Automation & Control
and other parts closely, and perform maintenance only when it’s actually needed. This not only helps the plant achieve a higher level of productivity, but it also enables operators to repair equipment before failures can occur. Additionally, operators can watch overall operations for
the furnace units and other areas of the plant from one location. This means that fewer employees can do more work and, because of the reliability of the system, they can also perform extra duties during their shifts. But real-time data is not the only advantage Bodycote gets.
The Wonderware Historian software provides management with the historical data they need to extrapolate furnace life and better plan for future capital expenditures. Because millions of dollars worth of equipment are required for the HIP plant, this is extremely important. Before adding Wonderware software, Bodycote’s operators
used ‘touch and feel’ to regulate power to the furnaces and maintain consistent temperatures. With the different furnace sizes and other variables in the environment, even the most experienced operators were put to the test. With the new system, recipes for repeated batches are
programmed into the Wonderware software. This has improved consistency over multiple runs, and has increased customer satisfaction. When a customer has a question, it can be answered quickly and in detail, thanks to the new reporting capabilities. The reports can prove adherence to a recipe, or can pinpoint the exact time and parameters of a change in the process. The need to re-process parts due to temperature
fluctuation or operator error has been nearly eliminated, and Wonderware SCADAlarm software alerts operators to equipment that needs attention, or triggers an automatic shutdown if a pre-determined threshold is exceeded. When asked, Crawford is quick to point out that the most important feature of the new Wonderware software solution has been its usability. He says that everyone in the plant enjoys working with it. Diagrams and on-screen icons representing equipment, configurations and recipes are easy to see clearly and quickly understandable. He points out that there are many different screens, but not so many as to confuse
Fig. 2. Wonderware allows example runs and problem situations to be simulated so that operators can learn how to best react.
operators - even less-experienced ones. As a matter of fact, Bodycote plans to use the Wonderware
software for training. Example runs and problem situations can be simulated so operators can learn how to react. And these exercises can be accomplished without taking the plant systems offline, so there’s no impact on productivity (Fig. 2). The Wonderware software has brought Bodycote the stability and repeatability required to turn out consistent products for its customers. It has improved preventative maintenance and the ability to cut costs for resources such argon gas as well as reduce expenses due to production errors. And not only that, the new solution has been popular with management and operators alike. Crawford feels that Bodycote has just scratched the
surface of the Wonderware software’s capabilities. He hopes to implement new ideas he has been developing for utilising data and reports for additional efficiencies and savings. The versatility of the solution and the resourcefulness inherent in Bodycote should enable the plant to continue to withstand market pressures - and succeed - for quite some time. n
Rapid design and running of batch applications R
ockwell Automation has expanded the application development capabilities of its FactoryTalk Batch software to help users more rapidly design and run batch applications.
The software features new intelligent recipe capabilities, secure operator overrides, expanded data collection and reporting, and improved material management capabilities. Tightly integrated with the scalable PlantPAx Process Automation System from Rockwell Automation, the FactoryTalk Batch software provides solutions ranging from small, basic sequencing to large, complex batch applications.
New features include: intelligent recipe features; improved run-time user control; expanded data collection and reporting; and improved material management capability. The FactoryTalk Batch version 11 is now shipping as part of the PlantPAx Process Automation System.
Meanwhile Emerson is also expanding its product portfolio, but by acquisition. The company has just bought Innovative Control Systems, a leading supplier of turbine control upgrades for the power generation industry. Innovative Control Systems specialises in upgrading control systems on gas turbines such as those used in combined-cycle power
plants. Such turbines offer high efficiency, low capital costs, and limited emissions compared to many other power generation technologies. Control retrofits have become an increasingly attractive way for power generators to cost- effectively boost the performance and reliability of existing generating assets. Innovative Control Systems provides turnkey solutions – including planning, engineering, configuration, installation, and commissioning – for control system retrofits of combustion and steam turbines. This complements Emerson’s expertise in turbine condition monitoring and protection systems, instrumentation, analysers, and valves. n
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