A major refiner contracted with us to replace their existing batch control system to blend petroleum lubricants. Their product sales required an increased number of recipes and ingredients as well as the need to modify recipes more frequently. The process involved five mix tanks, approximately 25 ingredients and more than 100 recipes.

The Solution

The control system utilized an Allen-Bradley PLC 5, Wonderware InTouch operator interface software and RSBizware Batch software. The system also used Microsoft Access for production reporting as an interface with the plant MES for recipe and inventory data. Extensive simulation was performed to allow for a quick system replacement. Testing was performed and documented for each recipe before implementing the system on site.

The Results

As a result of the testing and simulation efforts, the system was installed during a one-day shut down and was immediately placed into 24-hour-a-day operation. Increased reliability of the system resulted in a reduction of quality issues, increased production rates and reduced maintenance efforts. Integration of production data into the plant MES system reduced the operator’s workload and reduced costly inventory errors resulting from operator error during the data entry procedures. Data logging features of the system provided a historical record of all production activities, which was utilized by the production, maintenance, and QA departments.

Our ability to transform data into plant information with a business context tied together the client’s enterprise, increasing production, generating cost savings and providing a competitive advantage.

McEnery Automation also later implemented additional controls to upgrade this system. New features of this system included new mix tanks, finished product storage tanks, and truck loading equipment.

 
©2001 McEnery Automation