FEATURE DATA RECORDING WHY IT OFTEN PAYS TO KEEP THINGS SIMPLE
regulatory authorities specify that data must be recorded to prove that processes were carried out at the appropriate safe temperature for a particular foodstuff, the data recording method is not specified. Typical uses in the food industry are in
Easy to use, flexible and secure, modern paperless data recorders are ideal for localised data recording across multiple industries. Martin Binney, ABB Measurement & Analytics explains why...
M
any processes and applications need the data they produce to be recorded
– but what is the best way to go about it? You could install an all-singing, all-
dancing SCADA system that uses PLCs and PID controllers in a plant wide control network. Yet, for some smaller plants, a SCADA system can prove overly comprehensive, and expensive. Something smaller and more convenient
is needed. One option is a localised data recorder, which records the data produced by a process on a local device. Many people equate localised data recorders with paper chart recorders, with drawbacks such as running out of ink, the need to change the paper, and the risk of a component (such as a motor) failing, preventing data from being recorded. There is also the security aspect. With
paper chart recorders, pens can be manipulated while the data is being recorded, changing what appears on the paper. There is also nothing to prevent someone changing the recorded data. And what about storage and analysis?
When the inspectors from your industry’s regulatory authority want to see data for a specific time and date, will you be able to find it quickly and easily? How do you compare it against other equivalent production periods or show trends? Modern paperless recorders are a
completely different beast. For one thing they have a customisable digital display that puts the important parameters in front of the operator so they can see exactly what’s happening in their area of responsibility. The displays are easily customisable, enabling them to quickly obtain an accurate overview of the recorded data and any associated events. They are also reliable. All recorded data
38 FEBRUARY 2019 | PROCESS & CONTROL
is encrypted and stored onto internal memory and SD cards. Another useful function is the ability to configure and allocate multiple users with individual password and access rights, offering another layer of security. Accessing this data for analysis can be
done in two ways. The SD card can be physically removed from the recorder and its data uploaded to a PC, or via a networked data manager that can be programmed to perform scheduled collections. Although not all models offer wireless
connection, they can often be connected via Ethernet to a wireless network, allowing a web server to link to PCs or mobiles to display data. Some models offer a batch recording
option, enabling data, including batch numbers and product type information, to be recorded alongside process data. For example, with ABB’s DataManagerPro software, collected batch records can be displayed rapidly by searching for their batch number or batches with common attributes identified. With no extensive SCADA solution to
take account of, paperless data recorders are also easier to scale, can be working instantly right out of the box and offer a large degree of redundancy – if one device fails, the whole system does not go down. Ownership is also simplified. The various diagnostic and alarm functions within ABB’s SM500F and RVG200 paperless data recorders, for example, make it quick and easy to identify and fix problems. With a large SCADA system, the user would be tied into an extensive maintenance contract with the vendor. These devices are particularly appealing to smaller scale producers. Although
In the majority of cases, using data recorders to provide localised data collection and display can provide an equally cost-effective, flexible and legally compliant solution, at a fraction of the cost of installing and operating a plant-wide data collection system
applications such as temperature monitoring of fridges, freezers and cold rooms. Examples of typical minimum storage temperatures are –18 °C for frozen foods such as ice cream and frozen vegetables and 5°C for chilled foods such as ready meals and dairy products. The obligation to monitor can also extend to areas that are used for food preparation. With several inputs, a single recorder can collect data from several freezers and fridges. Doors can be monitored and alarms sent when these are left open for longer than expected. This gives users the peace of mind that
their temperature data is always available when needed by themselves or by third- party inspectors. Use of the recorder also facilitates the management of multiple sites as site managers can simply upload the data to a convenient central location. Because of the nature of the industry,
cleanliness is paramount, which means that recorders often offer IP66 protection, allowing them to withstand wash downs without suffering water ingress. Some data recorders are capable of
monitoring 24 parameters. So, in the food industry example, a recorder could monitor many of the production processes, keeping track of water pressure, levels of liquid in mixing vats and the temperature of pasteurisation vessels. Data recording rates can be programmed
As well as food and beverage, localised data recorders such as ABB’s RVG200 find use in many other industries, such as water and waste water, manufacturing of metal components and pharmaceuticals
to occur as frequently as eight times a second or once in 12 hours. Most applications will require recording rates of between one and 10 seconds. With input/output, display and data
logging, the modern localised data recorder is a simple one box solution for anyone who wants safe, accessible recording of their process data.
ABB
www.abb.com/recorders
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