A client asked us to provide an e-Solution to track the production and consumption of carbon dioxide throughout its facility. This solution would significantly reduce product cost and increase quality by identifying and eliminating losses. We also needed to connect the company’s entire enterprise by distributing data to many departments at the plant level as well as to corporate business systems. Our challenge was to ensure that we tied the plant floor all the way to the top floor.

The e-Solution

Our combined expertise in process control systems and business systems gave us the right tools to achieve the client’s objectives. We provided assistance all the way from electrical design work for installation of new metering devices to developing web pages to distribute data across the company wide Intranet.

Our design collected data from metering throughout the plant at the PLC level and then displayed this data through operator interface software process graphics and trending. Data was also logged to a database for use in corporate production reporting systems. Our custom-designed web pages allowed users throughout the corporation to query the database and display specific historical information via the corporate Intranet. Data could be sorted graphically by area, process, or individual instrument. We developed web pages using vbscript, Javascript and ADO technology.

The Results

We completed our e-Solution sooner and at a lower cost than similar projects finished at other facilities operated by our client. The project’s overall success was dependent on providing access by production and maintenance personnel in all areas of the facility. The Intranet web pages gave personnel critical access to process data. It allowed them to query historical data in a useful format designed to help them better perform their responsibilities. Connecting the entire enterprise also enhanced product quality and significantly reduced costs by minimizing losses of carbon dioxide and quickly identifying any potential problems.

The Challenge

Success breeds success. That is the case with an e-Solution designed to help a client track the production and consumption of carbon dioxide. The client achieved several objectives with this previous assignment, including enhanced product quality, reduced costs and minimized downtime. The client then asked McEnery Automation to deliver such positive results by developing a similar system in another area of its operations.

The new assignment focused on a Web-based valve monitoring system to provide critical information in the final step of a brewing process. Multiple users needed access to determine the precise length of time more than 200 valves took to open and shut. Access to this information across the enterprise would allow the company to greatly reduce downtime by spotting potential problems long before the system’s shut down. It also would give the client increased quality control for its finished product.

The e-Solution

Our engineering team employed its expertise in process control systems and business systems to develop a Web-based reporting system on the company’s Intranet.

All monitors on the 200-plus valves were identified, time parameters were set on each valve’s threshold for opening and closing, and programming was then established to track these predetermined thresholds. Our engineers developed a Sybase database to track each of the valves. The database interfaces with multiple PLCs to provide constant monitoring of each valve. Custom-designed Web pages allow users throughout the finishing area to review information on workstations by pulling up the monitoring system on Microsoft Explorer.

The system monitors alarms to identify valves that may be functioning improperly. Additionally, the system was designed to allow flexibility. In-plant personnel can make changes to the monitoring system to either increase or decrease the threshold time for each valve’s operation.

The Results

Our engineering team used existing utilities to reduce the cost of the project and to allow us to complete the project with no disruption in the production process. The completed monitoring system gives both production and maintenance personnel critical access to real-time information on the entire brewing area. This allows the client to identify potential problems before a valve fails and causes a shutdown. Repairs and replacement of problem valves can easily be made during scheduled downtime. Constant monitoring also enables the client to further ensure quality control and minimize waste when problem valves interrupt the production process. The monitoring system eventually may be tied into maintenance software to provide a seamless way to track and schedule repair or replacement of the valves throughout the finishing area.

 
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