity or the output of electricity. the RK Powergen plant has been designed to meet these diverse needs. they are deployed across the network with simple-to-implement distribution features and standardized algorithms that eliminate the need to duplicate data. Maintenance of the plant is another important consideration.
coop “Depending on the load.INDUSTRY: POWER Southern Mississippi Electric Power Association www. providing a project payback of less than one year • Expert System at soot blower maximizes heat transfer area in the furnace • Model Predictive Control provides increases boiler efficiency while maintaining steam temperatures and remaining within NOx specifications 107 . This benefit will provide a project payback of less than one year. potential heat rate improvements up to 1.smepa.5% are expected.5% .” Optimization System Increases Profitability of Southern Mississippi Electric Power Association Goals • Improve the performance of the Riley turbofired units • Improve the mill’s impact on the energy efficiency of the furnace • Lower NOx emissions Challenges • Improve heat rate and boiler efficiency while maintaining low NOx emissions Solutions and Products • SimSci-Esscor® Connoisseur™ Online Optimization Results • Expected heat rate improvements of 1.
Connoisseur™ runs in a separate platform so that the security of the existing DCS is not compromised. At SMEPA’s R. One recirculation fan returns flue gas to the bottom of the furnace combustion zone. with minimum disruption to the process. The Riley Stoker Corporation manufactures each steam generator unit. a supervisory control system was installed over the modern DCS to improve performance for these Riley turbo-fired units with ball mills. Nominal steam conditions at HP turbine inlet are 2400 psig at 1005 DEGF and 1000 DEGF at the IP turbine inlet. An Expert System Soot Blower Advisory supplements the heat rate benefits of applying Connoisseur™ by suggesting which blower to activate in order to maximize heat transfer area in the furnace. Ball mill optimization improves the grind in the mill. Mississippi – The Southern Mississippi Electric Power Association (SMEPA) uses the Model Predictive and Neural Network Based controller. An Optimizer is to determine the most profitable operating point The SMEPA generating plant in Hattiesburg utilizes two parallel boiler-turbine units with a capacity of 204 MW at 2400 psig. In addition. also regulated by a fan damper.D. potential heat rate improvements up to 1. Each has a turbo-furnace design with balanced draft operation. Model Predictive Control has provided an effective technology for increasing boiler efficiency while maintaining steam temperatures and remaining within NOx specifications.000 lhs/hr. To this end.Power Hattiesburg. the optimizer passes these values to the controller – the optimum values of the controlled variables (CVs) become set points for the CVs in the controller and the optimum values for the manipulated variables (MVs) become targets for the MVs in the controller. There are twelve Riley diffusion burners.575. in case the operator decides to “take over” control. as defined by a set of values for the controlled and manipulated variables in the process model. This benefit will provide a project payback of less than one year. the improved mill regulation increased maximum generation capability. Connoisseur™ to improve efficiency at their Hattiesburg station. Heat rate improvements were achieved through reduced dry gas losses and lower loss-on-ignition (LOI). Morrow Generating Station.5% are expected. particularly for lower grade coal. The application at SMEPA is designed to revert to the DCS based control seamlessly. SimSci-Esscor® Connoisseur™ Online Optimization The objective of the Optimizer is to determine the most profitable operating point for the boiler and mills. improving heat rate while maintaining low NOx emissions was extremely important. lowers LOI and improves the mill’s impact on the energy efficiency of the furnace. To drive the process to this point. The fuel is pulverized coal from three Riley doubleend ball tube mills fed by six Stock Gravimetric feeders. Dampers at each fan regulate airflow. This document was realized thanks to the support of: Southern Mississippi Electric Power Association 108 . Two forced-draft fans and two induced-draft fans deliver combustion air and provide balanced furnace draft to the scrubber. Operator acceptance has been excellent due to the stable performance of the system and the smooth interface with the existing ARC controls on the boiler. An Effective Technology for Increasing Boiler Efficiency For this application. Depending on the load. Maximum continuous steam rate is 1. Both furnace and ball mill controls were optimized with coordinated multivariable control. and is front and rear fired.
and new hydraulic actuators for the turbine stop/ control valves • Install new DCS and simulator to minimize errors and train employees on the system Challenges • Upgrade the plant. identify and minimize control system errors that can delay the unit startup and return to service.INDUSTRY: POWER Tucson Electric Power Company www.000 to $500.” Mike Puzzi Administrator for the DCS upgrade project Tucson Electric Power upgrades with a Foxboro Solution Goals • Install new turbine control system that include overfire air. especially with this complex interaction between Invensys Operations Management and Alstom.tucsonelectric. without creating lost generation costs Solutions and Products • Foxboro® Distributed Control System .000 customers in Southern Arizona • Identified and fixed over 350 errors before plant the plant even started up • Reduced startup time by seven days due to the operator’s familiarity with the controls 109 . low NOx burners.com I can’t believe how smoothly the actual unit startup went.I/A Series® Results • Prevents lost generation costs calculated at $250.000 a day • Helped provide continuous service to more than 375.
Assuming lost generation costs of $250. Chris Wallace. Even though the running Implementing the Solution TEP selected a Foxboro I/A Series Distributed Control System for its new automation system. the plant was still using the original Leeds and Northrup analog control system and ABB Turbotrol® turbine control system. In this case. As the project unfolded. control system errors. the project was modified to include a connection to GE Fanuc PLC 90-70 and 90-30 controllers. Foxboro® Distributed Control System . Even simple configuration errors take significant unplanned downtime to find and fix.000 a day.5 million Arizona residents. which was nearing obsolescence. Today. Tucson voters approved a 25-year extension of TEP’s franchise agreement. serves more than 375. and operator controls. UniSource Energy is parent to a growing family of energy companies serving more than 1. Arizona – Tucson Electric Power Company (TEP). This new Distributed Control System (DCS) was a major shift from the current. turbine protection. said. especially in that high-pressure environment. the principal subsidiary of UniSource Energy. man-machine interface. In order for the new Alstom turbine control valve actuators to be guaranteed. control system errors could cause catastrophic equipment damage. and DCS configuration tools to provide the most accurate representation of the control system. TEP selected Invensys to provide a high-fidelity simulator for operator training and detailed control system checkout prior to the unit coming back online. making the simulator a complete I&C workhorse. the benefits of the simulator do not end there. “The majority of problems found were minor. I/O. The simulator and DCS design went through concurrent development with major DCS loops tested and pre-tuned in the simulator. which ran the Alstom turbine control system programs.000 customers in Southern Arizona. TEP is the backbone to UniSource Energy’s success. Feedback from operators using the simulator was then used to fine-tune graphics and make control function changes based on TEP’s operating procedures. Using FSIM Plus. and new hydraulic actuators for the turbine stop/control valves in 2004. even minor.Power Tucson. This approach uses the actual I/A Series controller algorithms. As the unit returns to service. The Tucson Electric Power (TEP) Springerville Station consists of two 380MW net combustion engineering drum boilers that are coal fired with an ABB steam turbine. Simulator Project Manager. In extreme cases. TEP exceeded $1 billion in revenues for the first time in its history.000 to $500. Positive Results and Benefits Simulator Factory Acceptance Testing identified and fixed over 350 errors before going into the plant. a unique challenge emerged. saving two to four days of outage time will pay for the cost of the simulator project. This led to questions about interfacing to the Foxboro I/A Series Distributed Control System. However. could delay the unit startup and return to service. Plant Upgrade Challenges Like all major plant upgrades. it continues to discover innovative ways to provide safe. there are inherent risks with the project. reliable energy to homes and businesses while maintaining its historic commitment to community service.” The real value in the simulator was merging the Foxboro I/A Series Distributed Control System and Alstom control systems. Therefore. the unit required an upgrade to include overfire air. bench-mounted analog control. TEP now has the capability to move the controls and graphics back and forth between the simulator and control room. Constructed in the early 1980s. the simulator will become an invaluable training tool. such as graphics configuration errors. As TEP enters its third century of operations.I/A Series® approaching retirement age. simple point misconnections. That same year. these errors would have been found during critical testing on the live unit. Invensys pioneered the Virtual Stimulation approach by simulating the control system using the FSIM Plus™ simulation of the Foxboro I/A Series Distributed Control System. low NOx burners. the decision to include control checkout on the simulator was justified with a simple economic analysis. However. In 2000. without the simulator. With TEP’s main operator workforce 110 . Furthermore. an Alstom turbine control system had to be part of the configuration. launching the next chapter of a productive relationship that began more than 110 years ago.
TEP Project Manager for DCS Retrofit Project. initiating the Alstom turbine using the simulator uncovered dozens of interfacing problems. commented that the simulator paid for itself due to the fact that his operators went through simulator training during their normal training cycle. As a result.I/A Series® Furthermore. TEP will experience fewer unit trips in the future now that operators fully understand how the unit and controls react using Invensys’ Intelligent Runbacks. Plant Manager. As a result. and in addition. This document was realized thanks to the support of: Tucson Electric Power Company 111 . they all feel more confident about unit startups. Andy Hoekstra. The simulator was on site for six months of testing before the new DCS was put into Unit 1.Power turbine and simulator were not connected. One error in particular could have caused repeated turbine trips or damage on startup as the initial control valve demand caused runaway turbine roll-up. “The simulator saved at least one week of startup time due to the operator’s familiarity with the controls and advanced understanding of how they should interact with the unit. Foxboro® Distributed Control System .” said Rex Brown. saving valuable time and money. TEP uncovered over 300 necessary changes and will now use the simulator for more than just training.
000 unique assets and more than 33. • Efficiently tracks 6. Planning and Cost Tracking Goals • Eliminate inefficiencies in scheduling maintenance • Track completed work • Reduce operations.com “Being able to track info about planned and unplanned work was one of the key performance indicators we were trying to improve on.vectren. keeping track of work orders and labor time • Ascertains key performance indicators and benchmarks throughout the maintenance operation 112 .” David Reherman Reliability Engineer Avantis assists Vectren to attain new heights in Maintenance.000 individual spare parts. maintenance and capital spending. Because of the way Avantis interfaces with the workforce timetracking program.INDUSTRY: POWER Vectren Corporation www. while maintaining high availability within plants and continuously and efficiently serving customers. and capital spending Challenges • Reduce overall operations. Solutions and Products • Avantis® Enterprise Asset Management Software • Avantis InRIM™ Results • Supplies continuous and efficient power to two-thirds of Indiana and 16 counties in Ohio • Enabled management to capture and analyze data about maintenance work. we are able to get to this data much more easily. maintenance.
“We invest in maintaining our plants to be sure that they are available when the demand calls for it. Indiana – For those in the basketball-crazy Hoosier state and surrounding areas.B. Vectren is also in the wholesale market for power sales where availability has tremendous financial implications. One important Customer Challenge Vectren operates two power plants. Complicating matters was the fact that data. At the end of the process. It also helped track the cost of maintaining any given piece of equipment. “We weren’t necessarily looking to switch from our legacy Champs software. 113 . Changing the management procedures for these assets and parts could have a potentially significant impact on the daily work activities for some 225 maintenance personnel at the two plants. while keeping the availability high. which together use five coal-fired units and six gas turbines to produce about 1. David Reherman. said.” said Gary McCarty. Vectren today plays an integral part in the dayto-day lives of more than one million energy users. the Vectren management team selected the Avantis software and Avantis InRIM™ (Industrial Rapid Implementation Methodology). A merger of two companies.000 unique assets and more than 33. and allow us to improve the ratio of planned to unplanned work. Avantis® Enterprise Asset Management Software. Reliability Engineer. it did become clear that a new maintenance software solution was in order. The A. maintenance. and capital spending. the evaluation process was driven primarily by the need to streamline maintenance work and equipment processes rather than by any explicit requirements for software functionality. Vectren Resources is what you might call a “power forward.” After evaluating several competing offerings. Avantis gave Vectren an enterprise database that enabled management to capture and analyze data about the current and historical maintenance work. though. It accomplished this with the help of Invensys Operations Management Avantis® enterprise asset management software. Vectren management set out to eliminate inefficiencies in scheduling maintenance. Keeping these plants running continuously and efficiently is vital to Vectren’s mission to serve customers.B.” As a key part of its strategy for meeting this challenge. and parts were all managed in two separate locations.400 megawatts of generating capacity. keeping track of work orders and labor time. this $2 billion utility provides electricity or natural gas to nearly two-thirds of Indiana and 16 counties in Ohio. Culley facilities combined use more than 6. Maintenance Supervisor. and ascertaining key performance indicators and benchmarks throughout the maintenance operation. Avantis InRIM™ Streamlining the Maintenance Process The process of revamping maintenance operations at Vectren’s electrical power facilities began in mid-1999 with an evaluation of procedures. Our challenge is to reduce our overall operations. Brown and F. ordering parts and keeping track of completed work. The trick was to find a tool to help us do this without compromising the process. about 30 miles apart in the Evansville area.Power Evansville. labor.000 individual spare parts. “It was really more a case of asking ourselves how we could develop a maintenance model that would help us drive down the cost of doing unplanned work. on the extreme southern tip of the state.” From its base in Evansville. According to company officials. Indiana.
Vectren knows that since July. Manager of Technical Services. Avantis InRIM™ A Benchmark for Continuous Improvement Measuring the benefits of preventive maintenance is a long-term proposition. but the Vectren team is already gathering information that will help improve operations continuously. 7. 114 . it’s easy to find that part. or planning work ahead of time and will not be driven by an emergency.M. an inventory management firm from Ontario.000 work tasks. Avantis software also helps track progress of metrics such as productivity of workforce or reasons for delays on work orders. Ltd. a break-in.500 were preventive maintenance work tasks. Avantis and Vectren all working together to provide the optimal solution for the Indiana utility.Power reason was the way in which the Avantis solution has enabled maintenance personnel to interface with other key programs – notably Oracle for financial reporting. In addition.B. scheduling. They track the priority of work completed. “We publish what are called ‘Avantis Key Performance Indicators’ every two months. We also get the top ten system costs year-to-date and top ten entity costs year-to-date that help us determine how to spend our O&M (operations and maintenance) and capital dollars. making it much easier to access and order both stock and nonstock items. using Avantis’ Purchase Item Catalog feature. Previously. employees completed 250 “safety” work orders. and to keep track of it afterward. For example. it completed 12.. Brown facility. which will guide continuous improvement of its operations and services. with Performance Consulting Associates. Two other partners were key to Vectren’s success.A. procurement and accountspayable and the company’s workforce time and resource planning/utilization software. This combined assessment and implementation project stands as an excellent example of the kind of teamwork needed to make this kind of initiative a success.” said Reherman. separating expenditure data from information about what planned and unplanned work was being done was the source of considerable frustration. The ease of use also helped Vectren to implement one of the cornerstones of maintenance practice: the rapid acquisition of replacement parts. tell us whether it was an emergency.. with this type of information. we would buy a part. The Windows look and feel of the Avantis software also played into the decision.M. These look at work task backlog trends. According to McCarty. break-in. Now. A. There was not a lot of redevelopment of skill sets in learning to use it. Randy Simon. Performance Consulting Associates (PCA) of Atlanta conducted the asset reliability improvement initiative. renamed and renumbered every part that Vectren uses.” said. Ltd. “With all of the people we have working in this — from janitors to mechanics to supervisors to planners to management — the familiar Windows interface was a huge plus. In the future. to purchase it if it is not in our stock. They tell us whether the work was preventive or corrective. I. or scheduled. Vectren will be better equipped for more preventive maintenance.300 of which were corrective repairs and 3.” Avantis® Enterprise Asset Management Software.A. “Previously. Breakthrough Repair and Labor Tracking The Avantis solution also helped the Vectren plants achieve a breakthrough in tracking data at the work-order level. Vectren will receive comparable benchmark information. or a schedule-disrupting activity. I. Canada. and it would just sort of disappear.
Avantis InRIM™ solutions methodically with adequate up-front planning.” said David Reherman. Reliability Engineer. the costs involved. and even statistical information for us to do this job smarter if it shows up again. what needs to be done. Avantis facilitates this and allows us to track what work was completed. This document was realized thanks to the support of: Vectren Corporation 115 . we want to provide to the workforce the means to efficiently perform the task at hand by giving them all of the resources and information needed to do the job. failure analysis. They have better information about what work they have completed. and the right software solutions. I will be looking at and doing failure analysis using Avantis to improve equipment performance and life expectancy. Vectren has completed and effectively transformed the maintenance operation at its electrical facilities. The success at Vectren is a strong testimony to the value of approaching asset management Avantis® Enterprise Asset Management Software. collaboration. and what can be done to make the process better.Power “As planners and supervisors. The result will be lower cost to Vectren with greater availability that will pay dividends to the Indiana and Ohio customers that Vectren serves. Its 225 maintenance workers have changed the way they work and are now actively engaged in the process of continuous improvement. As the reliability engineer.
thus being able to become directly involved in the improvement process that Endesa is implementing. • To create a technological environment to automate processes. real-time information is gathered. • All the agents involved in the process have easy access to the information they need in a web-based environment. 116 . • The system helps to analyse the reasons for any inefficiencies and deviations by promoting constant optimisation of activities with a consequent reduction in costs. among many other benefits.endesa. gather real-time information and analyse the activity at terminals in order to achieve greater operational efficiency. • The particularity of the logistics industry at ports and the characteristics of the implemented process meant the need to have a system that could link up to a variety of devices and performed activities and be suitable for various types of users. have reduced the costs of the ship/port interface.es “Thanks to Wonderware technology.” Ana Belén Paz – Endesa Ferrol Harbour Terminal Manager Endesa responds to the challenges of the energy market by optimising its logistics processes with Wonderware Goals • To optimise the logistics process of the coal terminals owned by the company in Spain. Solutions and Products • ArchestrA System Platform • Wonderware Historian • Wonderware InTouch® Results • Endesa now has a fully automated logistics process in which reliable. • The remote location of the facilities required a web-based development environment for easy deployment. we are efficiently managing available resources.INDUSTRY: POWER Endesa www. Challenges • The process to optimise was being performed by Excel spreadsheets. improved the ratios of unloading/ optimisation of times and have greater flexibility in communications due to the introduction of different interlocutors in the control platform. which meant that the project included an element of cultural management as well as the technological complexity it involved.
” Using this as a starting point.Power Madrid. Some of its main objectives were to reduce and optimise the 117 .” explains Intermark Technologies. as well as also having a presence in the Mediterranean area of Europe. increased operational efficiency by reducing the transport cycle times. health and the environment.” explains the team involved in the project. “Increasing the efficiency of loading and unloading results in a shorter stay for ships at port. process management linked to the generation of electricity is one of the areas in which the company has been involved. As one of the major Spanish listed companies. Consequently. Wonderware InTouch® Responding to Environmental Challenges The production of electricity from thermoelectric power plants.” Once the improvements paths were identified and the state of the process used was checked – based on Excel spreadsheets from work reports. thus minimising the time spent in port and optimising operational costs. allocating 53% to Spain. Despite positive developments in the extraction of this fossil fuel throughout the world. With a socially responsible vocation. Endesa is the largest electric utility company in Spain and the leading private electricity company in Latin America. ArchestrA System Platform. Based on a thorough analysis of the situation. as well as being efficient. would lead to eliminating these. which produce deviations in unloading performance compared to theoretical forecasts. archive folders for historical data and other various informational elements – the decision was made for an ambitious project entitled “Ulysses” that would radically change the way of implementing control of the logistics activity of receiving the coal and helping both local management at each terminal and global management in terms of all facilities. thus allowing for a greater number of annual trips and. distributing and marketing electricity. transportation of this mineral is becoming increasingly complex. uses coal as the raw material for the process. the Spanish natural gas market is also an important area of its development. They also point out that Endesa understood from the beginning the importance of having available all operational information in real time: “Immediate availability of data in the event of incidents occurring would allow for rapid decision-making. the multinational identified other areas in which it was possible to improve the process: “A detailed analysis of bottlenecks. As of July 2008. Portugal and others and 47% to Latin America. “Ulysses was designed as a computerised integrated management system for the coal terminals that Endesa has to supply its thermal power plants. In addition to its services of generating. In this context. competitive and committed to safety.” according to Intermark Technologies. Wonderware Historian. The rise in imports by China and India. thus decreasing any non-productive times. corresponding to 35% of Endesa’s total electricity generation. it has approved a strategic plan for the period 2011-2015 that includes investments tailored to market conditions. the multinational is firmly committed to growth as a way of bringing value to the company and its investors. existing bottlenecks in port infrastructures and the low availability of bulk carriers are among some of the reasons that have driven up the prices of this mineral. the company applies a strict process of continuous improvement and innovation in order to achieve the highest quality products and services based on criteria of profitability. the systems integrator responsible for the design and deployment of the project. Spain. the price of coal rose by 100% over the same period last year and transport costs increased to 70% of the total price of the product. ultimately. Endesa anticipated by evaluating that one of the factors that could contribute to offset the high costs of this raw material was to minimise and optimise times and operations at ports: “Reducing the costs of the process between the port and ship means improving the efficiency of the entire logistics chain of cargo handling and transhipment. which currently stands at around seven billion tons.
Wonderware Historian. broker. “Firstly. A general user was also set up in the event that an agent was not represented by any of these predefined profiles. decreasing nonproductive times. facilitate coordination between the different internal and external agents involved in the procurement process and provide immediate availability of data from the process. Wonderware InTouch® From Manual Management to a Fully Analytical Environment As explained by Intermark Technology. Four types of user needs to which Ulysses should respond were identified: terminal user. the project was designed in three main stages based on the premise of leading to a turnkey system for Endesa. logistics user. Next. volume of material and calculation of forecasts. “The large number of inputs/ outputs offered by Wonderware technology. calendar management. At a higher level. where the key was facility management. etc. but also the control of activity. The application was prepared to collect data and analyse information during an unloading process at the port of Ferrol. optimise the management of the facility by analysing the length of stay in port. “The complexity implied by the move from management based on information gathered by Excel spreadsheets to full automation led to the need to carry out an in-depth design process for the resulting technological architecture of Ulysses. mobile devices.” The system was configured in a 100% web-based environment for easy deployment in the farthest reaches of the logistics network of the coal transportation process. a Historian server for storing data and two databases.Power costs of logistics operations. The magnitude of the project to be implemented – which would begin with the Ferrol port terminal. among other aspects. unloading. consequently. remote. in other words. the entire architecture is monitored from an Endesa control centre located in Madrid. . ship documentation and information.” explain the project managers. User definition was one of the most important aspects when designing the system. Wonderware conformed to these system requirements and also offered full analytical capabilities to comprehensively handle the optimisation process that had begun. along with its networking capabilities. and finally in relation to freight forwarding. lifting. one in real time and the other transactional. in which not only legal aspects were involved. helped to create a system that truly responded to each of Endesa’s needs. with the idea of extending it to Endesa’s other port terminals – and the information requirements that the energy company established for the new system led to the need to search for a technology supplier that was able to communicate with the multitude of devices in the loading terminals. handle multiple user profiles – local. tablets. ArchestrA System Platform.” This was how the first stage of defining function consisted of a detailed breakdown of each of the activities that were taking place at the terminal. with special emphasis on reporting for transport and planning. coordination of customers and suppliers and the improvement of performance and planning. This web-based environment connects to web clients at each unloading port – through computers. shift work. It consists of a System Platform server in which the functional logic of the system resides. as the aim was to ensure complete consolidation of the information for all staff involved. internal and external – and offer real-time information through a shared system for all involved. Once Ulysses was actually down on paper. attention was focused on everything related to the unloading process itself. there was an analysis from the beginning to the end of the process chain of everything related to activity planning. improve performance of unloading coal. etc. with Wonderware InTouch – or with remote clients in the case of suppliers or other agents outside the system. thus promoting decision-making in real time and. the critical stage of deployment began. it was decided which indicators should be considered and gathered to ensure full monitoring and analysis of the activity. “The key was to conduct a thorough study of informational needs to design a 118 technological architecture that would help achieve the goal of optimising the process. and carrier. analysing parameters such as types of cargo ships or the requirements of berths. with parameters such as the control of stock and space available. responsible for compliance with legal obligations.” Once all the processes involved were identified.
” the team claims. monitor the state of the elements at the terminal. ArchestrA System Platform. receive information about stoppages and breakdowns. the advantages result from an increased simplicity of management: “Documentation management associated with contractors has been simplified and professionalised and the legal requirements of trucks.” Intermark emphasises that “Endesa now has reliable information available about its logistics processes revolving around the procurement of coal for its thermoelectric power plants. Endesa is able to make a complete forecasting and historical analysis of its activity. Finally. check and approve invoices by minimising any possible incidents. Analysis and Continuous Improvement As the Intermark Technology team explains. as well as ship schedules or searches for unloading processes made by having immediate access to the documentation associated with each ship. planning of calendar shifts and worksheets. In terms of transport. critical issues such as billing for both transportation suppliers and other external agents to Endesa have been included in the system so that it is easy to emit. reduced fatigue and increased team performance – have resulted in another dimension of improvements in the workplace. which allows greater mobility and availability in those periods of time when we are not present at the facility itself. logistics operators and drivers have been guaranteed. shared interface for all users “is one of the greatest operational benefits obtained. adding that having access to all activity information in real time through a simple. it also has the ability to perform simulations of stock in the analysed area in accordance to the unloading processes made and intended lifting rate. Wonderware Historian. such as ship unloading ratios. The system also allows for the easy registration of new vessels. According to Ana Belén Paz from Endesa. deployment of the global technology infrastructure began. It is possible to view the unloading process in progress.” explains Intermark Technology. We can also immediately and easily obtain reports and statistics of past activity. Alongside this. perform a detailed analysis of their causes and manage the inventory of stock based on reliable and immediate information. the benefits of carrying out remote unloading in a fully automated manner – increased safety. 119 .” she states. one of the great benefits after the deployment of the control platform was real-time management of port activity: “We know the state of the unloading process at each and every moment and we can easily know about changes in the facility at a future time based on activity forecasts we are handling. which allows us to make decisions in a short period of time.” After this pilot test. The system was working well from the beginning. results did not take long to emerge after the project was initiated.” explains Intermark Technologies. monitoring of the activity in real time is a reality today. The change has also been profound in regards to operations: “In addition to the automation of all processes. A control panel of indicators for managing the operations has been introduced. Wonderware InTouch® Availability of Information. taking into account planning and deployment. There is full traceability of the process in terms of planning. Endesa now had a new control and automation system for its coal terminals that offered full visibility and control over the implementation of its operations. which quickly led to the commencement of exploiting the information collected there and initial data was obtained that indicated how to begin the process of improving the logistics management of coal. “It was essential to ensure the correct acquisition of real-time information. via Blackberry or PC and in real time. etc.” the team points out. In less than a year.Power The control of the process that had been carried out would at the same time be maintained in order to confirm that there was total reliability in the data collected. Ana Belén Paz further emphasises the ease of monitoring processes: “Wonderware technology allows us to connect from anywhere. lifting of coal. It is possible to design improvement actions thanks to the exploitation of historical data and costs have been significantly reduced by an increase in operational efficiency. In this sense. “The results obtained in this first test were analysed and proved to be completely successful.” The project reveals its full potential by analysing each of the areas where Wonderware technology is being used today. unloading and lifting of the material. In the planning stage.
Regarding reports, through Wonderware technology Ulysses helps users to report and exploit information for each of the process stages: preparing activity schedules and attendance sheets, predefined reports on unloading and lifting, reports on activity at each terminal and the possibility of carrying out enquiries that are adapted to the needs of each user. Finally, in relation to the environment, which is a key area in all the improvement processes undertaken by the multinational power company, the benefits have also been indisputable, achieving a significant reduction in atmospheric contamination – both dust and noise – and lower energy consumption for implementing the process. In terms of technological features, according to Intermark Technology the advantages are no less important: “Endesa now has a flexible platform to create a model for any type of process by accessing information in a simple and intuitive manner. The large number of inputs/outputs, along with their ability to link up to other systems and devices, has helped to design and deploy a system that the company needed, without fear that future requirements would not be able to integrate with the architecture.” Endesa is now undergoing a substantial change in response to the challenges established by the energy market and Wonderware is fully prepared to accompany the company throughout this process. “Thanks to its technology,” claims Ana Belén Paz, “we are efficiently managing available resources,
ArchestrA System Platform, Wonderware Historian, Wonderware InTouch®
have reduced the costs of the ship/port interface, improved the ratios of unloading/optimisation of times and have greater flexibility in communications due to the introduction of different interlocutors in the control platform, among many other benefits.” The prospects of the project’s future involve further improvements to the integration of different elements at the terminals so that they can provide new information and, consequently, maintain the process of continuous improvement, including electrical power consumption meters, water treatment plants, geolocation systems, etc. The plan is also to make more use of the information gathered through business intelligence tools that help to make even better use of the information processed by Ulysses.
This document was realized thanks to the support of: Endesa and Wonderware Spain
INDUSTRY: PULP & PAPER
Weldwood of Canada
“Many spare parts are no longer inventoried, but are simply ordered when a repair is scheduled and its work order is cut — which is a new capability that we gained, since the new system combines both work scheduling and parts purchasing.”
Hank Dickey Maintenance Superintendent
Weldwood of Canada uses Avantis.PRO solution to reduce operation cost and increase efficiency
Goals • Enhance production efficiency with new computerized maintenance management system Challenges • Update outdated management system did not integrate the maintenance functions with plant purchasing systems, which required larger inventories of spares to be on hand Solutions and Products • Avantis.PRO® Results • Diverse operations in both type and geography are now tied together • Enhanced productivity through more efficient maintenance activities, helping to produce nearly 230 million square feet of plywood each year • Achieved ISO 14001 certification at Williams Lake
Pulp & Paper
Williams Lake, Canada – Weldwood of Canada
Ltd. is one of North America’s leading producers of plywood and lumber products. To meet everincreasing demand for the company’s products, this subsidiary of West Fraser Timber Co. Ltd. has made key investments in new technology in recent years to increase plant capacity at its facilities in western Canada. Weldwood’s Williams Lake plywood plant, located about 330 miles north of Vancouver, British Columbia, is a good example of how an asset management system can help management enhance both maintenance and production.
extensive maintenance assessments prior to installation in order to be sure their processes were optimized. They installed the Avantis solution first at the Williams Lake plant. Based on initial experience with the installation here, they then rolled it out to five additional plants in just over one year.
Integrating Multiple-Site Maintenance
The Avantis solution is now integrated tightly with all aspects of solid wood products manufacturing at plants in Williams Lake, Quesnel, 100 Mile House, Houston, Burns Lake and at Hinton, Alberta. It is used to track equipment and asset utilization, schedule manpower for maintenance and repair services, track and manage parts inventories and disbursements, and generate work orders automatically for preventive maintenance (PM) and on-demand for emergency repairs. The Avantis solution provides features that enable Weldwood management to tie together operations that are diverse in type and geography. It uses an “entity” concept to facilitate recording of costing and maintenance activity records for anything users wish to track. “Parent-child” relationships can be set up easily to build hierarchies for cost rollups and operating statistics. Work management features ensure that maintenance personnel have control of incoming work while providing a flexible way to track work in progress. Planning functions include information on labor, materials, tools, drawings, and instructions, plus subcontractor requirements, and this detail can be included on work orders. PM functions can be structured in libraries of standard jobs with automatic work order generation, inspection checklists, PM routine specs, and parts lists.
As part of its expansion program, Weldwood has done far more than just add capacity — management has also streamlined operations to make existing facilities run more efficiently. Among the tools used to enhance production efficiency are new Computerized Maintenance Management Systems (CMMS) that have been installed at several of its plants in British Columbia and Alberta. These systems have helped make the plants more productive by streamlining maintenance procedures so they are more efficient and take less time from production schedules to perform routine Preventive Maintenance (PM) or emergency repair services. In addition to increases in production equipment uptime, the CMMS has increased the efficiency of scheduled maintenance work and has reduced costs for spare parts inventories. At the same time, improved maintenance practices have also led to production of more consistent and uniformly high quality wood products. The Williams Lake plywood plant, located about 330 miles north of Vancouver, British Columbia, is a good example of how an asset management system can help management enhance both maintenance and production. The company previously had used a mainframe computing system for managing maintenance planning functions, but the system was outdated. One of the main challenges was that it did not integrate the maintenance functions with plant purchasing systems, which made it cumbersome for automating purchasing paperwork in ordering parts, which in turn required larger inventories of spares to be on hand. Weldwood management reviewed several CMMS and selected the Avantis® solution. The company’s maintenance management team conducted
producing power for British Columbia Hydro. Workflow can be better planned and purchasing and procurement functions can be tied directly into maintenance programs.000 items that can be generated instantly on a work order. but if we need more time we can add to it as needed. It helped the company meet stringent audit requirements for environmental systems because of the performance audit trail it provides on all equipment and maintenance operations. with 4. Maintenance parts inventories can be better managed. Maintenance Supervisor. This document was realized thanks to the support of: Weldwood of Canada 123 .” The new system has been an important tool in Weldwood’s achievement of ISO 14001 certification at Williams Lake. The bark and waste are used to produce heat for drying lumber as well as for heating buildings. said. Mobile Equipment Supervisor. and coordinated and monitored at head offices in Vancouver. then predicts and schedules PM based on that data. Avantis. This is critical for managing service of sophisticated equipment so that production keeps humming at the Williams Lake plywood plant. We know ahead of time when we have bigger jobs. and the program tracks the average use of each machine. We enter weekly readings into the Avantis solution. and take action accordingly.PRO® According to Rick Brandson. It’s all based on production needs. Don Gibson. pine. The Avantis solution has also proven to be a valuable tool to help Weldwood maintenance management achieve a good return on investment at Williams Lake.615 inventory items in the catalogue that identifies specific equipment. Similar databases are maintained for five other Weldwood plants. The database has 2. so the chips are trucked to a Northwest energy plant that burns it to generate steam.Pulp & Paper Using the detailed equipment information history that is developed via day-to-day activities. Enhancing Production Efficiency The Avantis solution has become a valuable tool for Weldwood because it has helped the company enhance productivity through more efficient maintenance activities. supervisors can analyze failure histories. The master purchasing catalogue has 66 parts lists with a total of more than 15. “We have a maintenance meeting every Thursday to schedule our PM and other service.365 entities defined. when there may be a bit of excess waste. almost a perfect balance of incoming and outgoing materials — for both fuel purposes and environmental issues. with nearly 1. This single plant produces nearly 230 million square feet of plywood each year from spruce.200 PM tasks and 240 safety procedures. then machinery type and parts lists. “We monitor odometer readings and fuel consumption statistics on all the trucks and mobile equipment.” The Avantis solution database that facilitates maintenance planning at Williams Lake is designed to handle data on equipment usage from large entities down to the smallest — from division-level entities down to departments. About 115 PM jobs are predefined in the system. The only exception is in the summertime. especially when dealing with large numbers of unique and low unit value items that can often be subject to unpredictable demand. for any repair. track failure causes. We then adjust those maintenance windows accordingly so we can minimize the impact on production. The normal window is seven hours. and we track actual hours of equipment operation in the plants. The plant is just about 100% self-sufficient. and fir logs brought in from Crown lands throughout British Columbia.
for profitable semiconductor production Solutions and Products • Foxboro® Measurement & Instruments Results • Reliable monitoring of ST-26 in real time • Online determination of critical process solution viability • Reduced costs for materials and maintenance • Increased productivity 124 .com “Flowthrough conductivity sensing technology has allowed TI to take a proactive role by heading off problems before they happen” Foxboro Flowthrough Conductivity Sensing helps TI improve Productivity while reducing Material and Maintenance Costs Foxboro Flowthrough Conductivity Sensing helps TI improve Productivity while reducing Material and Maintenance Costs Goals • Reduce costs for materials and maintenance by improving ST-26 monitoring in real time Challenges • Accurately monitor and analyze process material quality to achieve reliable monitoring.ti.INDUSTRY: SEMICONDUCTOR Texas Instruments www. without interrupting production or jeopardizing worker safety.
from the point of delivery through application. which is a key material in its wafer production applications. in a pristine “clean room” environment. analyzing ST-26 water balance required taking samples to a processing lab. If undetected and used. Texas – Headquartered in Dallas. TI is a company with a history of firsts. U. triggers an alarm. engineers at TI Houston concluded that conductivity sensing would be the right solution if they could find a sensor with the right combination of measurement capability and process-compatible components. When conductivity reaches the lower limit. design or sales operations in more than 25 countries. The FT10 sensors feature all virgin PFA for compatibility with TI’s requirements for measuring water in ST-26. TI installed the FT10 flowthrough sensor in their process on a 3/4-inch line using TI’s preferred Flaretek connections. real-time determination of their process solution viability. Texas Instruments (TI) has manufacturing. with design and development facilities that collaborate to produce the semiconductors used in computers. TI met this challenge at its Stafford. Traditionally. Thus. without interrupting production or jeopardizing worker safety..S. Texas. it is critical to monitor the ongoing viability of the solution during production. Reliable monitoring. the sensors make an on-line. Frequent and accurate monitoring of process material quality is important to profitable semiconductor production. Located just 20 miles outside of Houston. the process is then remedied to restore the ST-26 solution back to acceptable parameters with no loss of production. especially given that TI uses hundreds of gallons of ST-26 a day. 125 . they selected the Foxboro FT10 conductivity sensor.Semiconductor Dallas.A. Texas facility in monitoring the quality of the photo resist stripper ST-26. TI’s Stafford facility is the company’s worldwide Digital Signal Processing center. The on-line process viability of the ST-26 solution is dependent on its water content. When the results did arrive. Monitoring Quality Semiconductor fabrication involves a carefully orchestrated sequence of intricate procedures. TI has now found the right solution — using flowthrough conductivity sensing technology from Foxboro. Foxboro® Measurement & Instruments Conductivity Sensor Solution After evaluating many other analytical approaches. ST-26 that has unacceptable water balance can cause substantial material loss as well as significant lost production. but the FT10 is suitable for numerous semiconductor applications — including acids — with measurements ranging from less than 50 μS/cm to 2000 mS/cm. automobiles. they could show unacceptable water balance only after the fact. with the Foxboro 875EC intelligent analyzer. TI has found that the allowable range of water content is between 400 and 500 μS/ cm. After discussions with the conductivity product manager at Invensys Operations Management. is an ongoing challenge for the industry. including the first commercial silicon transistor and the first integrated circuit. PC games and wireless telephones. at approximately $30 per gallon. The TI application requires a measurement capability in the 500 μS/cm range. By monitoring the change in conductivity as an index of percent water. Maximizing yield of acceptable product requires keeping all process materials at their precise original specification. where results might not be available for hours or sometimes-even days. the FT10 sensor.
while productivity has improved. Material and maintenance costs have been reduced. which significantly reduces scheduled maintenance time and related exposure of personnel or the environment to aggressive and dangerous chemicals.Semiconductor Foxboro® Measurement & Instruments into the line. with associated costs and safety concerns. The FT10 calibration plugs permit quick. TI has eliminated lost product resulting from unacceptable water levels. Another significant advantage of Foxboro FT10 sensors is in-line calibration. Eliminating Lost Product and Improving Productivity Since installing the FT10. The FT10 features a calibration port that eliminates the need to break This document was realized thanks to the support of: Texas Instruments 126 . precise calibration with a shirt-pocket tool. Flowthrough conductivity sensing technology has allowed TI to take a proactive role by heading off problems before they happen.
etc) that is able to meet the high standards of excellence and reliability required by the company. head of the Systems Development Department at Ferrocarrils de la Generalitat de Catalunya Wonderware enables new management model for rail system providing service excellence and user accessibility Goals • To deploy a supervisory control system for a railway system in Spain that involves the remote control of rail station operation (ticket sales. a strong policy for preventing incidents and better response times for passengers. opening and closing of doors. access control. fully automated manner and with total process reliability. 127 . Each year. lighting. Trains have to be punctual. • To complete the deployment of the new supervisory system without halting plant services and to ensure the smooth functioning of the countless remotecontrolled operations at each station: ticket vending machines. etc. escalators. Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware Historian Software Results • The new control architecture has helped Ferrocarrils de la Generalitat de Catalunya improve its customer satisfaction by providing a excellent seamless service. • To integrate multiple units of servers and owner PLCs into a single supervisory environment with a common interface for all processes.fgc. stations must be kept clean and fully operational and any complaints or suggestions should be addressed and resolved.INDUSTRY: TRANSPORTATION Ferrocarrils de la Generalitat de Catalunya www. • Management of the remote-controlled operations by professionals in the control centre is carried out in a simple. • To integrate existing automated processes in order to obtain the most out of previous technological investments Challenges • To maintain a high level of customer support by improving service despite an increase in processes in the network being controlled. we seek to achieve higher satisfaction levels from our users and Wonderware technology is an essential tool in achieving this.” Alicia Coca.cat “The challenge we have set ourselves as a company is that of excellence in customer service.
Under this premise. responsible for the operational running of trains. it was decided that system upgrading of the Station Monitoring Centre would be carried out by SICE using Wonderware technology. lighting and pump shafts. opening and closing of entrance doors. which together add up to 76 train stations and 200 kilometres of rail tracks – FGC is committed to a model that constantly innovates. Consequently. Thus. As the head of the Systems Development Department at Ferrocarrils de la Generalitat de Catalunya. FGC was the first public rail transport company in Spain to opt for the remote management of stations by automating its operations and ensuring a high quality of service to its customers by taking care of such details as ticket sales. the mission of FGC is to manage its rail services and infrastructure efficiently and effectively. The open architecture of its solutions provides it with unique interconnection capabilities and fitted in perfectly to the requirements of integration and operational reliability required by Ferrocarrils de la Generalitat de Catalunya. enabled FCG to operate all stations in the network from a central location. the Rubí Operational Centre (COR) was created. Alicia Coca. Following a public tender. housing both the Station Monitoring Centre and Traffic Control Centre. As a public company. Spain. which had hitherto been supervised separately. Wonderware Historian Software Innovate by Creating a New Concept of Rail Management Although FGC had already been providing rail transport services to citizens before 1996. operating 24 hours a day. lighting and air-conditioning. which are an essential part in the functioning of each station. “Despite being a pioneering system that marked a turning point in how train stations were managed in Spain. a complete renovation was undertaken of the integrated station management system to improve and advance system features and incorporate the new multi-line concept. Customers could not feel that they were being deprived of services because of the change. We had as many islands of information as controlled processes and this made things very difficult. FGC has impeccable management that delivers unprecedented service excellence in the industry.” The need to integrate all controlled operations into a single supervisory system through a common management interface was the next stage of the project. Ferrocarrils de la Generalitat de Catalunya (FGC) is a public company managed by the Catalan Regional Government providing rail transport services to over 80 million passengers (data from 2010). As a change to the railway operational model.” she explains. as well as the Customer Information Centre. has excellent service and respects the environment. explains that: “By eliminating ticket offices. With 1. it was decided to create the Integrated Command Centre (CCI) for the joint management of the two network lines. Little by little. For example. Today. Through the new remote-controlled model for the facilities. .300 workers and two transport lines – BarcelonaVallès and Llobregat-Anoia. the station personnel would be able to provide immediate support. the company began an ambitious organisational and technological reform of its operational management in 1996. but quite the opposite. 365 days a year.” explains Alicia Coca. with every function controlled through an individual proprietary system whose functioning was not linked with other operations at the station. the greater the customer satisfaction. “the supervisory system operated in a completely distributed manner. Coinciding with the creation of the new CCI. air-conditioning. the Centre began overseeing the proper functioning of everything related to the station: ticket vending machines.Transportation Rubí (Barcelona). ArchestrA System Platform. a range of leisure activities that meet their level of expectations. Barcelona-Vallès and Llobregat-Anoia. that year it launched a new operational model for stations by providing new value added services that went far beyond traditional ticket sales. public address system. FGC was transferred in 1979 by the Spanish Government to the Catalan Government to improve the mobility of its citizens and to make available to them. The creation of the Station Monitoring Centre. the automation began to replace the functions previously performed by station staff. the automation of ticket sales through vending machines enabled the station personnel to focus on direct customer support. among countless other functions. a supervisory architecture had to be developed to 128 help control each of the functions that had until that time been handled by the permanent staff at each station. Wonderware InTouch® HMI. if users required any information or had an emergency situation. the company’s key contribution is proving that the greater the commitment to process innovation and automation. However. CCTV. access control.
providing us with a common management interface for controlling all operations. Wonderware InTouch® HMI. communicating information online and operating simultaneously because of the security requirements of FGC. connecting in the back office with each of the servers or PLCs that control the various operations. what functions we wanted to improve and what functions we needed to add. “The dynamics of our service oblige us to have systems that are always operational. He points to the fact that the new architecture had to replace an operational SCADA. This simple and transparent architecture was determined by the functional requirements of the network. as well as a database server. equipment and type. the solution was based on two servers functioning as input/output servers. ArchestrA System Platform. he also refers to the challenge implied by working with diverse facilities: “Some of the communications equipment that provided information on the state of facilities. the first being an ArchestrA System Platform. the users. Therefore. the operation was repeated with the Llobregat-Anoia line. and that also helped to send commands to them. Julio Martínez at SICE. the management of the two lines operated by FGC. the control system was structured into two servers.” explains Alicia Coca. thus concluding the third stage of implementation. a 129 . as well as a week with backup personnel in case the new system failed. with load distribution and redundancy.” he explains. that connect to seven operator stations loaded with InTouch. A year after implementation. Wonderware Historian Software The second stage of the project was the implementation of the Barcelona-Vallès line and this was no less complex. which were detailed in the first stage of the project. Alongside this. Technologically. Wonderware gave us the flexibility we required and guaranteed us a seamless link to each of the network systems.” This was how the Multi-Line Integrator System (SIM) was designed: a supervisory environment using Wonderware technology that for the first time linked together. “In terms of engineering. that do not return to ‘zero’. The only way to ensure successful implementation was by working closely with the operational team at FGC.” explains Alicia Coca. because any incident in our remotecontrolled operational model implies an extraordinary deployment of technical and human resources.” he explains. the challenges were “varied and complex”. their functions and location or way of accessing the system were defined.” says Alicia Coca. run and validated. following extensions that have been carried out that improved availability. The plan also included a development server where new software versions and solutions can be installed. as well as the degree of reliability required. which meant that tests had to be done in parallel without interfering with operations. the hardest part was getting the two systems to coexist simultaneously by capturing field signals without interference. the new architecture to control and monitor stations with Wonderware was fully operational. “Once we knew how the system worked. In terms of functionality. According to the integrator involved in the project. “We wanted an open system that would allow us to develop specific drivers for units that did not always work with traditional PLCs. and another server with a Wonderware Historian server. we knew the number of signals. but delivering to the front office. had been in operation for a long time. The inability to halt the service meant that the development of the new control architecture had to be carried out simultaneously with the existing one without any shutdown. “The premise was to design before constructing. without any detailed documentation and sometimes the manufacturer no longer existed. according to Julio Martínez at SICE: “On the one hand. the system architecture has evolved towards a solution based on four servers. we decided what functions we wanted to change. but it had its own private communications protocols.Transportation The Challenge of Interconnection and Reliability The first objective established to update systems was to ensure the reliability of the control architecture. After three days of operations with double the staff in the old and new command centres.” she explains. Currently. as they were the ones who would ultimately use the solution. The first stage of the project began with the team analysing how the system should be based on experiences gathered over the more than 10 years that the previous control architecture had been operating. the Multi-Line Integrator System (SIM) interacts with the various third-party subsystems. In terms of the servers.
000 signals from the most diverse existing units.Intercom voice recording systems . station lighting.Data usage: creation of reports (intercom calls. only three operators are required for the BarcelonaVallès line and two operators for the LlobregatAnoia line to ensure excellent service to the 300. The supervisory infrastructure that has been Multi-Line Integrator System Operations Controlled by Wonderware Technology Stations . Closely linked to this desire for improvement. seven days a week. extraction and ventilation shafts.Access control at stations: locking/unlocking of station entrances . escalators. airconditioning. we have absolute security and reliability about what is happening at each point of our network because the system provides us with information 24 hours a day.Information and SOS points where users can contact FGC staff .Video recording systems .5-3 seconds.FGC information panels . etc .” explains Alicia Coca.” The benefits are innumerable for system management.” ArchestrA System Platform. Ferrocarrils de la Generalitat sees the degree of user satisfaction increasing: “The model of centralised operation at the stations has strict criteria of excellence. in relation to maximum response times for incidents.000 people using our services every day. the SIM knows when a machine is about to run out of change or is about to run out of the roll of paper on which the tickets are printed. for example. Julio Martínez at SICE highlights the ability of Wonderware to adapt itself to the requirements of a continuously developing management environment: “FGC stations are in a process of constant renovation and growth. Thanks to the capacity of the supervisory system. Wonderware InTouch® HMI. Proper design of the adopted solution and Wonderware platform architecture based on objectives helps the system reflect changes and introduce new equipment at the stations. remote control of vending machines or barriers at entrances and exits.Transportation common management interface to control CCTV. “Wonderware currently provides integral management for about 50. automatic doors at station entrances and shutters. the responsible control centre operator notifies the station agent and he or she resolves the problem before it has even occurred. ticket barriers.Real-time camera footage at stations . “Today. and right through the quality of 130 . Year after year.Reception of alarms from station facilities . The fact that the system built on Wonderware provides full real-time visibility about what happens in the network is undoubtedly one of the key elements that ensures maximum passenger satisfaction. According to Alicia Coca. outdoor shutters. internal and external telephony.Remote support for sales operations in ticket vending machines . 365 days a year and always in real time. alarms and incidents. station entrances. operator actions) and consultation of historical data Command Posts .Ticket vending machines . As soon as the alarm sounds.Management of incidents arising from alarm signals received Central Systems .Informational screens with train times .Corporate telephone systems The response time of the integrated control system for operational actions required by stations is between 2.” she claims. elevators.Analogue and IP video to monitor facilities through closed-circuit TV (CCTV) . station intercoms and the many remote control features such as escalators. implemented helps to ensure prevention protocols in virtually all areas: “Today. Wonderware Historian Software Excellence in Customer Service This investment in technology using Wonderware at FGC has resulted in greater customer satisfaction.Rear projection systems . through customer surveys.” points out Alicia Coca.Services: lighting. Satisfaction goes beyond the technological aspect of the project.Intercoms .
Each year. the operator receives the signal. in an environment that has an increasing level of demand.” This document was realized thanks to the support of: Ferrocarrils de la Generalitat de Catalunya and Wonderware Spain 131 . thus achieving “impeccable management.Transportation support received from Wonderware and the system integrator. Wonderware Historian Software a passenger uses a station intercom.” he explains. “To have the immediate support of the integrator and by Invensys. Trains have to be punctual. If ArchestrA System Platform. “The integrated system has given us the ability to automate logical tasks that were previously carried out manually. “The challenge we have set ourselves as a company is that of excellence in customer service. we can adapt the system architecture to design requirements with such useful features as creating non-standard drivers that can be incorporated into the system as if they were native. assess the incident and directly manage the machine to resolve the issue.” explains Alicia Coca. Julio Martínez is clear when it comes to the advantages provided by Wonderware: “The ArchestrA System Platform provides the elements for overall integration. answers and. Alicia Coca also refers to the fact that the supervisory system has simplified the daily work of the operators at the Station Monitoring Centre. this is important when working with critical systems. Today.” At the technology level. because the machine also has a camera. It is dynamic in terms of client and server architecture and allows for growth. we seek to achieve higher satisfaction levels from our users. reduce response times and improve the operation of operators at the Station Monitoring Centre. Wonderware InTouch® HMI. the signal is automatically sent to the video wall at the control centre so that the operator can see what is happening instantly.” The Wonderware solution has also helped to guarantee system availability. and Wonderware technology is an essential tool in achieving this. stations must be kept clean and fully operational and any complaints or suggestions should be addressed and resolved.
Using remote control on A12 motorway has helped reduce energy costs and increase drivers’ safety.it “Adopting an industrygrade automation solution was the first step to the successful implementation of a project characterized by a large number of controls.a. S.p. reduce energy and maintenance costs of the AI2 Motorway • Obtain real-time information about status and alarm conditions of toll gate and tunnel equipment • Enable the automatic control and operation of tunnel lighting and ventilation systems Challenges • Manage a critical infrastructure with 24 tunnels and 75 km classified as “B-class mountain” motorway • Deploy an application featuring a large number of control units and ensuring uninterrupted operation • Immediately identify possible anomalies or malfunctions along the motorway. Goals • Improve safety.A. providing diversified information and access to each role within the organization • Use high-performance automation solutions to guarantee real-time data collection and system monitoring Solutions and Products • ArchestrA System Platform • Wonderware InTouch® for Terminal Services • Wonderware Historian Results • Safe operation of the A12 highway • Optimization of energy consumption is realized through the automated management of tunnel lighting and ventilation systems • Preventive maintenance system based on the centralized real-time monitoring of installed equipment enables savings in cost of spare parts 132 . www.salt. and mostly. by the need to guarantee uninterrupted operation.” Eraldo Benedetto Automation Manager Giordano & C.INDUSTRY: TRANSPORTATION SALT – Società Autostrada Ligure Toscana p.
with consequent risks related to human errors. Salt (Società Autostrada Ligure Toscana). At night. who must handle a flow of 50 million vehicles annually. using and technology provided by Wonderware. because the proper level of visibility must be guaranteed according to weather conditions. for this reason. the opposite approach should be adopted: as you drive from the dark outside into a lit gallery. the tunnel lighting must be dimmed at the entrance and exit. a vehicle running 133 . Galleries’ General Overview Within this time lapse. When visibility outside the gallery is excellent. In the design stage . Wonderware Historian at high speed covers a few meters. and mostly. but also for the motorway management company. “These requirements could be met only with solutions and expertise from the industrial domain. with the driver basically “blinded”. ArchestrA System Platform. lighting is one of the most critical elements. Wind in the tunnel Inside a motorway tunnel. automation manager of Giordano & C. CEO.” explains Paolo Pierantoni. crossed by thousands of vehicles every hour. Traditionally. the entrance to the tunnel must be “daylit”.” says Eraldo Benedetto. For this reason. a Cuneo-based solution provider specializing in industrial automation. Time scheduling is based on an astronomy calendar where sunrise and sunset timetables are stored. with devastating effects in case of long stops. It takes a few fractions of a second for a driver’s visual apparatus to adapt to sudden changes in lighting conditions. The A12 highway includes as many as 24 tunnels and 75 km of “B-class mountain” roads.Benedetto underlines . Salt “As they are characterized by high reliability and have the capacity to handle large-scale applications”.Transportation Viareggio..Driving on a motorway requires a great deal of attention. This situation endangers the safety of people and. as due to high speed. Italy . to grow again towards the exit. this activity was entrusted to a worker. reducing visibility and making air unbreathable. by the need to guarantee uninterrupted operation. This was combined with delays that. and because maintenance and power consumption have a significant impact on the balance sheet of the managing company. and vice versa. Then. A delay by even few minutes when the lamps are turned on and off may result into significant energy saving or additional costs. lighting intensity may decrease gradually towards the inner section of the tunnel. you have to react promptly to any abnormal or unexpected situation. For this reason. also had an economic impact. It is a challenging route not only for the drivers. in 2007. “Adopting an industry-grade automation solution was the first step to the successful implementation of a project characterized by a large number of controls. Attention must be further increased when you drive along the 155 km asphalt belt that leads from Sestri Levante to Livorno. Light in the tunnel On a motorway with 24 tunnels. taking the track up to the 348 meters above the Bracco pass. Salt selected Giordano & C. Wonderware InTouch® for Terminal Services. exhaust gas concentrations may rise quickly. which detect real weather conditions. decided to invest in a remote control system with two goals: improve safety and reduce energy and maintenance costs. including possible corrections triggered by a network of twilight sensors and light meters.we focused on the reliability and redundancy of all installed systems. the company that manages this critical motorway. the automated management enabled by ArchestrA System Platform was a substantial technological leap. “A motorway is always open and any failure of technology systems might endanger the lives of dozens of people. in order to guarantee optimal control under any circumstances”. To face these challenges. requires a proper adjustment of the tunnel lighting system. besides affecting safety.
smoke opacity. which is mostly relevant for ordinary management operations. So. In case of fire. especially in tunnels like Saturnia. Engineering is also effectively supported by the object-oriented programming logic of Archestra. All technology equipment.. is monitored remotely from a control room in Viareggio. where two redundant servers are installed. a complex measurement system has been installed. In this respect. Right on time While energy is the most apparent cost factor. In this way. Wonderware Historian Application Architecture Proper ventilation is therefore essential. even before analyzing the cost effectiveness of a system. and to determine the proper air extraction direction according to environmental conditions outside the tunnel. Any traveller has experienced the inconvenience that is due to road works. so it is particularly suitable for the implementation of hybrid client/server or peer-topeer architectures. For this reason. in terms of human resources. which can be modified in the course of project deployment without restarting development from scratch. A key element to support preventive maintenance and centralized management is the visualization system Wonderware InTouch HMI. Such request is not always compatible with the detailed analysis of each technology component. in order to optimize the operation of every single fan. it might be necessary to close down the motorway. which can perform smart calculations based on exhaust gas concentration. as well as detailed information about the operating hours of each element. it’s a matter of delicate balance. with a consequent loss of revenues. from lamps 134 Motorway alarm Of course. quickly and reliably.Transportation ArchestrA System Platform. the control room staff knows the conditions of any piece of equipment in real time. while taking into account specific atmospheric pressure conditions that can affect the efficiency of the system. the flexibility of ArchestrA System . in case of extensive works or emergency situations. This is annoying for drivers and expensive for the management company. explains: “Wonderware technology is also flexible as relates to operating system and basic remote management services (RDP/ICA). to fans. For instance.. including power switch cabinets. fan rotation speed and direction must be adjusted to support the extraction of smoke without further feeding the flames. Silvana Pettiti. equipped with 14 fans. information is collected by 40 PLCs that supervise the operation of each system locally. In this respect. Such conditions can be further worsened by the fact that. safety is a factor that a motorway management company cannot neglect. wind and atmospheric pressure. the financial impact of maintenance should also be evaluated accurately. On a complex motorway like A12. for this purpose. maintenance requires special attention. Knowing the useful life of installed equipment. all the necessary solutions to safeguard travellers must be adopted. A dedicated optical fiber link. enabling subcontracting companies to work during low traffic hours and minimizing inconvenience for drivers. operating in Terminal Service mode. Salt managers demanded to be informed promptly about any anomaly. ensures the rollout and cloning of controls in record time. Project Manager at Giordano & C. the possibility to duplicate previously developed and tested systems and models. Wonderware InTouch® for Terminal Services. Basically. we have developed almost the entire project over a remote connection to the application servers in Viareggio from our offices in Boves near Cuneo! ”. equipment and organization. accurate management is required both to avoid useless operation that reduces the operating life of systems and increases consumption. you should not go against the wind flow. they can plan maintenance operations in advance. In view of this situation.
where all details of any situation can be examined to identify the required technical action or to modify specific parameter settings remotely. and to meet all customer demands during development. is a success factor for a motorway controlled by over 40 thousand I/Os. This procedure makes each operator aware of his/her responsibilities and enables to analyze the effects of any action at a later time. 135 . ArchestrA System Platform.Società Autostrada Ligure Toscana p. And don’t forget that some functionalities were added later on. is informed about current events through a highly intuitive alarm system. Wonderware InTouch® for Terminal Services. supported by explanatory charts and the possibility to compare highly heterogeneous parameters. the software platform where all industrial automation applications converge – adds Pettiti. S.Motorway Toll Station To comply with the strictest safety standards. is performed in the Viareggio control room. “as energy bills are showing to Salt managers that energy savings achieved have paid back the entire investment in a very short time. but also a car crash or other abnormal situations. Detailed analysis. instead.p. spanned across one year. using a remote control system supported by industrial automation technology has turned out to be very effective. Wonderware Historian HMI Screenshot . Giordano & C. The number of I/Os keeps growing. in charge for launching rescue operations in case of emergency. as it allows to provide diversified information and access to each person. We have also been able to create data exchange tables towards other systems. tailored to our needs. the operator’s task is just to request the intervention of rescue squads or skilled workers. Such capacity. Under emergency conditions. would take minutes even for simple data collection. any change is automatically recorded and stored in the Historian database. such delay would put many lives at stake. In case of a similar event. The control room operator. including the possibility to access through a common browser.” Due to the complexity of the plant. as it enables the real-time management of a system that. as soon as operators started to appreciate the benefits of remote control. Wonderware’s HMI software graphics can visualize a failure on the operator panel. would have a negative impact on profitability. – have proved to be very useful during programming. And every day. says Benedetto. it would cause delayed actions that.Transportation Platform was a decisive factor. This document was realized thanks to the support of: SALT .a. so that it cannot be edited any further.A.” “The openness of Wonderware’s Historian database and the virtually unlimited capabilities of System Platform. with less performing solutions.
gov.” Dr. ventilation and drainage. industrial zone and central business district • Ensure the effective management of tunnel conditions and operation equipment including power.cn “The Invensys solutions use advanced component object-based technology that enable us to reuse templates from previous projects allowing faster implementation of new processes.INDUSTRY: TRANSPORTATION Wuxi Transportation Tunnel System en. achieving full deployment of the entire road • Reduced engineering costs. as well as emergency response operations Challenges • The control center has to rapidly react to emergency events such as accidents. maintenance of road conditions and management of energy use Solutions and Products • ArchestrA System Platform • Wonderware InTouch® HMI • Wonderware Information Server • Wonderware Historian & Historian Clients Results • The management team can now efficiently monitor various systems. Wu Zhichun Mayor of Wuxi Invensys Technology Enables Remote Monitoring of Wuxi Transportation Tunnel System in China’s Rapidly Growing Industrial and Technology Business Hub Goals • Remotely manage the series of tunnels. lighting. fires and floods in accordance with contingency plans • Respond to tunnel operations management issues including effective operation of equipment. improved overall operation efficiency and decreased travel time through the central city • The system now supports more than 10 clients as compared to the previous six clients and achieved a lower headcount 136 .wuxi. roads and pedestrian paths that connect the city’s residential area.
delivery and maintenance of real-time and historical information. scalable platform that enables system managers to control and supervise operations using object-based technology which enables configuration. increases quality. China – Wuxi earned its nickname of “little Shanghai” for its proximity to China’s most populous city and for its booming economy and rapid growth of business and industry. The solution was required to observe and manage tunnel conditions. The industrial focus includes technology.” ArchestrA System Platform. To manage the complex series of roads. “The city required an open architecture software solution that would enable operators to quickly and easily modify the remote monitoring system to address the continually changing conditions of the tunnel and road conditions. With the rapid growth in industry came an explosion of jobs and more people moving to the city and surrounding areas. Wonderware Information Server. operators can quickly develop templates that can be easily replicated and revised as needed. Invensys turned a potentially complex and difficult undertaking into a streamlined operation. traffic congestion became an issue.” said Dr. electronics.Transportation Wuxi. three general traffic tunnels and three bridges. industrial zone and central business district via a series of tunnels that would alleviate traffic congestion and streamline travel for the city’s residents. The Wuxi tunnel and Inner Ring Road loop project required a software system that could successfully manage the Wuxi transportation corridor via a remote monitoring system. pharmaceuticals and chemical processing. maintenance and operational costs. ventilation and drainage. city officials required a technology management system that could monitor traffic conditions. Wuxi was ranked as the third best city for business in China in 2008. and lowers development. As with other metropolitan areas experiencing this type of growth. However. logging. manage equipment operations including power. Wonderware System Platform provides a single. In 2005. In 2008. lighting. This unique traffic management design enables residents and the business community to save an extra 15 minutes when traveling through the central city. The combination of these standards-driven systems maximizes productivity. and handle emergency response procedures. Wonderware InTouch® HMI. Wuxi selected Invensys Operations Management solutions because it could fulfill all the requirements needed to remotely monitor the complex tunnel transportation system. Wuxi implemented ArchestrA System Platform along with InTouch® and Wonderware Historian to provide a variety of remote monitoring capabilities and data collection operations. According to Forbes magazine. After reviewing the offerings of several technology providers. optimizes user effectiveness. tunnel functions and emergency situations. This significantly cuts down on the cost associated with engineering development of technology applications. “Because the Invensys solution uses a component object-based model. the 50 square kilometers of tunnel work was completed and includes the Inner Ring Road loop which connects five interchange tunnels. 137 . the Wuxi city government established plans to connect the city’s residential area. mayor of Wuxi. Wonderware Historian & Historian Clients Visualization Enhances Traffic Management Monitoring the traffic paths and conditions of one of China’s major industrial and business districts is no easy task. Wu Zhichun. machinery. InTouch is the HMI solution which operates in conjunction with System Platform and provides graphic visualization of the entire Wuxi tunnel operations for easy tunnel management. bridges and tunnels. control and process optimization.
it must relay information immediately in accordance with the city’s contingency rescue command plans. Information Server also connects operations personnel with other open data sources so they can access the system’s entire performance record. Information Server is integrated with Historian Clients. enterpriselevel reporting capabilities. analyze the best means to achieve their objectives and optimize existing investments in software and equipment. “The use of InTouch added a great deal of power and flexibility to the system design.” said Zhichun.” Wonderware Historian is designed to assist users to visualize improvements in operational effectiveness and efficiency. Because the control center is responsible for monitoring emergency situations. allowing us to efficiently and cost-effectively integrate an enormous amount of system information. Knowing that Invensys software is providing accurate. Wonderware InTouch® HMI. transportation engineers can more easily troubleshoot operations and obtain a better understanding of their process based on detailed. “Online access to critical data from all locations within the control command center allows us to make better operations decisions and immediately address problems as soon as they occur. accurate information.” Wonderware Information Server provides an interactive. which provides enhanced Web-based. “This enabled us to concentrate on the real-time control portions of the monitoring and emergency systems. integrated package. 138 . By combining process analysis. Wonderware Historian & Historian Clients Advanced Analysis and Reporting Capabilities Boost Operations & Safety Processes Not only are traffic and tunnel conditions important to monitor. Its ability to provide data in other forms compatible with corporate portals expands its usefulness to a wide range of users within an organization. predefined trend charts and reporting into a single.” said Zhichun. Wonderware Historian using Historian Clients provide historical data relating to activities in the tunnel environment. open method of delivering critical operating information to workers engaged in a variety of industries including transportation infrastructure processes. flooding. “Information Server enables our team to access information and content anywhere at anytime.Transportation “The monitoring system is responsible for a wide range of complex operations and safety activities. “Effectively viewing. analyzing and processing a variety of tunnel data is extremely important to the overall operation of the transportation system. emergency services rely on the remote command center to provide details on fires. Online Access to Information Improves Department’s Response Time The backbone of the Wuxi tunnel technology solution is the Wonderware Information Server. These reports can be customized and tailored to the information needs of specific operations management users.” said Zhichun. or other crises that occur within the Wuxi tunnel system. real-time information on tunnel conditions is a reassuring factor in management of the transportation system. enabling department managers and operators to analyze operation trends and provide highly informative production and performance reports. utilities and water/ wastewater.” ArchestrA System Platform. Wonderware Information Server.
Wonderware InTouch® HMI.” The scalability and reusability of the Invensys solution enhances the Wuxi transportation management team’s ability to effectively manage its advanced tunnel system.” said Zhichun.Transportation As a unified portal and content server. Designed for operations intelligence. the use of these templates significantly reduces engineering time and costs as well as the overall total cost of ownership. providing the enterprise with a common real-time information dashboard. “The Invensys solution enables us to easily deploy the same process in other locations without the need for recoding. Invensys software enables the department to continue to cut costs through use of the component object-based technology and update the tunnel surveillance system with customized software templates. This document was realized thanks to the support of: Wuxi Transportation Tunnel System 139 .” Lower Engineering Costs Benefit Department’s Operations Budget By using Invensys software. Managers and operators at all levels can obtain an enterprisewide view of production operations and KPIs. Soon Wuxi may also be known as the “city of tunnels. Wonderware Information Server enables flexible access to applications. reporting and visualization information using a Web browser. Wonderware Historian & Historian Clients “Providing a single. Wonderware Information Server. the Wuxi transportation department is able to reduce operating costs by reusing component templates. comprehensive solution for management of the Wuxi tunnel system enables us to rapidly reuse and deploy process components providing tremendous cost savings and streamlining engineering practices. ArchestrA System Platform.
and sorting work orders. we avoid problems related to lost or inaccurately completed forms. expected savings is about $17.INDUSTRY: WATER AND WASTEWATER Southern Nevada Water System www. employee performance management and equipment status tracking 140 . and potentially inaccurate paper recordkeeping Solutions and Products • Avantis.000 in reduced administrative costs • More efficient work order processing and timely maintenance project tracking • Improved accuracy in form completion.PRO® Results • In its first year of operation. filing.” Jeffrey Deitch Business Systems Analyst with the Technology and Special Projects Division PDA-Based Planning and Scheduling Solution cuts costs and paperwork for Southern Nevada Water System Goals • Improve maintenance project and equipment status tracking • Reduce inaccurate recordkeeping • Increase employee performance Challenges • Automate the maintenance planning and scheduling system. We save cost of producing.000 in work order processing and $33.com “In addition to eliminating paper shuffling. reduce paperwork and free field technicians from costly. time consuming. and we have better tracking of employee performance and equipment status.snwa.
PRO. and at the River Mountains Water Treatment Facility. manages treatment of up to 900 million gallons of water every day. At the end of the technicians shift. This helps to plan and schedule field maintenance. SNWS took its first step toward automated maintenance planning and scheduling (automating work order. located in Henderson. including emergency or break schedule work that came in during the day. parts. Thirty pumping stations distribute water across 163 miles of pipeline to users throughout Southern Nevada.Water and Wastewater Henderson. A single planner/scheduler coordinates use of Avantis VIP Advanced Scheduling software on HP IPAQ handheld computers. and inventory management) with the installation of the Avantis. information analysis. the PDA is returned and synced with Avantis. Therefore. and efficient resource deployment. entity. The planner/scheduler can then see the status of all existing and pending work orders instantly. assets. he saw the opportunity to 141 . system performance monitoring. a department of the Southern Nevada Water Authority. requiring mechanical skill. Less paperwork means more wrench time for the technicians and that means more availability of equipment and better service to the Authority. located on the shores of Lake Mead. and other resources are lined up and available to the technician. Water is treated at the Alfred Merritt Smith Water Treatment Facility. “Maintaining a system of this magnitude is an enormous undertaking.” said Jeffrey Deitch.PRO® free field technicians from costly. less paperwork in the back office frees administrative staff to perform other value-added activities to improve the efficiency of our operation. instead of receiving a stack of paper work orders for the day. and potentially inaccurate paper record keeping. Nevada. Advanced Scheduling Solution When Deitch learned that Invensys Operations Management offered an Avantis planning and scheduling client for personal data assistants (PDAs). time consuming. The planner/scheduler then uses the VIP tools to coordinate sick calls or any other schedule changes that are required and reconciles them with new work orders so that the updated PDAs are ready for crews when they report to work the next morning. technicians now receive a PDA. which the planner/scheduler has already docked to the network and loaded work assignments for the day. Also. for example. Nevada – The Southern Nevada Water System (SNWS) refers to the system of treatment and distribution facilities that diverts raw Colorado River water from Lake Mead and delivers potable water to Southern Nevada’s municipal water providers.” Savings and Impressive Results SNWS now has 12 technicians on PDAs. helps schedule the maintenance and measures schedule compliance. A calendar wizard. Avantis.PRO enterprise asset management software. which consolidates all activity into a single database view. Business Systems Analyst with the Technology and Special Projects Division. Efficient planning and scheduling is the key. Streamlining Management Operations and Reducing Paperwork SNWS. “Our primary objective was to reduce paperwork. The software ensures that all required people. According to Deitch. tools.
Water and Wastewater
in work order processing and $33,000 in reduced administrative costs. “Through the display, I can see daily or weekly availability of my entire crew in a single Gantt-style chart,” said Deitch. “Color-coding tells me where they are, what work has been started, and what has been completed. It is accurate up to the preceding day. Getting that kind of information would otherwise require a tremendous administrative effort, which would take away from wrench time. The software also helps make better use of the new time they have available.” communicate schedules to the technicians on a timely basis, and obtain accurate and timely records back into the enterprise system. In its first year of operation, SNWS is expecting to save about $17,000 Running Avantis VIP advanced planning and scheduling software on PDAs has proven to be a multi-part solution for SNWS.
This document was realized thanks to the support of: Southern Nevada Water System 142
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