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Wonderware Customer Success Stories

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Wonderware Customer Success Stories including Brisa on page 7

Wonderware Customer Success Stories including Brisa on page 7

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  • 1. CUSTOMER SUCCESS STORIES WONDERWARE SOFTWARE SOLUTIONS AT WORK ENABLING REAL-TIME SUCCESS
  • 2. Wonderware Mobile Solutions Integrate the field with the management team. Harness your mobile workforce for aligned business success. Getting your workforce in sync with your bottom line objectives takes more than an electronic clipboard.You need a complete workflow and data management solution that captures and enforces the best operational practices out there in the field. Configurable out of the box, the Wonderware IntelaTrac® System makes it easy to for your field workers to focus on the right priorities and ensures that their safe operational procedures match today’s challenging business goals. Go to Wonderware.com and get a FREE White Paper on how you can rapidly harness your mobile workforce to help improve your bottom line. ©2009 Invensys Systems, Inc.All rights reserved. Invensys, IntelaTrac and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies.All other brands and product names may be the trademarks or service marks of their respective owners. www.wonderware.com/mobile WNDR-789 MobileWhite-WW_A4.indd 1 17-06-2009 10:12:19
  • 3. 3 Editorial Enabling Sustainable Success..........................................................................................................................5 Automotive BRiSA Bridgestone Sabancı Lastik Sanayi ve Ticaret A. - Turkey.............................................................6 Gates Power Transmission Ltd. - United Kingdom .....................................................................................9 Grupo Antolin - Spain...................................................................................................................................13 Magna Automotive - United Kingdom.........................................................................................................17 Schaeffler KG - South Africa.........................................................................................................................21 Chemicals Bayer CropScience AG - France..................................................................................................................25 sia Abrasives Industries AG - Switzerland .................................................................................................28 Construction DiGeronimo Aggregates - USA...................................................................................................................31 Facility Management Logitek, S.A. - Spain .......................................................................................................................................35 National Security Technologies, LLC - USA..............................................................................................39 TheVenetian and Palazzo Resort Hotels & Casino - USA....................................................................43 Food & Beverage Amadori Group, GESCO Consorzio Cooperativo - Italy ...................................................................47 Coca-Cola Fortune (Pty) Ltd. - South Africa ............................................................................................51 Elledi S.p.A. - Italy...........................................................................................................................................55 Frito-Lay Gıda San. ve Tic.A. - Turkey ........................................................................................................58 HuysVoeders N.V. - Belgium........................................................................................................................61 Lotte SamKang Co., Ltd. - Korea ................................................................................................................65 New Belgium Brewing Company - USA....................................................................................................68 Orley Foods (pty) Ltd. - South Africa .........................................................................................................71 OSM Piatnica - Poland...................................................................................................................................76 The South African Breweries Limited - South Africa ..............................................................................79 Metal Products Alcoa Inc. - Spain ...........................................................................................................................................83 Hoco ChromeV.O.F. - The Netherlands.....................................................................................................87 Otefal S.p.A. - Italy.........................................................................................................................................91 Mining AngloGold Ashanti Limited - South Africa.................................................................................................95 Assmang Limited - South Africa...................................................................................................................99 Oil & Gas Chevron Oronite Company LLC - France.............................................................................................105 Pharmaceuticals Cambridge Reactor Design Ltd. - United Kingdom ..............................................................................109 Power Bodycote plc - USA ....................................................................................................................................113 Eskom Holdings Limited - South Africa...................................................................................................117 S.T.E. Energy S.p.A. - Italy...........................................................................................................................121 Process Engineering Meteng Pty - Australia ................................................................................................................................125 Pulp & Paper Lenzing - Austria ..........................................................................................................................................129 Transportation Tecnositaf S.p.A. - Italy ...............................................................................................................................133 Transports Publics de la Région Lausannoise (tl) SA - Switzerland..................................................137 Water Treatment Comunidad de Regantes de Motril-Carchuna y Cota 2000 - Spain................................................141 Global Water Management, LLC - USA..................................................................................................145 Ontario Clean Water Agency (OCWA) - Canada...............................................................................149 Puerto Rico Water and Sewage Authority - USA ................................................................................153 Tragsa (Empresa de Transformación Agraria, S.A.) - Spain.................................................................156 Wonderware Representatives..................................................................................................................162 CONTENTS
  • 4. It may not be a corner office, but the impact will be just as great. Accelerate your career with Wonderware Mobile Solutions. Configurable out of the box, theWonderware IntelaTrac® System can empower you to become an integral part of the business decision-making process.Don’t just collect data with a clipboard– become a key player in achieving operational goals.Catch issues early–before they become bigger problems, while helping to save substantial production and maintenance costs. Break away from the tedium by being a part of a more streamlined workflow. Make your mark, using a powerful solution that supports safe operations, savings and value that you help create every day. Go to Wonderware.com and get a FREE White Paper on how an empowered mobile workforce can help improve your company and your career. ©2009 Invensys Systems, Inc.All rights reserved. Invensys, IntelaTrac and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies.All other brands and product names may be the trademarks or service marks of their respective owners. www.wonderware.com/mobile WNDR-787 MobileBlue-WW_A4.indd 1 17-06-2009 9:50:30
  • 5. 5 Dear Reader, Welcome to the 2009 collection ofWonderware Success Stories with the focus on Enabling Sustainable Success. Sustainable success takes two forms. The first is the recognition that our world has finite natural and human resources and both of these must be properly sustained. The second form of sustainable success is your career and business success. It is important that you invest in yourself and your company to ensure long term, sustainable success. This is what drives us to innovate new and better ways of doing things every day. Our mission is to deliver software solutions that empower the success of a wide range of production workers in the Operations Management market space. In this collection of stories, you will discover proven examples of people being able to do their jobs better with faster agility, real-time collaboration and decision support. Production workers are inclusive not only of plant and facility operators, but also their supervisors and managers, as well as the IT staff that manages the IT infrastructure on which these software solutions run, along with other applications that integrate withWonderware software. Production workers also include all of the quality, safety management, maintenance and engineering staffs. Over 570,000 licenses ofWonderware software solutions are in use in over 125,000 locations in 181 countries in the world. This is an amazing testimony to the widespread applicability of our open software platform for a wide range of manufacturing and infrastructure 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 – sharing innovative approaches that were used to help drive real world business success. When we enable our customers and partners to innovate new ways of performing their work better, faster, less expensively and greener - they are on the fast track to achieving sustainable operational excellence for their businesses. I would like to thank all of the customers and partners in this most impressive issue. I also invite our readers to challenge and engage with us in ways that accelerate our mutual innovation in support of sustainable success for a brighter future. WishingYou Every Opportunity for Success, Mark Davidson Vice President, Global Marketing Invensys Operations Management Company Overview About Wonderware Wonderware (www.wonderware.com) is the market leading software solutions and ecosystem brand for real-time operations management software and associated ecosystem partners providing solutions for: Supervisory HMI (Human Machine Interface), GeoSCADA (Supervisory Control and Data Acquisition), Mobile Operations, Production Management, MES (Manufacturing Execution System), Performance Management, EMI (Enterprise Manufacturing Intelligence), and integration with asset management, supply and demand chain and ERP (Enterprise Resource Planning) applications. Wonderware is a brand offering of the Operations Management Division of Invensys. Invensys Operations Management is a leading provider of automation and information technologies, systems, software solutions, services and consulting to global manufacturing and infrastructure industries. Headquartered in Plano,Texas, its solutions are used by more than 40,000 clients around the world in over 200,000 plants and facilities. Invensys Operations Management solutions include control and measurement instrumentation, safety critical and distributed control systems, a wide range of real-time operations management software and professional services that help its clients design, operate and manage the safety, efficiency, productivity, sustainability and profitability of their assets and operations. Invensys clients are some of the world’s most important industrial organizations - large oil refineries; chemical, gas, LNG (Liquefied Natural Gas), power, pharmaceutical and mineral processors; food and beverage companies; metals and mining companies; water and wastewater facilities; pulp and paper mills - and its solutions deliver significant cost benefits associated with the secure, efficient operation of industrial plants and facilities. Invensys Operations Management’s other offerings are delivered under several prominent industry brands, including: Action Instruments,ArchestrA,Avantis, Barber-Colman, Continental Industries, Eurotherm Chessell, Eurotherm Controls, Foxboro, IMServ, InFusion, SimSci-Esscor andTriconex.The company’s approximately 10,000 employees and global partner ecosystem integrate these products and services to help clients collaborate across people and systems in real time - to make faster, better decisions and synchronize their operations from the plant floor to the executive offices, aligning production goals with business objectives. Invensys is headquartered in London and is listed on the London Stock Exchange (ISYS.L), with approximately 25,000 employees working in 60 countries. For more information, visit www.invensys.com. EDITORIAL
  • 6. Automation Solutions /// Automation Solutions /// Automation Solutions /// What goes up and down at the same time? Productivity and Costs. Increasing productivity and lowering costs is a tough challenge and one that was faced by a large engine manufacturing group. Working with their specialist integrators, the group’s team built a state of the art production facility in Dundee, Michigan, USA. Here, hundreds of Mitsubishi CNC controllers, PLCs, HMIs and servos were integrated to make a single e-F@ctory where systems operated together to create large volume production, lower rework and overall lower costs - in fact up to $100 million dollars lower cost are claimed by the customer. You may not be producing automobile engines but you can still benefit from Mitsubishi Electric’s high octane Automation Solutions. Mitsubishi Electric: Making e-F@ctory work for you. www.mitsubishi-automation.com For those who want to know more.
  • 7. Industry:Automotive, General Process Manufacturing BRiSA www.brisa.com.tr “Now, operators are able to concentrate on their work. Efficiency has been increased since they now focus their energy on increasing performance and productivity”. YamanYazgan, Project Manager, BRiSA Wonderware HelpsTurkey’s BRiSATire Factory Achieve High Quality, Productivity and Efficiency by EST (Enerji Sistem Teknolojileri Sanayi) Goals: • Implement a Manufacturing Execution System (MES) to help increase product quality and manufacturing efficiency and eliminate manual data collection and reduce production procedures. Challenges: • Inconsistency in the manual collection of the plant data affecting the plant’s efficiency and product quality; • Develop a clear upgrade path for the MES system to enable improvements as technology evolves. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Historian; •Wonderware Manufacturing Execution Module. Results: • Significant increase in productivity; • Huge improvement in lot traceability; • Previous hard copy of archived information now avail- able with just the touch of a button; • Huge improvement on quality; • Increased Operators’ Efficiency. 7 “Now, operators are able to concentrate on their work. Efficiency has been increased since they now focus their energy on increasing performance and productivity”. YamanYazgan, Project Manager, BRiSA
  • 8. Izmit,Turkey – BRiSA is the number one tire manufacturer inTurkey and the sixth biggest tire producer in Europe. BRiSA operates the largest tire factory in the world, operating under one roof, as well as being one ofTurkey’s quality leader. BRiSA has implemented the ‘Shop Floor Project’ in order to realize a Manufacturing Execution System (MES) to help increasing product quality to its top. The Quest for Consistent High Quality Initial project studies started in 2001, followed by a Functional Analysis phase, a Pilot Application phase, a Test Implementation, Execution and Commissioning phase, the project ended in 2008.The project is the most comprehensive MES project inTurkey. For the Shop Floor project, BRiSA adopted Wonderware software solutions to realize data collection process, to send set point values to machines, and analyze production and machine performances. The Shop Floor project was defined to manage the production at BRiSA factory. As other global large companies, BRiSA utilizes the system to follow up their production, in order to maximize their production quality. The application software aims data collection, as well as setting the process parameters for the machines and record the downtime values of the machines. One of the most important data is the inventory information. Real time stock data is updated when materials are utilized, hence users can see what product, semi product or raw materials are used, and where, for a given time instant.The Project also includes the quality control system. Process parameters used for production can be followed up in real time. It is possible to retrieve the historical data of materials for a product.The most important phase of the project is the machine integration. Data quality increased, since machines produce the data and store it to the sofware automatically. Culture Change for the Factory Before the deployment of the MES Project, all production reports were created on paper. This included production plans, setpoints, alarms and other plant data.The manual recording of information on paper by operators resulted in a lot of inconsistencies. It was difficult for the operators to collect information and operate the plant at the same time. Once the fully-automatedWonderware- based MES was installed, all inconsistencies and errors were reduced and efficiency improved.The automation enabled the operators to focus in producing products because the previous manual operations, such as work order and production data collection, became automated. BRiSA project managerYamanYazgan states:“We have managed to improve our manufacturing in two main categories: First, we had a big increase in productivity, due to the automation of the previous manual data collection. Operators, now, have access to accurate information; inconsistent data coming from different sources has been eliminated. Second, we have improved in lot traceability. Before the project, we had to bring a lot of paper from the archive and, now, we receive the same information with just the touch of a button”. “Operator’s errors at the plant have been almost completely eliminated. This has resulted in a huge improvement on quality”,Yazgan continues to tell that the best result of all is the change in production culture.“Now, operators are able to concentrate on their work. Efficiency has been increased since they now focus their energy on increasing performance and productivity”. WonderwareWalks with BRiSA through the TechnologyWaves Bimsa,Wonderware system integrator inTurkey, is the preferred partner of BRiSA because of their long working relationship over the years and the experience in plants’ production and manufacturing. TurkishWonderware Distributor, EST Enerji has been working with BRiSA and Bimsa for more than ten years, providing support for the current installation.They are poised together as BRiSA looks to adopt theWonderware System Platform in the near future. This document was realized thanks to the support of: BRiSA and Bimsa,Wonderware system integrator. 8 ActiveFactory software, InTouch HMI,Wonderware Historian, Wonderware Manufacturing Execution Module. Automotive, General Process Manufacturing
  • 9. Industry:Automotive, General Process Manufacturing Gates PowerTransmission Ltd. www.gates.com “With the help of Wonderware software, we have become a leading company in time-to-market, on-time performance, meeting customer expectations and cost- base reduction.We win our orders on quality.The level of performance our customers receive from the products leads them to buy from us.” Roddy Edgar, IS Manager, Gates PowerTransmission Wonderware assists efficient production of automotive and industrial belts byWonderware United Kingdom Goals: • Create an Enterprise Manufacturing Intelligence system with real-time bi-directional integration from disparate shop floor to Enterprise Resource Planning level. Challenges: •The plant had different hardware and software solutions, making it difficult to acquire data from different technologies that are spread across the world. Wonderware Solution: • ActiveFactory software; • InBatch software; • InTouch HMI; • QI Analyst software; •Wonderware Historian; •Wonderware Manufacturing Execution Module. Results: • Real-time bi-directional integration from disparate shop floor Programmable Logic Controller systems right up to Enterprise Resource Planning level; • Ease of use ofWonderware software solutions and comprehensive training provided byWonderware United Kingdom enables Gates’ staff to carry out ongoing in-house enhancements to the system; •Winner of the Best Engineering Plant in the UK accolade at the 2008 Best Factory Awards supported by Cranfield University andWorks Management magazine. 9
  • 10. Dumfries, Scotland –The Gates Corporation has been recognised as one of the leading manufacturers of automotive power transmission products since its inception in 1911. Gates employs some 38,000 personnel worldwide of which 6,400 are dedicated to PowerTransmission. Gates is a geographically diverse corporation with locations throughout the world.The European HQ for Gates PowerTransmission is in Erembodegem, Belgium, and manufacturing sites are located in Dumfries, Scotland;Aachen, Germany; Nevers, France; Balsareny, Spain and Legnica, Poland. Some 390 staff are located in Dumfries, working four shifts round the clock to produce 500,000 belts a week. The Dumfries facility manufactures synchronous belts and couplings for the automotive and industrial markets.The site produces everything from the small belts found in food mixers to large industrial belts utilised in ski lifts and farm machinery. Gates supplies most of the major automotive customers with OEM (Original Equipment Manufacturer) products and also produces aftermarket spares. The industrial side manufactures belts for everyday equipment such as vacuum cleaners, cash dispensers and automatic doors. Gates Dumfries facility also produces Poly Chain® polyurethane belts which replace conventional chains on motorbikes for customers such asYamaha and Kawasaki. Custom belts are also produced for bicycle manufacturers and industrial applications using Gates Poly Chain® GT® Carbon™ high- torque drive systems. Improving Efficiency of Production Processes withWonderware A corporate initiative saw the introduction of InTouch HMI (Human Machine Interface), Wonderware Manufacturing Execution Module and Wonderware Historian software in 2000, and three years later, QI Analyst software was introduced for statistical analysis. Gates implemented a new global production system in 2004 and this initiative combined withWonderware technology has helped to improve the efficiency of production processes. “We wanted a window on the manufacturing processes,” says Roddy Edgar, MIS Manager at Dumfries. “There were two sides to this need – we wanted visualisation, to see what was happening and we also wanted history and analysis of data to enable possible improvements in quality. In addition, we obtained traceability and lot control using our MES solution based on the anWonderware Manufacturing Execution Module software-based MES solution.” 10 ActiveFactory software, InBatch software, InTouch HMI, QI Analyst software, Wonderware Historian,Wonderware Manufacturing Execution Module. Automotive, General Process Manufacturing 2000 InTouch HMI and Manufacturing Execution Module introduced 2003 Wonderware Historian introduced for statistical analysis 2004 Global production system introduced, the combination with Wonderware improves production efficiency 2006 Gates operates with 3.5 days inventory, down to 15 hours and unit costs have fallen by 3.5% 2008-9 Gates wins numerous industrial awards Figure 1: Belt Quality Control.
  • 11. A key issue was the need to acquire data from different technologies.“There were different Programmable Logic Controllers, different Enterprise Resource Planning systems, and different technologies spread across the world,” says Edgar.“For example, we use Allen Bradley systems in the US and Siemens in Europe.We have an IBM mid-range AS400 Enterprise Resource Planning system running in Dumfries.” TheWonderware solution provided Gates with real- time bi-directional integration from disparate shop floor Programmable Logic Controller systems right up to Enterprise Resource Planning level. “We are now at the point where users see real benefits from using the systems in their day-to-day work. Enhancements are now pulled by users because their eyes have been opened by the power of the system,” says Edgar. Against this, there are the European drivers in that sales and marketing, forecasting and budgeting are handled at the European HQ near Brussels. The trends in Dumfries will be comparable to those on similar machines in the different countries in which the company operates. Major Benefits TheWonderware software solutions involving InTouch HMI,Wonderware Manufacturing Execution Module,Wonderware Historian, QI Analyst software, ActiveFactory software (the front-end system for Wonderware Historian), and InBatch software were provided byWonderware United Kingdom and Swift Automation. The ease of use ofWonderware products and comprehensive training provided byWonderware United Kingdom enables Gates’ staff to carry out ongoing in-house enhancements to the system. Dumfries also utilises InBatch software to control a batch process producing water-based adhesives used 11 ActiveFactory software, InBatch software, InTouch HMI, QI Analyst software, Wonderware Historian,Wonderware Manufacturing Execution Module. Automotive, General Process Manufacturing Figure 2: Belt production. Figure 3: Inspection.
  • 12. in the production process. InBatch software controls the entire batch process providing full traceability of recipes, equipment and materials. Key Achievements Gates Production Systems have evolved over time, and indeed are continually evolving.“We utilise a cell manufacturing process, so we can commission Wonderware on one cell and then later, start on another cell,” says Edgar.“There is great flexibility with Wonderware, we can install different products at different times but still integrate everything together creating a total solution.” Introducing the Gates Production System in 2004 has resulted in more efficient operations. Improvements to material flow have added further savings.At the start of 2006, Gates operated with 3.5 days inventory – it is now down to 15 hours and other improvements have reduced the need for working capital. As a result of the new system, unit costs have fallen 3.5 per cent. “We useWonderware for improving the quality of our products and also for error proofing the manufacturing process”, says Edgar.“The system gives visibility on the process at all levels in the organisation.This enables people to make faster decisions and improve the quality of the process”. That Gates PowerTransmission has made great strides in its work at Dumfries can be proven through its winning the Best Engineering Plant in the UK accolade at the 2008 Best Factory Awards supported by Cranfield University andWorks Management magazine, and being Highly Commended in the Supply Chain award, sponsored byToyota. This document was realized thanks to the support of: Gates PowerTransmission. 12 ActiveFactory software, InBatch software, InTouch HMI, QI Analyst software, Wonderware Historian,Wonderware Manufacturing Execution Module. Automotive, General Process Manufacturing Figure 4: Finished product.
  • 13. Industry:Automotive Grupo Antolin www.grupoantolin.com “The Performance solution and ArchestrA architecture allowed us to develop a scalable OEE system by using all the functions of a Supervisory Control and Data Acquisition (SCADA) system. Because of this, there has been a reduction in development time.” André Brandão, Project Manager, Sysmaker Grupo Antolin Lusitânea optimises its production processes withWonderware solutions byWonderware Spain Goals: • Improve the efficiency in order to respond to higher volume demands; • Optimise efficiency in one specific assembly line to later replicate it on other production lines. Challenges: •The system needs to be implemented without any shutdown to the existing production lines. Wonderware Solution: • InTouch HMI; •Wonderware Performance software; •Wonderware System Platform. Results: •Visibility of line efficiency, showing opportunities for process improvement. Grupo Antolín now has great visibility in the efficiency of its Lusitânea production lines.The critical data is used to analyse new ways to improve the process; • Seamless integration with current control systems; • Low impact on shop-floor operation, due to automatic work order synchro and data collection. 13 “The Performance solution and ArchestrA architecture allowed us to develop a scalable OEE system by using all the functions of a Supervisory Control and Data Acquisition (SCADA) system. Because of this, there has been a reduction in development time.” André Brandão, Project Manager, Sysmaker
  • 14. Vila Nova de Cerveira (Lusitânea),Portugal - Thanks toWonderware technology,GrupoAntolin has achieved great improvement in efficiency and quality in one of the production lines of its Lusitânea plant,obtaining critical information to study new possibilities in real-time improvement and decision- making. Leading Spanish Multinational in its Sector As the leading Spanish multinational in the design and manufacture of components for car interiors, Grupo Antolin focuses its strategy on integral services that include the conception, design, development, manufacture and distribution of car roofs, doors and seats.With a global turnover of approximately 2.2 billion euro in 2007, a presence in 22 countries with 86 plants and 20 technical/sales offices, Grupo Antolín has over 10,000 professionals working to ensure full customer satisfaction. The group’s origins date back to 1950. It has a big organization doing research and development, using highly qualified personnel and the most advanced technologies capable of adapting to client needs. Grupo Antolin offers multi-technological products, thanks to its expertise in materials, advanced simulation techniques, electronics, industrial processes, safety, acoustics and vibration. In Search of Optimum Efficiency GrupoAntolin Lusitânea has implemented a Wonderware solution for its factory located in the town ofVila Nova de Cerveira (Lusitânea - Portugal) with the aim of optimising the efficiency of its production lines. According to Rui Araújo, Production Department Director at Grupo Antolin’s Lusitânea plant:“The automobile sector is becoming more demanding;To be able to respond to the demands of our clients, we needed to improve the efficiency of one our assembly lines, especially the one dedicated to assembling door locks. This is why we decided on technological change through the adoption of the latest generation software.” The company was looking for a solution that could be integrated without interfering with the production line. It was then that they contacted Sysmaker, aWonderware ArchestrA-certified system integrator. Sysmaker created a PLC solution that gathers information from all field variables.They also developed a complete Overall Equipment Effectiveness (OEE) system based onWonderware Performance software. All the data is collected through the PLC from the different equipment on the assembly line.This includes all detectors, sensors, pneumatic and electric system controls, alarms, separation of OK/notOK parts, management of manufacturing model changes and accounting of manufactured amounts.TheWonderware solution is essential in helping to compile, store, process and organize the required information that interacts with the PLC system by translating the data it receives into an understandable format. “The aim is to implementWonderware technology in the line for door lock assembly and then to replicate it later on other production lines. In the end, to have standard OEE (Overall Equipment Effectiveness) in all the lines” adds Araújo.The OEE solution helps to measure the production efficiency of industrial machinery and it involves monitoring all essential production parameters.These parameters are based on availability (real-time functioning of the production machine), usage (real production obtained in comparison with forecasts during the functioning time of the machine) and quality (number of good pieces obtained). A Complete, Personalised OEE System The implementation of the software began after Sysmaker carried out the corresponding test phase. TheWonderware software complied with all the initial 14 InTouch HMI,Wonderware Performance software, Wonderware System Platform. Automotive Figure 1: Real time efficiency according to diagram of specific times.
  • 15. demands set by GrupoAntolin by providing the latest generation solution and integrating it into the plant without interference.It also added a very important element:the ability of adapting to client demands. Consequently, a complete OEE analysis system was implemented in accordance with the requirements of Grupo Antolin’s Lusitânea plant. The application is based onWonderware Performance software, a scalable solution that allows the addition of new functionalities such as traceability, genealogy, execution of job orders, control of intermediate stock and man-hour management.The software is a component of Wonderware Enterprise Manufacturing Intelligence (EMI) and it includes functions that facilitate complete OEE monitoring.The system is able to identify areas of improvement, such as small stops and low production speed that affect performance. A Unique, Integrated Platform Grupo Antolin has implemented aWonderware solution to obtain a shared platform of industrial applications that can run on practically any existing system.Wonderware System Platform provides a unified environment that facilitates plant visualisation, historization, communications and integration of other industrial automation applications. Full Functionality and Scalability Wonderware System Platform is built on ArchestrA technology, an innovative architecture for plant automation and information based on a real-time Service Oriented Architecture (SOA).This makes it possible to reuse existing automation applications. “The Performance solution and ArchestrA architecture allowed us to develop a scalable OEE system.Because of this,there has been a reduction in development time” explainsAndré Brandão,Sysmaker Project Manager. “TheWonderware Historian on the other hand,compiles and stores all the plant information,providing full visibility of the data that enables correct decision-making,” points out the manager of GrupoAntolin’s Lusitânea factory. TheWonderware Information Server uses Microsoft SharePoint andWeb Part technologies to present and collect production and plant performance data on the Internet or the company’s Intranet. Grupo Antolin professionals at the Lusitânea plant access the information and make informed decisions in real time, thus helping to detect errors beforehand.This saves on costs and improves staff efficiency. The last element of this innovative platform is Wonderware InTouch HMI (Human Machine Interface), which is outstanding for its usability and ease of use.The HMI helps to control all the factory processes in an intuitive, clear and descriptive manner.“TheWonderware staff helped Sysmaker to personalise and make the specific required changes for the PLC programme and the Performance database,” concludes Brandão. Main Benefits GrupoAntolin now has great visibility in the efficiency of its Portuguese production lines.The critical data is used to analyse new ways to improve the process. In the words of Rui Araújo, Production Department Director at Grupo Antolin’s Lusitânea plant:“Thanks to the OEE system, we have managed to automatically compile data and automatically manage job orders, edit information, analyse graphics and create reports that we define through a user interface.” This document was realized thanks to the support of: RuiAraújo,Production Department Director,GrupoAntolin, André Brandão,Project Manager and João Caldeira,AutomotiveTechnical Engineer, Sysmaker,WonderwareArchestrA-certified system integrator. 15 InTouch HMI,Wonderware Performance software, Wonderware System Platform. Automotive Figure 2: History of machine use condition.
  • 16. Does missing data cost your company money? Active directory® support Data time stamped at source Redundant logging For more information visit our web site at www.eurotherm.co.uk SNTP (Global Time Synchronisation) Flexible secure acquisition of business critical data with ‘Store & Forward’ Store then forward your batch records even with loss of communication Secure data available from measurement to Manufacturing Execution System (MES) Guaranteed data capture ensures greater production efficiency Eurotherm Solutions for Electronic production records Data management solutions from input to report Ensuring high integrity data capture Regulation compliant
  • 17. Industry:Automotive Magna Automotive www.magna.com “Wonderware’s object based technology, especially with the new embedded graphics capability, was a huge benefit to the successful completion of the project.” Nigel King, Senior Software Consultant, SDI Group Logistics boosted at Magna Automotive byWonderware United Kingdom Goals: • Magna Automotive was required to increase the number of panel variations to handle the requirements for both the outgoing and new vehicles, which meant an increase in the number of variances of around 17 per cent. Challenges: •The project had to be completed in a very short time; •There shouldn’t be any plant shutdown and production had to be maintained while expansion is being undertaken; •The new system must show improvement in quality, throughput and space utilization. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: •The ease of use of the operator screens required minimal input.This enabled new personnel to operate the plant with very little training; • On-Time delivery; • Increased Productivity by an increase in available workforce equating to a headcount re-deployment of 8 per cent; • Enhanced the Automation and Control System by improving stock control, production planning, and inspection of stock produced, as well as adding advanced, automated reporting capability. 17
  • 18. Burton-on-Trent, United Kingdom - Magna Automotive is a major supplier of components to the automobile industry. Faced with increasing demand and the need to improve plant efficiency and product quality, they have decided to re-vamp their manufacturing facility in Burton-on-Trent, UK. This was a major task that had to be undertaken without any stop in production. Magna Automotive selected theWonderware System Platform because its capabilities provided the ideal solution to address the short project completion schedule and in- project continuous improvements. Magna Automotive operates a manufacturing and production site at Barton Business Park in Burton- on-Trent.The facility is part of the company’s Interiors Division supplying injection moulded internal door panels to a nearby car manufacturer. It provides parts for two different vehicle models, working on a just-in-time inventory strategy with a four-hour notice period for incoming orders. The Situation - Increasing Capacity with Minimum Cost The plant manufactures door panels for two vehicle models but there are a number of different variations because of different interior options that are offered to the consumer. A planned model change scheduled for the first half of 2008 has necessitated Magna Automotive to increase the number of panel variations to handle the requirements for both the outgoing and new vehicles.This meant a 17% increase in the number of variances.As a result, additional space was needed at the Burton-on-Trent facility to accommodate the extra production equipment. Magna Automotive wanted to identify the most cost-effective solution that met production needs. Seeking at Solution SDI Group UK was invited by Magna Automotive to design the automated system for the storage and retrieval of the injection moulded interior car door panels manufactured at the production site. A turn- key solution was required to primarily optimise the existing facility, freeing up valuable space for new equipment, whilst avoiding any disruption to the ongoing operation. The project’s scope also included enhancing workforce productivity; maximising capacity for future business wins; and increasing operational visibility and control.The solution would have to take into consideration the unique needs of a just- in-time inventory strategy within the automotive sector, which demanded particularly high levels of accuracy, faster completion time and increased product quality. The Solution – an Improved Control System Powered byWonderware An essential aspect of the solution was a sophisticatedWarehouse Control System (WCS) installed with aWonderware software solution.The WCS has enhanced the overall control of the manufacturing plant and increased the ability to better manage the site.Wonderware software 18 InTouch HMI,Wonderware System Platform.Automotive Figure 1:Automobile components in motion.
  • 19. provides overall control at each stage of the production process from manufacture of parts, through to storage and then transfer to production areas and drop-off points.This comprehensiveWCS not only had to control the automated storage and retrieval system, but the entire life of each part from manufacture and production to the point of dispatch. A key feature of theWCS is the easy-to-use touch screen operator interface using InTouch HMI (Human Machine Interface).The operator screens were designed for ease of use and minimal operator input.This means that new operators can be introduced with very little training on the software required. The software also offered greater control over stock, operating an effective FIFO (first in first out) parts usage system, as well as providing a complete audit trail for every part within the facility.The automated solution utilised more than 3,500 sensor points providing useful stock data and enabling the ability to monitor parts trolleys throughout the process. Data could be accessed and inputted via office-based computers or five touch screen monitors situated within the production facility. Each operator station can display a live animated visualisation of the control equipment with pan and zoom functionality.This provides detailed diagnostic information to engineers and operators right on the plant floor. Detail of stock holdings by part and by location with ‘drill down’ comprehensive information is available to the plant personnel.The details and destination of all trolleys moving on the conveyor system are also displayed in real-time. A history of the trolley’s movement is available. A remote Management PC also provides the same equipment visualisation and stock information but with additional features for supervisors.These features include part definition creation / modification, part to storage lane allocation, user management, problem recovery and software application status display. TheWonderware Historian has enabled data to be stored and collated for reporting purposes, something that was previously processed manually. The Core of the Solution –Wonderware System Platform TheWonderware System Platform provides real- time automation supervision for theWCS (Warehouse Control System). Nigel King, Senior 19 InTouch HMI,Wonderware System Platform.Automotive Figure 2: New mezzanine.
  • 20. Software Consultant, SDI Group,“Wonderware object based technology, especially with the new embedded graphics capability, was a huge benefit to the successful completion of the project.” Wonderware System Platform was designed with real-world project experience in mind where objects can be designed and rigorously tested and deployed repeatedly in multiple instances across the application.TheWCS usesWonderware System Platform and six InTouch HMI nodes for visualisation and supervisory control. The system’s natural connectivity takes care of communications to automation controllers (mainly Beckhoff PLCs) and external databases.The Wonderware Historian provides History andTrend information.When the production facility matures, it will provide detailed insight into operational performance and provide useful information for continual improvement programmes. Although SDI Group is a long standingWonderware user, Nigel added,“We needed confirmation of our decision making and approach with the new version of Wonderware System Platform,Wonderware United Kingdom support staff and consultants provided knowledgeable and helpful guidance in both the initial learning curve and during the project’s execution.” Return on Investment SDI group delivered all of the requirements that were part of the project; these resulted in measurable business benefits that ensured early payback of the investment:The materials handling solution took just 10 months to be designed, installed and become fully operational.The project was completed within the required schedule with zero operational downtime. Increased Productivity resulted by an increase in available workforce equating to a headcount redeployment of 8 per cent. Implementation The installation was completed within the required timeframe, so Magna Automotive has been able to meet the delivery deadlines for new parts to its customer’s car production line. Zero downtime was achieved during the course of the design and build process, with no forced stoppages as a direct result of the project; this ensured that Magna Automotive was able to continue to serve its customer without disruption throughout the course of the installation. On-Going Benefit Notwithstanding the 2009 economic situation, Magna Automotive now has a far more efficient production system which will provide business benefits long into the future.The utilisation of the Wonderware System Platform will continue to provide measurable cost savings in operation and when inevitable changes to production occur. This document was realized thanks to the support of: Magna Automotive. 20 InTouch HMI,Wonderware System Platform.Automotive
  • 21. Industry:Automotive Schaeffler KG www.schaeffler-group.com “The extensive preparation work done by the team in first understanding the requirements and harsh nature of the environment, together with the use of the most sensible tools resulted in an excellent working solution, fulfilling our requirements completely.” Gwilym Wilkins, IT manager, Schaeffler Automotive. End-to-end batch mixing and tracking at Schaeffler’s Port Elizabeth plant byWonderware Southern Africa Goals: • An automated warehouse inventory control system; • A batch tracking system that would track raw material batch numbers through to final product and vice versa; • Reporting facility. Challenges: • System to operate in adverse and dirty conditions. Wonderware Solution: • InTouch HMI; •Wonderware Manufacturing Execution Module; •Wonderware System Platform. Results: • Automated process – Greatly reduced operator error while providing the necessary guidance for optimal smooth running of processes; • Accurate warehouse management system; • Easier, more reliable operation; • Mixing benefits with strict recipe management and scrap reduction; •Traceability – It is now possible to trace raw material batch numbers from the suppliers to the end product and vice versa • Reports – Using the company’s intranet, reports such as stock levels, batch tracking, raw material tracking, batch details (e.g. weights per material) and exception errors such as process problems can be viewed. • Computer failure recovery. 21
  • 22. Port Elizabeth, South Africa -With its three strong brands - INA, LuK and FAG - the Schaeffler Group is involved in the automotive, industrial and aerospace industries and stands for a pronounced customer focus, innovative power and the highest possible product quality. In 2008, approximately 66,000 employees at over 180 locations worldwide achieved sales totalling nearly 9 billion Euros.The group belongs to the leading suppliers of the rolling bearings industry worldwide and is a valuable partner of nearly all automobile manufacturers. With the LuK brand, the Schaeffler Group is one of the world’s leading clutch and transmission component manufacturers.Today, one in four cars worldwide has a LuK clutch and customers include several renowned automotive manufacturers. Schaeffler’s Port Elizabeth manufacturing facility consists of a 15,000 m2 production area and 3700 m2 warehouse all on a 36,000 m2 site with 450 employees, 15 of whom are involved with research and development and 27 in the tool room.Annual turnover is 40 million Euros and 2007 production achieved 2.5 million facings and 1.1 million clutch sets.The plant has the capacity to produce 1.7 million clutch sets and more than half its production is targeted for export. No matter how exotic the car, vehicles not using ‘wet’ clutches (automatic transmission) rely on a relatively thin layer of special material to interface engine power with the driven wheels – the clutch facing. In order to live up to Schaeffler’s (LuK’s) exacting quality standards while meeting large demands, the production process of these facings at the company’s Port Elizabeth facility needed to be revised to incorporate the latest batch mixing and tracking technologies in a difficult manufacturing environment. Project Requirements The business objectives called for an automated warehouse inventory control system, a batch tracking system and a reporting facility. Material would be picked according to its expiry date while provision would have to be made for stock levels and the location of all stock to be readily available to qualified personnel. The batch tracking system would need to track raw material batch numbers through to final product and vice versa.There was also a need to interface to a laboratory testing facility. While the need for reliable operation goes without saying in a real-time production environment, the conditions at the plant proved to be somewhat challenging with an atmosphere thick with carbon black (figure 1). To overcome this, a simple and robust operator interface was required as the standard keyboard/mouse combination had proved useless and even touch panels were prone to failure. Solution Selection Both the hardware and software needed upgrading and a fresh approach was necessary. “Since the existing SCADA facility was based on Wonderware’s InTouch HMI (Human Machine Interface) andWonderware Manufacturing Execution Module (previously known asWonderware InTrack software) solutions which had served the company well since 1997, it made sense to continue using products from theWonderware stable,” says Barry Clemence, software engineer at DC Industrial Scanning, the system integrator chosen by LuK. DCI Scanning chose theWonderware System Platform based on ArchestrA technology as well as theWonderware Information Server. 22 InTouch HMI,Wonderware Manufacturing Execution Module, Wonderware System Platform. Automotive Figure 1: Not the best environment for electronic equipment.
  • 23. Solution Architecture The system topology is shown in figure 2, which also illustrates the three-button operator interface and hand-held wireless computer. The buttons allow for easy navigation between screens, function selection, SQL grid selection and executing the stepping sequence while being easily replaceable at very low cost.The mouse and keyboard are now only used for administrator functions.“The buttons are connected to a standard serial port and a .NET object was written inside ArchestrA to do the interfacing,” says Clemence. “The result is a robust unit made from readily-available components.” The hand-held wireless computer is used to guide the operators via screen prompts while allowing them to scan barcodes or key in information on the move throughout the plant.This was also integrated directly intoWonderware System Platform with another .NET object. The newWonderware System Platform SQL object provided a reliable way to interface to the SQL database.The new SQL Grid proved to be very flexible and was a great way to display database information. “One place we used the grid was to display the various recipes thereby enabling the operator to select and start the required recipe using the button interface,” adds Clemence. TheWonderware System Platform application is interfaced with LuK’s Oracle system to retrieve the information for the material received and the system had to be developed, tested and implemented live.“We did dry runs where possible,” says Clemence,“but with implementation came the normal teething issues and specification changes.” Realised Benefits • Automated process –The level of automation and checks and balances incorporated into the system has greatly reduced operator error while providing the necessary guidance for optimal smooth running processes; • Accurate warehouse management system – This now provides current stock levels immediately on request and knows where each bag of material is stored and how much is left.This has led to less material loss due to material expiry; 23 InTouch HMI,Wonderware Manufacturing Execution Module, Wonderware System Platform. Automotive Figure 2: System topology. Figure 3:The pre-mix process.
  • 24. • Easier, more reliable operation –Wireless scanner and screen prompts as well as the robust button user interface allow operators to do a better job; • Mixing benefits – Strict recipe management now prevents the wrong materials being added to the mixture or added in the wrong amounts which all contributes to reducing scrap; • Traceability – It is now possible to trace raw material batch numbers from the suppliers to the end product and vice versa; • Reports – Using the company’s intranet, reports such as stock levels, batch tracking, raw material tracking, batch details (e.g. weights per material) and exception errors such as process problems can be viewed. The back end is powered using a combination of Microsoft SQL Reporting Services andWonderware Reporting Services; • Computer failure recovery – It is now easy to recover from a computer failure whereas this wasn’t previously possible. This document was realised thanks to the support of: GwilymWilkins, Schaeffler Group, and Barry Clemence, DC Industrial Scanning. 24 InTouch HMI,Wonderware Manufacturing Execution Module, Wonderware System Platform. Automotive Figure 3:Aerial view.
  • 25. Industry: Chemicals,Agriculture Bayer CropScience AG www.bayercropscience.fr Wonderware and SITAM participate in increasing the plant treatment productivity with the FROGSS project (Fungicide ROtating Greenhouse Spraying System) byWonderware France Goals: • Increase treatment capacity with regards to the Biology department; • Reduce biologists’ contact with the treated plants; • Implement a new organization within a maximum of 18 months; • Provide operating tools that are easy to use. Challenges: • Referral agent partners for each business involved in the project; • BAYER / SITAM work group: a commitment for the success of the project; • An open software environment. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Historian. Results: • Comply with priorities and deadlines in implementing and deploying the solution; • Cost of the solution controlled thanks to the stringency of the SITAM management processes; • Quick familiarization; • Control and transparency of the information: factors for successful collaboration. 25 “The choice of Wonderware was in this project a major step and we can now measure all of the flexibility that this has provided us with in the implementation of this robot.” Martine ZUCCO Manager, RoboticsTeam, Bayer Cropscience France
  • 26. La Dargoire (Lyon), France - Bayer is an international group of which the core businesses fall within the health, nutrition and high-performance materials sectors. Bayer CropScience AG, a subsidiary of Bayer AG, with an annual sales figure of about 6.4 billion euro (2008), is a company leading the way in innovation worldwide in the fields of crop protection, non- agricultural pest management, seeds and plant biotechnologies. The company offers an extensive range of complementary products and services for modern and sustainable agriculture, as well as solutions for non- agricultural applications. Bayer CropScience has invested nearly 10 million euro at La Dargoire over the last two years in order to provide the existing laboratories with state of the art equipment. The Biology department has benefited from a part of this investment in the creation of a new fully- robotized system for large-scale testing of the effectiveness of new molecules on plant diseases. The FROGSS (Fungicide ROtating Greenhouse Spraying System) project was born. Its functional scope concerning the steering monitoring solution remains to be defined. The customer’s request was to obtain a tool that was able to change easily according to needs identified during the course of the project without jeopardizing what already exists. Their choice was quickly orientated to a Wonderware solution which offers a modular and open architecture based on market standards. The FROGSS project consists in automating: • the spraying of plant sets from a loading zone; • the drying for sprayed solutions in a drying tunnel; • the classification of plants by disease in trolleys; • the washing and storing of the sets used in a storage zone; • the transporting of sets to the various zones mentioned above; • the identification of treated sets and pots. The sequencing of all of these treatments is called a ‘Run’.This automation implements several elements: computers, automatic devices, conveyors, robotic arms, a LiquidHandler, trolleys, carts, doors, valves, cylinders, nozzles, elevators, lifts, shafts, motors, pumps, cells, barcode readers, DataMatrix code readers, etc. In addition to automating the process, traceability is implemented throughout the entire installation from taking the set to arranging the pots, including spraying. The IT portion’s architecture is articulated around aWonderware solution interfaced with the customer’s management system (BCS). The solution developed with the Wonderware InTouch HMI (Human Machine Interface) and Wonderware Historian allows the following functions to be provided: • Representation of the process structured in the form of block diagrams; • Real-time acquisition of process parameters; •Visualization of safety elements; • Acquisition of safety data; • Alarm management; • Recording and sorting of events or alarms for those in the past or currently in progress; • Management of manufacturing program parameters; • Configuration for the ‘Run’; •Traceability management; • Exchanges with the BCS system. “The management of alarms in the event of a default, their traceability and the facility for repair is a notable advantage. In addition, the possibility viaWonderware to 26 ActiveFactory software, InTouch HMI, Wonderware Historian. Chemicals, Agriculture
  • 27. secure the access by setting up different user levels was a major criterion in our choice” states Martine Zucco, Manager, RoboticsTeam, Bayer CropScience France. The InTouch HMI supervision interface was designed in such a way as to provide operators with optimal facility and user- friendliness in use. A geographical representation of the equipment allows for a complete view of the monitored installation. Navigation guarantees access to the information with a minimum number of mouse clicks, either from the geographical location of the equipment, or via shortcut buttons or a contextual menu.The interface is configured automatically via user profiles, which allows each person to retrieve their working environment. “It is certain that the speed of users getting familiar with this new tool is directly correlated with the excellent ergonomics of the different HMI screens,” states a user at Bayer CropScience. This documents was realized thanks to the support of: Bayer CropScience. 27 ActiveFactory software, InTouch HMI, Wonderware Historian. Chemicals, Agriculture Figure 1: Precision seed drill.
  • 28. Industry: Chemicals sia Abrasives Industries www.sia-abrasives.com “The automated management of scheduling activities and online information coming directly from plant floor facilitates the coordination with other divisions. Response time to changes in scheduling has been substantially reduced.” Thomas Brandes, Work Order Planning Department, sia Abrasive. A Comprehensive Plant Solution for the Production of Coated Abrasives byWonderware Switzerland Goals: • Paperless connection between production and production management systems. Challenges: • Outdated, inconsistent systems; • Local loss of data causing discontinuity and frequent errors. Wonderware Solution: • ActiveFactory software; • Development Studio; •Wonderware Historian; •Wonderware Information Server; •Wonderware Manufacturing Execution Module. Results: • Unified dataflow; • Elimination of paper records; • Higher product quality and work simplification; • Faster reaction times thanks to the availability of real-time data; • Better coordination between production and other departments. 28
  • 29. 29 Frauenfeld, Switzerland - sia Abrasives Industries AG at Frauenfeld (Switzerland) is one of the world‘s leading manufacturers of coated abrasives.The company offers a product range of several thousand items that are subject to continuous improvement. sia Abrasives employs about 1.100 persons worldwide, 690 of which work in Frauenfeld. In 2007, the business volume reached 298 million CHF, and great attention is being paid to the performance and efficiency of the enterprise. The Products: Coated Abrasives forVarious Fields of Application The coated abrasives produced at Frauenfeld are made up of a carrier material such as paper, tissue, vulcanized fibre or plastic film.Through a continuous process, abrasive grains are applied to the backing and anchored by bonding adhesives. sia Abrasives products are distributed worldwide and are used in metalworking, woodworking, automotive bodywork, panel production et al. Starting the Project sia Abrasives produces coated abrasives on several production lines based on specific products and each consisting of a number of subordinate units. Before the introduction of production management system, there was no connection between the controls of the individual production units.Thus, the planning of the various production processes and the management of the machines’ setup were highly laborious and inefficient. Moreover, manufacturing data were administered via different, non-compatible systems which led to errors caused by media conversions. As process data accumulated locally, great efforts had to be made for consistent quality control because of the lack of a common database. sia Abrasives therefore decided to introduce an extensive automation solution that facilitates production control and reporting. After evaluating different options, sia Abrasives decided to entrust this challenge toWonderware software and acs ag, aWonderware system integrator fromWil / Switzerland.The implementation began in 2003 with the final goal of creating a paperless solution that connects the plant floor to the production planning and control (PPC) system. Developing a Comprehensive Plant Solution All plant information is now stored centrally through aWonderware Historian.Thanks to this high-performance real-time database, the information from the control system used for planning and reporting are available to all work stations based on the different roles and authorization of the personnel. The Manufacturing Execution Module and the open interfaces provided by Wonderware software enables the standardization of data flow.The solution enables production orders to be centrally dispatched via a PPC (production planning and control) work station. At any time it is possible to check and supervise the status of batches in the various process steps. Plant floor is constantly updated with real-time production order information. ActiveFactory software, Development Studio, Historian, Information Server, Manufacturing Execution Module. Chemicals Figure I:A wide product range for various fields of application.
  • 30. 30 The Results: a Secure and Open System Thanks to the newly established connection between control units and database, it is possible to manage machine setup automatically. Since it is no longer necessary to input data manually, the Wonderware solution helped eliminate an important source of errors. Thanks to the network connection, it is now possible to comprehensively evaluate, analyze and supervise several production lines. It is also possible to easily expand the system in connection with the production scheduling and control system (PPC): Due to the use of state-of-the-art technologies and non- proprietary interfaces provided byWonderware software, further equipment and applications can be integrated with the existing system. SuccessThanks to System Integrator The Swiss company acs ag has been successfully realizing projects in automation and MES (Manufacturing Execution System) withWonderware software solutions for more than 15 years.Thanks to this considerable experience, they were able to satisfy completely the customer’s requests.An in-depth analysis of the given situation, as well as the best combination and set-up of software components, led to maximum benefit for the end customer. This document was realized thanks to the support of: sia Abrasives Industries AG and acs ag, ArchestrA-certified system integrator. ActiveFactory software, Development Studio, Historian, Information Server, Manufacturing Execution Module. Chemicals Figure 2: Each production line consists of a number of subordinate units.
  • 31. Industry: Construction, General Process Manufacturing, Mining DiGeronimo Aggregates www.digeronimoaggregates.com “Allowing local control of equipment using the tablet computers and wireless network has easily paid for itself in savings compared to the cost of running conduit and wire for local control.” Andy Holtom, Electrical Engineering Division Leader/Principal Wonderware Software Brings Aggregate Plant Up to Date and Enhances Operations byWonderware Goals: •Transition fuel system from oil/gas to coal; • Comply with EPA regulations and reporting guidelines; • Improve product quality and consistency; • Expand plant and ensure future scalability. Challenges: • Facility built in the 1800s, operating with outdated electrical systems and equipment; • Plant is spread out over 65 acres; • Huge power requirements to operate kiln; • End-product uniformity dependent on consistent kiln temperature. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Industrial Computers (InTouch HMI embedded); •Wonderware System Platform. Results: • Energy and time savings throughWonderware- enabled proactive maintenance of kiln and other equipment; • Ability to plan and schedule maintenance brings cost savings of $5,000 each time a pre-heat/re-heat of the kiln is avoided, resulting in total savings of over $100,000; • Remote monitoring added for improved visibility and management of overall operation; • Operators more efficient due to at-a-glance ability to assess plant conditions; • Scalability and standardization ensure quick and easy equipment additions and expansion. 31
  • 32. Independence, Ohio – Just a couple of years ago, a time traveler from the 1800s visiting the DiGeronimo Aggregates plant would have been in familiar surroundings.The operation was burning gas and oil and operating as it had for the last 150 years – crushing raw shale and bringing it to the kiln where it is heated, then cooled, ground and graded. The process yields a versatile end product that is used for high-performance, lightweight structural concrete and masonry, professional turf, horticultural applications and geotechnical fills. But the plant’s new owners had a more modern vision and aspirations to improve productivity and product quality while planning for future expansion. They set about transitioning the facility to coal fuel, upgrading the electrical system and other equipment to better meet EPA regulatory requirements, and improving the overall efficiency of the enterprise. Managing a Multifaceted Project The management team at DiGeronimo Aggregates wanted to implement the new system in the most cost-effective and timely manner, so they decided to supervise the project internally, enlisting a number of key partners to assist.Wonderware Cincinnati, the regionalWonderware distributor working closely with the management team recommended Hull & Associates, Inc. aWonderware ArchestrA- certified system integrator with experience in electrical engineering and control systems automation. DiGeronimo agreed with the selection of Hull & Associates, Inc. because they could provide standardization through theWonderware software solution that would enable coordination of the many suppliers, which was vital to the teamwork and ultimate success of the complex implementation. Besides the economic advantages of switching from oil to coal, the initial analysis uncovered an opportunity to design and deploy a centralized manufacturing automation solution incorporating programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) capabilities, and a human machine interface (HMI).The resulting system was projected to decrease energy use and deliver operational cost savings as well as a higher quality, more consistent product. Challenges for Operators and Management Because of the age of the plant and its 65-acre size, operators faced a number of impediments.Their primary means of monitoring the kiln was visual; if the size of the flame seemed steady, the temperature should be in an acceptable range. More accurate, real-time data was not available and conduit running between the numerous stations was used for wired communications. Operators had to travel to remote stations to determine whether they were functioning properly and to record and report data. Additionally, the plant management office was across town, so executives did not have the ready access to current performance data that they needed for informed decision making. The Kiln is the Key Component The centerpiece of DiGeronimo Aggregates is the kiln, which heats the crushed shale, altering its cellular structure to form a material which is light, yet extremely strong and durable. To produce consistent product batch after batch, the kiln temperature must remain as stable as possible at around 2,200 degrees Fahrenheit. 32 ActiveFactory software, InTouch HMI,Wonderware Industrial Computers (InTouch HMI embedded),Wonderware System Platform. Construction, General Process Manufacturing, Mining Figure 1: DiGeronimo Aggregates HMI screen.
  • 33. Saving Energy Means Saving Money Energy consumption is a major concern for the plant because the kiln operates 24/7 to produce up to 700 tons of product each day. Maintenance is critical, because unplanned shutdowns are extremely costly. Returning the equipment to its very high operating temperature requires a large amount of fuel and takes time, lowering productivity. Conversely, the ability to plan kiln maintenance can save energy and money while maximizing output. Now, withWonderware software, sensors in the kiln alert operators to changes that might indicate the need for a future repair.And the system enables management to schedule required maintenance. Eric Dombrowski,Vice President for DiGeronimo Aggregates, puts it into perspective, “It costs about $5,000 for each pre-heat or re-heat of the kiln. Since going online withWonderware, we’ve been able to plan for maintenance, rather than having forced shutdowns, which has helped out tremendously.” Consistency is Crucial for Quality Because different fuel sources burn at different temperatures – and because temperature has a significant affect on the quality of DiGeronimo’s product – the switch to coal had to be made carefully.TheWonderware solution gave management and operators the ability to set benchmarks and make needed adjustments during the transition so the new system was running consistently in a short time. PLCs provide feedback that helps prolong the life of equipment by monitoring corrosion, which can be caused by temperature fluctuations. Complying with Strict EPA Requirements DiGeronimo Aggregates is subject to stringent Environmental Protection Agency (EPA)TitleV regulations.The plant is required to report daily, monthly, peak and low average measurements for dust emissions, lime injection statistics and coal-feed rates. In the past, these records were kept manually, and it was time-consuming and slow to compile the EPA- required reports. But with the addition of Wonderware Historian software, collected data is now downloaded, processed and charted for submission quickly and easily. For out-of-compliance events, theWonderware solution shows on-screen alarms, plus it enables operators to generate reports to show how quickly corrective actions were implemented and operations returned to compliance. Improved EfficiencyThrough Remote Monitoring and Real-time Data Another benefit of theWonderware solution is that its central control station has improved operator productivity. In the past, operators had to travel around the large DiGeronimo campus to inspect each motor station. Now, with the central station and remote monitoring capability, operators have real-time information on which stations need attention, and they can make most corrections without having to visit the actual equipment. Additionally,Wonderware Industrial Computers InTouch HMI embedded) and a wireless network have been deployed, so when an operator is required to go to the site of a motor, bearing or temperature element, the operator can view the Wonderware screens on the tablet and make adjustments immediately in the field. Operator communications abilities have also improved with new docking stations in each electrical room and radios. Cameras display critical equipment and conveyor belts to provide visual verification of operations.All of these capabilities help DiGeronimo remain as productive as possible and head off problems before they happen. TheWonderware solution’s remote access has also helped Hull & Associates, Inc. serve DiGeronimo better when it comes to remote configuration, continued development and maintenance. Even though the integrator is over 100 miles from the plant, changes can be made overVPN immediately. 33 ActiveFactory software, InTouch HMI,Wonderware Industrial Computers (InTouch HMI embedded),Wonderware System Platform. Construction, General Process Manufacturing, Mining
  • 34. Ease of Use and Standardization With theWonderware solution, all of these capabilities have come together to form a standardized system that has been well-received by DiGeronimo’s operators and managers. Dombrowski says, “We were able to identify critical values and ask Hull & Associates, Inc. to customize our screens very quickly.” New equipment can be added simply and easily and operators are already familiar with the corresponding on-screen objects and commands.They can see the entire plant in one glance and make immediate judgments, rather than having to generate and then interpret spreadsheets. A Modernized System with Scalability for the Future So if that same time traveler visited DiGeronimo Aggregates today, they would be impressed with the operation’s 21st Century capabilities. Operators could explain how much more efficient they are, since they can view the entire plant on screen and do much of their jobs from the central station.They could report on their increased ability to proactively repair equipment and avoid unexpected and costly shutdowns.And management could talk about how better real-time and historical reporting is enabling them to make better decisions for the profitability of the enterprise. Just as importantly,Wonderware software has provided DiGeronimo Aggregates the flexibility to meet the needs of the current transition as well as to plan for expansion. Hull & Associates, Inc. installed a limited number of servers during the initial development and deployment. In the future, they will be able to help DiGeronimo scale up by adding servers and more licenses, but without the need to invest in a lot of additional development time and hardware. Some might even say that – with help from Wonderware – DiGeronimo Aggregates is taking advantage of the best of both worlds: 150 years of heritage and experience along with the most advanced manufacturing operations management systems of today. This document was realized thanks to the support of: Wonderware Cincinnati. 34 ActiveFactory software, InTouch HMI,Wonderware Industrial Computers (InTouch HMI embedded),Wonderware System Platform. Construction, General Process Manufacturing, Mining
  • 35. Industry: Facility Management Logitek, S.A. www.logitek.es Logitek opts for domotics in its main office building and promotes energy savings withWonderware technology byWonderware Spain Goals: • Control the building’s installations; • Remote control; • Save energy. Challenges: •The integration of different technologies (light, air conditioning, domotics, security...) in only one application; •To avoid different kind of local manual control; •To make all the facilities’ systems working in concert in order to obtain the best environment. Wonderware Solution: • ActiveFactory software; • InTouch HMI forTerminal Services; •Wonderware System Platform. Results: • Integration of the company’s domotic services with access from various stations via a clear, attractive interface; • Direct access to installation data (temperature, consumption), thus helping to reduce energy costs; • Availability of a platform in which any new building device can be integrated; • Energy saving. 35 “Thanks to the installation of the Wonderware System Platform in our offices, we now have a platform in which we have been able to integrate all the domotic features of the building as the need arises. Its open architecture does not impose limits on the inclusion of new functions.” Fernando Conde, Application Consultant, Logitek
  • 36. Rubí (Barcelona), Spain -Thanks to the installation of theWonderware System Platform and B&R technology, Logitek has managed to integrate all the domotic features of its building into its main offices (located in Rubí, Barcelona), with the possibility of incorporating new functions as the need arises. From the control of lighting and blinds to air-conditioning and the library’s projection screen, its open architecture does not impose limits, helping to create a work environment that is more accessible, safe and respectful of natural resources. Towards an Intelligent Headquarters Logitek is a leader in providing process automation solutions that allow industrial companies to make intelligent real-time decisions. In November 2008, Logitek centralised its various corporate departments into one same building.This coincided with the move to its new main offices in Rubí (Barcelona). As a company that is always at the vanguard of technologies, Logitek wanted to implement a system that would save energy in its facility.This is keeping in line with the company’s philosophy of respecting the environment and promoting sustainability. From this need arose the requirement to automate the different domotic systems of its main office (air- conditioning, lighting and control of blinds) and design an intelligent building with the capacity of integrating new functions as the need arises. Logitek decided to implement an application based onWonderware System Platform to integrate the domotic systems and monitor energy resources. Because of this, Logitek was able to achieve its three main aims: to optimise energy consumption (by modulating water, air-conditioning and light consumption), to improve building safety (with greater control over alarms and security cameras) and to make available reports and statistics using collected data. An Integrated Environment As Fernando Conde, Logitek Applicant Consultant, explains:“The aim is to control the building’s various installations, integrating the hardware and protocols of different systems into one environment.” The platform is based onWindows 2003 that acts as an object server, communications controller, Wonderware Historian and InTouch HMI (Human Machine Interface) forTerminal Services. TheWonderware solution is comprised of: •Wonderware System Platform that provides a unique platform for all automation needs; • InTouch HMI forTerminal Services, software for process visualisation and control; •Wonderware Historian, real-time historian; • ActiveFactory software, a complete series of highly flexible tools to access to visualise and analyse data. Complete Environmental Control The installation was fully carried out by Cognicase Management Consulting, aWonderware system integrator that has great experience in domotic applications.The following functions were initially developed through theWonderware Application Server which is part ofWonderware System Platform solution and InTouch HMIView: • Changes to air-conditioning orders; • Monitoring of, and manually forced, lighting in the main office and monthly programming turn on/off lighting according to sunlight conditions; • Programming the rolling up and down of blinds in accordance with specific times and sunlight conditions; human presence and facade orientation; • Control different scenario in the Meeting Room. Intuitive handling was an important design consideration because of the high number of users accessing the control of the InTouch HMI screens. 36 ActiveFactory software, InTouch HMI forTerminal Services, Wonderware System Platform. Facility Management Figure 1: Office synopsis showing the temperature level controlled by Wonderware System Platform.
  • 37. Large buttons were used with few keyboard entries in order to optimise the use of the touchscreens. Once the installation had been activated, a check was made to see if the installed infrastructure could serve as a basis for other elements and functions that were not initially planned. Fernando Conde explains:“These elements were gradually integrated in accordance with our needs. One example is the security cameras positioned at the entrance to the offices: using the InTouch HMI software solution, we’ve made it possible for it to change direction so the most suitable video can be viewed.” Similarly, thanks to the cable structure of the offices, the cameras are connected to the local network via TCP/IP and included in the touch control of the InTouch HMI application. This complete control capacity also extends to the electricity consumption and environmental temperature control.Consequently,“by using the peripherals distributed by B&R,measurement can be made of the total electrical air- conditioning consumption,” adds Conde. The air-conditioning parameters used in temperature control are stored by theWonderware Historian,“has helped to optimise the operation times of the air-conditioning.” Major energy savings were achieved thanks to this and it truly had an economic impact. TheWonderware solution also helps to control various different scenarios.For instance,with one single key,the system controls lighting,blinds,the projection screen and adapts the room to different uses. Main Benefits The implementation of a shared platform based on theWonderware System Platform, combined with the peripherals distributed by B&R has helped to integrate all the domotic features of the building. Full system access and control using easy-to-use and clear interfaces has also facilitated the acceptance of the system by all personnel.Similarly, its open architecture does not impose limits when it comes to adding new functions.This provides the possibility of integrating new devices into the building easily. “The projects already exist to integrate automatic garden watering, access control into the offices and the anti-theft alarm into the same application,” points out Conde. The publication of different information (and some application screens) is also implemented in a Wonderware Information Server portal.The Wonderware Information Server on that helps to add and present performance and production data obtained via the Internet or Intranet. By using the Wonderware Information Server, it is possible to add large quantities of process data in production reports. Fernando Conde concludes:“Direct access to data relating to the installation, regulation and efficient control of air-conditioning, lighting and water consumption translates into an huge reduction of energy costs, thus helping to create not only ideal room temperature for the staff, but also showing how to become more mindful of limited natural resources.We save more than 5% energy due to the reduction of the electricity consumption, when people are not at the office and also because the automatic disconnection of all the electrical appliances when the alarm turns on.” The benefits of domotic applications are being strongly incorporated into the day-to-day activities of companies, helping to create greater comfort, safety and ease that promote a much more agreeable, healthy and sustainable work environment. This document was realized thanks to the support: Logitek and Cognicase Management Consulting,Wonderware system integrator. 37 ActiveFactory software, InTouch HMI forTerminal Services, Wonderware System Platform. Facility Management Figure 2: General view with all lighting system, air conditioning and shutters.
  • 38. To an open, energy-saving Facility Management Solution www.wonderware.com/fms Make the Switch Facility managers, building owners and end-users now have a competitive choice with open and flexible software from Wonderware. Our open Facilities Management Solution and network of independent system integrators can help reduce your total cost of ownership for installation, maintenance and service of applications. Lower energy costs and improve the security and performance of your workforce regardless of which building automation system you’ve installed. Ask for our FREE White Paper on how the Wonderware Facilities Management Solution can release you from costly proprietary systems. www.wonderware.com/fms ©2008 Invensys Systems, Inc. All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners. WNDR-784 FacilityMan-ASHRAE.qxd:WNDR-ASHRAE.qxd 22-01-2009 11:40 Pagina 1
  • 39. Industry: Facility Management National SecurityTechnologies, LLC www.nstec.com “We have a very stringent preventative maintenance program.The summer months are tough. If a piece of equipment breaks, I know it immediately.” Mark Lowell Froehlich Senior Operations Specialist/Automation Department of Energy NSTec Nevada’s First Government-Owned Green Building Uses Wonderware Software for Consistent Environmental Control byWonderware Goals: • Reduce energy consumption and increase conservation, including decreasing the facility’s dependency on oil; • Comply with Energy Policy Act of 2005 and DOE Order 430.2b, including extensive reporting requirements for electricity and water use; • Comply with ABSI/ASHRAE Standard 135/2004 (BACnet) for interoperability. Challenges: • Nearly 20 year-old Building Automation System was not interoperable with other systems, making control and compliance very difficult; • NSTec planned to perform all integration in-house, so ease of implementation was needed; • Demanding desert environment and high summer temperatures required enhanced preventative maintenance capabilities. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware System Platform. Results: • Reduced costs due to improved ability to manage energy use during peak demand periods; • Better communications and integration of systems by replacing the old, drum-based control system with a state-of-the-art, object-oriented system; • More flexibility, centralized control and the ability to make changes and upgrades quickly through server virtualization; • A more customized system, including templates to facilitated accelerated expansion. 39
  • 40. LasVegas, Nevada –When most people think of LasVegas, they imagine the intense heat of the desert, the bright lights of the Strip, and the clang of slot machines.With the immense amounts of electricity it takes to entertain visitors and keep them comfortable, the city is not one you would immediately associate with conservation. But an important government agency based there is at the forefront.The Department of Energy National Nuclear Security Administration’s North LasVegas facilities include Nevada’s first government-owned building to earn green status. This goal was met with the help of National Security Technologies, LLC (NSTec).Team NSTec manages the operations of the North LasVegas facilities complex, where experiments that are vital to the nation’s security are overseen. The company maintains these buildings in accordance with the Energy Policy Act of 2005 and DOE Order 430.2b – regulations which provide incentives and mandate control of vital power systems such as electricity and water. The ultimate objective of these regulations is reduced energy consumption and increased conservation, resulting in decreased dependency on oil.And federal agencies are required to lead by example in compliance and validation. Additionally, NSTec helps the facility achieve cost reductions by managing energy use during peak demand periods. Strict Requirements for Control and Validation To accomplish the goals of conserving energy, observing regulations for compliance, and saving money, NSTec requires the highest possible control of the campus.The diverse environment must meet established standards for climate, air quality, lighting, and all other critical building systems. Reports and records must show that these standards are being met continuously.Additionally, the facilities have to comply with ANSI/ASHRAE Standard 135-2004 (BACnet), the international protocol that ensures interoperability and future flexibility as the operation’s building automation system grows. This is no small task, considering that the North Las Vegas facilities’ 18-year-old Building Automation System functioned in standalone mode without a graphical user interface or real-time visibility for management of electrical, lighting, HVAC and other key systems. It lacked a common platform for integrating equipment monitoring, energy efficiency management, alarms and trending that would be necessary for control and compliance. Two and a half years ago,Team NSTec decided to explore opportunities to evolve the existing systems to meet current and future needs.Any new solution would have to regulate the facilities, of course, but it would also have to provide a more strategic approach for critical equipment and systems management.The team partnered with authorized distributorWonderwareWest to plan and implement the project. The Right Elements to Fit the Requirements Team NSTec was looking for a number of important capabilities that would meet the needs of the main building now as well as the other areas of the complex in the future. First, a stable backbone for managing the strategic functions that comprise the new system was essential.The solution would need to be .NET compliant and based on the Microsoft® platform for compatibility with existing systems. Ease of implementation was a necessity, asTeam NSTec hoped to perform all of the integration in- house. Then there was the desire for an advanced graphical user interface that would map the complete operation.Team NSTec wanted a visual representation that would be flexible, intuitive to 40 ActiveFactory software, InTouch HMI, Wonderware System Platform. Facility Management
  • 41. use, and that would help staff and management ‘see’ the entire campus. Multiple scripting would be a plus for customization and speedy implementation of changes. ForTeam NSTec, preventative maintenance is essential because of the desert environment, especially in the summer.A solution was needed that could provide real-time monitoring and trending capabilities that would fit the facility’s requirements. The new solution required tools to enable plant workers to troubleshoot disruptions, study potential operational inefficiencies and eliminate the time- consuming process of locating data. Finally,Team NSTec wanted the new system to automatically identify possible problems and alert the staff when established thresholds were breached so that corrections could be made rapidly.And it would need to provide all of the reports necessary to track performance and keep the facility within compliance. After evaluation,Team NSTec decided that the Wonderware solution was the right choice. Implementation and Future Plans With the new solution in place,Team NSTec quickly began to see the benefits that corresponded to their specific requirements. First, theWonderware solution updated the antiquated drum-based control system.With the new state-of-the-art, object-oriented system, the Team got the improved communications and integration it was looking for.The new solution enables the use of efficiently controlled systems and critical equipment such as power meters across the entire facility. Due toWonderware software’s exceptional scalability, the entire building automation system for the North LasVegas facilities complex is globally managed from NSTec’s central station.The team can trend the equipment performance and monitor the energy that it consumes.Along with equipment health monitoring, they also can see its overall performance, and theWonderware solution enables control of data centers, generator sets, substations, transfer switches and phone switches. Another significant benefit – server virtualization – brings added flexibility for management. Now that the servers are virtualized, preparations for integration into a server farm are in the forefront, allowingTeam NSTec to control and operate the systems from wherever they are, even outside of the main control room.Additionally, virtualization means that NSTec can maximize server resources and swiftly deploy changes and upgrades. Dependability and compatibility are also improved. Because it is built on the .NET architecture,Team NSTec can easily integrateWonderware software with other systems. Team NSTec agrees thatWonderware Software’s multiple scripting capability is its best feature.The ability to easily create objects and symbols and to define attributes means that the system is highly customizable.And its templates facilitate accelerated expansion and implementation of changes. TheWonderware solution also supports preventive maintenance requirements. If there are problems, the central station receives notification, and prioritized pager and mobile phone messages are also sent to staff working elsewhere.This ensures that emergencies and faults are addressed according to severity. Best of all, real-time reporting, trending and historical reports are easy to access and use. This requires little or no training for the staff. It also ensures that the facility is consistently controlled, and it stays in compliance, which is the #1 goal for Team NSTec. To take these capabilities even further, Wonderware software would permitTeam NSTec to develop a system to perform demand-side management, a key element in achieving green building recognition and remaining within regulatory compliance. TheWonderware software solution will enable the team to monitor and control the facility’s systems to decrease electrical energy use during peak periods. 41 ActiveFactory software, InTouch HMI, Wonderware System Platform. Facility Management
  • 42. To do this, the company will employ many techniques, including raising set points in the building and locking out second-stage compressors or other lower-priority equipment. Rolling outages will enable load-shedding and temperatures will be strategically controlled by cooling the building prior to peak periods so that lower temperatures are experienced during the heat of the day without excessive energy use. A Higher Purpose With the combination ofTeam NSTec and the Wonderware software solution, the complex has become a leader in facilities management system initiatives. By achieving compliance with the rigorous standards of the Energy Policy Act of 2005 and DOE Order 430.2b,Team NSTec andWonderware have helped the North LasVegas facilities become a model for environmental best practices and green initiatives. In fact, it is anticipated that one day many more public- and private-sector buildings nationwide will standardize the design of their systems based on the Wonderware solution as implemented byTeam NSTec. But even with all of this progress, the team breaks their efforts down to a more basic level. Mark Froehlich says,“The DOE expects us to set the example for energy efficiency and share our knowledge with the community.We have to be the shining star, and there’s a grave need for us to do so.As our population increases, our natural resources are lessening, and we have to make some changes.We’re taking little steps and improving our world.” AndWonderware is pleased to help! This document was realized thanks to the support of: National SecurityTechnologies. 42 ActiveFactory software, InTouch HMI, Wonderware System Platform. Power, Energy, General Process Manufacturing
  • 43. Industry: Facility Management TheVenetian Resort Hotel www.venetian.com “(The Wonderware solution) is a lifesaver. I can’t see not having it.” Jerry Jaggers, Senior Project Manager, TheVenetian Hotel Resort Casinos World’s Largest Resort Relies onWonderware Solution for Non-Stop Power byWonderware Goals: • Provide uninterrupted power to the entire resort complex; • Maximize the efficiency of widespread equipment and workforce; • Enable flexibility and adaptability to accommodate rapid growth. Challenges: • Biggest hotel and resort in the world covering 67 acres and 14 million square feet; • 66 substations, 62 PLCs and staff are spread out over a large area; • Any disruption of power can result in loss of clientele and revenue. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Historian. Results: • Power management and redundancy capabilities ensure uninterrupted power 24/7/365; • Real-time monitoring enables proactive trouble shooting and fixes; • Central monitoring of remote substations saves staff time, resulting in bottom line savings; • Reporting and record-keeping capabilities support rapid planning for expansion; •Wonderware solution supports green and sustainability goals. 43
  • 44. LasVegas, Nevada –When visitors come to Las Vegas, they may expect a few surprises in the casinos or enjoy an unexpected moment of amazement during a show. But they definitely do not imagine that their lavish vacation will be disrupted in any way – especially by interruptions in electrical power. Behind the scenes, complicated systems and dedicated teams work tirelessly to ensure that everyone has a fabulous experience. One of the brightest stars on the Strip isThe Venetian Resort Hotel family of properties.With TheVenetian,TheVeneziaTower, the Sands Expo Convention Center andThe Palazzo LasVegas, these properties comprise the largest hotel and resort in the world, covering 67 acres and approximately 14 million square feet of facilities. And so it comes as no surprise that the complex has one of the most innovative redundant power and Facility Management Systems ever developed. Part of the resort,The Palazzo LasVegas, has been awarded a Silver LEED® Certificate (Leadership in Energy and Environmental Design) by the U. S. Green Building Council. According to the Council,The Palazzo is not only the largest green building in existence, but is over four times bigger than the second-largest recipient of the designation. A commitment to green and sustainable processes can be seen throughout the resort. ATeam Focus on Growth Managing the growth ofTheVenetian has been a major task. Since its beginning in 1999, the other properties have been built or incorporated at a very fast pace. DistributorWonderwareWest and system integrator Electrical Systems Consultants (ESC) have collaborated withTheVenetian’s experts to create a facilities and power management software solution to provide real-time status monitoring as well as to support the other critical needs of the resort. President of ESC, Kevin Hartig, describes the effort,“In LasVegas, things operate at warp speed, andTheVenetian’s no exception.They added one tower after another, so we’ve had to respond very quickly with expansions to the system. Wonderware has allowed us to do that cost effectively and quickly.” For instance, the initial system was based on Wonderware InTouch HMI (Human Machine Interface), which provides an easy-to- use, intuitive view of the resort.Then ESC assisted with the addition of the Wonderware Historian to expand real-time and historical data collection and reporting capabilities. And future plans have been mapped to otherWonderware components that can be smoothly integrated when the time is right. According to Jerry Jaggers,TheVenetian’s Senior Project Manager,“when we addedTheVenezia, the main reporting ofWonderware saved us.We actually took the reports to see where we could add power to the other buildings and to see the usage.Then when we built The Palazzo, we used it to see how much more power we could use and where we can save it.” Redundancy Enhances Guest Experiences and Protects Revenue In LasVegas, normal takes on a whole new meaning. 44 ActiveFactory software, InTouch HMI, Wonderware Historian. Facility Management
  • 45. And this applies toTheVenetian’s power capabilities as well.The resort requires a predictable supply of power around the clock to fulfill its promise of a word-class guest experience. The advanced redundant power system is fed with 138,000 volts of electricity that come directly into the complex from NV Energy, the region’s power supplier.The power is broken down through two transformers and distributed to the 66 substations that serve the vast property. All substations are double-ended and work in conjunction with 62 PLCs which constantly monitor the flow of electricity. If one of the transformers is not sending power, the PLCs communicate this information through the Wonderware software. Such a fault would trigger the substations to react and pull power from the other transformer to minimize fluctuations and eliminate downtime.The software also works through the PLCs to perform real-time load shedding to adjust generator capacities. Plus,Wonderware software also monitors standby generators that are available to supply electricity to high-priority systems in the event of a complete loss of power. The redundancy system and its sophisticated management capabilities are critical toTheVenetian. It’s imperative that guests enjoy continuous electricity to power theirVenetian experience – because in such a competitive environment,any inconvenience for guests can mean lost business.An extended loss of power can mean billions of dollars in lost revenue for the resort. Real-Time Monitoring Brings Ease of Use and Efficiencies TheWonderware solution’s real-time status monitoring capabilities enhanceTheVenetian’s ability to meet the very high expectations of their visitors. With the system,facilities managers can view power usage at every substation on the property.The status of all equipment is visible on screen.Faults and alarms appear as they happen in an easy-to-read graphic format. This increased level of visibility has brought dramatic gains in efficiency for the enormous campus. In many cases, operators can make corrections at a central station, eliminating time-consuming trips to remote locations.And even when personnel do need to go to a site, they know exactly what they are looking for, so issues are resolved more quickly.This saves time as well as costs. Dale Mitchell, Electrical Supervisor, explains,“Wonderware has improved our efficiency to stay on top of maintenance.We go in and look at the gear online, and we’ve spotted problems before they’ve arisen. So we’ve had a chance to rectify those problems before we had downtime.” In the event of an emergency,theWonderware software can speed up response. While members of the team are monitoring an alarm event at the station,others can be dispatched to the location of concern.And the central team can be in constant contact to communicate current conditions and provide additional information to minimize power problems. Supporting Sustainability and Success By enabling proactive management ofTheVenetian’s power and providing ways to maximize staff for time and cost savings, theWonderware software fits nicely with the resort’s focus on green and sustainability goals.The solution has been entrusted with delivering superior capabilities, ease of use and reliability toTheVenetian’s management and staff. And they, in turn, are responsible for providing an enjoyable experience to guests and visitors. It’s a partnership that is paying off handsomely for today and for the future. This document was realized thanks to the support of: WonderwareWest and ESC Engineering. 45 ActiveFactory software, InTouch HMI, Wonderware Historian. Facility Management
  • 46. Accelerate performance. Right out of the box. Introducing Wonderware Industry Application for Packaging. Consistent performance coordination–that’s what’s missing! Packaging machine diversity and isolation is hindering fast and accurate production and process information.You need to get your products to market faster–and with higher profitability, efficiency and throughput.Wonderware Industry Application for Packaging software can help tie together your diverse set of packaging line equipment and give you greater visibility to your operations.Ask for our FREE White Paper on how the Wonderware Industry Application for Packaging can optimize your packaging operations–right out of the box. www.wonderware.com/packaging ©2009 Invensys Systems, Inc.All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies.All other brands and product names may be the trademarks or service marks of their respective owners. Something missing from your packaging operation? ww_AD_Industry Application for Packaging 1 9-04-2009 16:07:39
  • 47. Industry: Food & Beverage Amadori Group, GESCO Consorzio Cooperativo www.amadori.it The IdealTemperature byWonderware Italy Goals: • Optimize temperature management during the meat processing steps; • Ensure traceability, with exact temperature data for every step: processing, stocking and preservation; • Deploy a system that improves plant efficiency. Challenges: • Difficulty in software migration from an outdated version to a highly innovative and scalable system; • Create a temperature control system that adjusts according to the external weather conditions. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Historian. Results: •TheWonderware solution enabled the compliance with government regulations; •The new system optimized production cycle and energy management; •The automation of the production cycle helped eliminating manual data entry errors; •The scalability of the solution, initially only implemented in limited departments, has been subsequently painlessly deployed in all the other processes. 47 “In recent years, Amadori has always been asking for the most innovative solutions, aware that technological innovation allows us to remain competitive on the market.And this goal has led us to the deployment of Wonderware solutions.” Carlo Caramanico, Software Support, Cid Engineering
  • 48. Teramo, Italy - Amadori is one of the market leaders in the food processing industry. Founded in SanVittore di Cesena forty years ago, the Group – with a turnover of over 1 billion euro in 2008 – leads the Italian market with 16 industrial plants and 33 subsidiaries. It employs 6400 people. Amadori has been successful because of its innovation and decision to manage the whole production cycle directly, allowing immediate control over every production step.This includes choice of raw materials, farms, hatcheries, feed mills, processing plants, packaging and distribution. Tradition and innovation are the Group’s hallmarks: it is comprised of a professional team that presents innovative gastronomic solutions and works to deliver fresh and safe products to consumers. In the processing plant inTeramo, where breaded products and the ‘Il Campese’ line are produced, full temperature control is essential to ensure high product quality. The popularity of the Amadori Group has increased exceedingly in the past few years, thanks to advertisements featuring company testimonials and the ‘guaranteed by Francesco Amadori’ slogan. By emphasizing the high quality of its poultry products in various versions, the company is sending out a strong and important message. The IdealTemperature One of the most important challenges facing industrial plants is guaranteeing a consistently high quality level. The most sensitive part of production is the correct management of temperature, both in the processing and in the stocking and preservation steps. Temperature must be kept constant in the cold stores used in the preservation of slaughtered meat, to prevent it from quickly getting spoiled. It is important to avoid guesswork in the temperature settings during the processing steps: every department is constantly monitored to prevent the modification of temperature metrics. A high temperature, for example, could favor microorganism growth, risking to affect product quality. On the other hand, if the temperature is too low, the meat would be difficult to bone. This is strategic in the global operations because difficulties in the separation phase could slow the production process down, affecting the whole supply chain. Moreover, if conditions are not optimized, part of the meat could remain on the bones, causing considerable waste that affects the overall business. GrowingTogether Because of this, Amadori is especially focused on deploying systems that are able to optimize temperature management during the processing and stocking steps.“That is why – says Carlo Caramanico, software support, Cid Engineering – Amadori has been investing in high performance control solutions, able to support the company’s business and expansion.At end of the past decade, we got in touch with Amadori for the upgrade of existingWonderware InTouch HMI.” This mutual collaboration consolidated during the years, and Cid Engineering has been supporting all Amadori’s upgrades and deployment of new platforms and functionalities.“In recent years, – says Caramanico – Amadori has always been asking for the most innovative solutions, aware that technological innovation allows us to remain competitive on the market. And this goal has led us to the deployment of Wonderware solutions.This choice has been determined by the fact that, as qualified partners, we are highly 48 ActiveFactory software, InTouch HMI, Wonderware Historian. Food & Beverage Figure 1: Packaging Line.
  • 49. experienced in these applications and that, during the years,Wonderware has been introducing new innovative solutions, able to meet the demands of the highly complex Amadori’s business.” Quality and Savings Temperature management has been accurately studied over the past years, specifically its effect on savings and energy efficiency.The old system was based on simple thermostats, which is characterized by excessively slow response.Wonderware InTouch HMI (Human Machine Interface), on the other hand, allows smart operation.The system is able to manage the activation of the conditioning system according to actual needs. It also establishes the power needed to guarantee the ideal conditions. Aside from temperature values, air quality and humidity must also be taken into account. Humidity, in particular, must be kept within pre-set values, in order to preserve a healthy environment for the operators in the processing plant.TheWonderware InTouch HMI nodes help analyze environmental conditions, helping in the control of the airconditioning system. It is the ability to operate effectively that allows the system to turn on and off according to the different working cycles, in both the automatic calculations. By evaluating the external conditions, the system determines the time necessary to reach the right temperature according to actual needs.This prevents early cooling of certain environments and eliminates the postponement of processing because optimal conditions are not met. The History of Temperature The optimization of environmental metrics has a strong impact on product quality and the working conditions of operators. It also plays a decisive role in precise food traceability. Industry regulations require a trace back of all the operational conditions food has gone under, and the authorities usually check this information. In many cases, big customers want to verify the contractual compliance of the production processes. In the past, all these values were entered manually by the operators. But this way of working caused considerable problems, both for the need of employing extra operators who manually transcribe information, and for the high risk of human transcription errors.TheWonderware Historian software is specifically designed for the historicization and archiving of process data and helps solve this problem. ActiveFactory software accesses all this information and transforms it into graphics and useful information that allow operators to visualize historical event-related temperature trends intuitively.This feature helps with traceability and it also allows the operators to be immediately informed about abnormal situations. In this way, it is possible to act timely in case of deviations from set values, often before problems occur. The high scalability of the solution, initially only implemented in limited departments, has been subsequently painlessly deployed in all the other processes, thus ensuring the optimization of the production cycle and energy management in the Teramo plant. Recently Amadori chose to replace the old S5 PLC with a the newer Siemens S7 PLC.This has been successfully implemented without affecting the Wonderware automation solution. Once the new hardware had been configured, it has been immediately deployed, with no implication on the production cycle. Thanks to the most innovative and advanced technologies, it is possible to ensure the highest efficiency levels that always ensure high quality products. This document was realized thanks to the support of: Gruppo Amadori and CID Engineering. 49 ActiveFactory software, InTouch HMI, Wonderware Historian. Food & Beverage Figure 2: Aerial view of Cesena plant.
  • 50. www.indeff.com YOUR MES PARTNER FOR EMEA SYSTEM INTEGRATORSYSTEM INTEGRATOR SOME REFERENCES Arcelor – Brouwerij Martens – Chevron Philips Chemicals – EPZ – Franson – FrieslandCampina – Q8 – LU – Mora – Nestlé – Philip Morris International – GlaxoSmithKline – Ovako – Purac – Voeders Huys – Rogers Corporation – Fluxsys – LambWestonMeijer INDEFF implements and supports all Wonderware MES solutions: > Performance Management > Operations Management > Flexible Batch Management > Quality Management Our services include consultancy and expertise to support international and multi-site customers to achieve their operational objectives and to define an optimal MES solution architecture with a roadmap to operational excellence. Exclusive focus and expertise on Wonderware MES solutions to improve operational excellence
  • 51. Industry: Food & Beverage Coca-Cola Fortune (Pty) Ltd. www.cocacolafortune.co.za “The plant now has real-time visibility across processes and equipment and a much higher level of operational data integrity, while being nearly paperless.” DanieTredoux, Division Project Manager, Coca-Cola Fortune A refreshing look at business for Coca-Cola Fortune byWonderware Southern Africa Goals: •To achieve the lowest unit cost in Coca-Cola Fortune and also to establish a number of new best practices for Coca-Cola Fortune and Coca-Cola SABCO; •To achieve the highest labour productivity and plant efficiency (OEE) as well as lowest energy cost and water usage. Challenges: • Integration with non-OMAC compliant OEM equipment; •Tight time constraints; • A tight budget; • Integration with Coca-Cola Fortune’s IT infrastructure. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Operations software; •Wonderware Performance software; •Wonderware System Platform. Results: • Coca-Cola Fortune’s Bloemfontein plant now has a nearly paperless environment that will reduce administrative load and that, together with better management information, will drive efficiency up and costs down; •The plant now has great visibility into its equipment and process performance as well as a high level of process and information integrity. 51
  • 52. Port-Elizabeth, South Africa - Coca-Cola Fortune is one of 4 Coca-Cola licensed bottlers operating in South Africa.The plant is located in Bloemfontein. Coca-Cola Fortune is responsible for approximately 23% of the total SA Coke and related product sales. The business is expected to sell 7.5 million hectoliters or 66 million cases of beverage in 2009, utilizing 14 production lines. Coca-Cola Fortune is part of the Coca-Cola SABCO business entity which is licensed by Coca- Cola to bottle in 12 different African and Asian countries. Coca-Cola SABCO, with the Group Office in Port Elizabeth, has an excellent reputation for product quality and bottling excellence. Whatever its financial position, the world can still enjoy a Coke and the company responsible for more than 20% of South Africa’s enjoyment of Coca-Cola and hundreds of other refreshing products is Coca- Cola Fortune, part of the Coca-Cola SABCO group. With an annual production of 7.5 million hectolitres across 344 products and 14 production lines, Coca- Cola SABCO looked to a Manufacturing Enterprise Solution (MES) system fromWonderware to manage complexity, improve efficiency and reduce costs at its Bloemfontein facility. Coca-Cola Fortune Cheetah plant in Bloemfontein is the first plant in Coca-Cola Fortune to implement a MES system. Apart from the usual extensive MES functionality, the system was chiefly to focus on batch tracking, line performance, operations management and Overall Equipment Effectiveness (OEE) functionality.This was a Greenfield plant that could capitalise on available technologies while the rest of the group used mostly manual or semi- automatic systems. Business Objective “The objective with the Cheetah plant was to achieve the lowest unit cost in Coca-Cola Fortune and also to establish a number of new best practices for Coca-Cola Fortune and Coca-Cola SABCO,” says Ryan van Kerkhof, Manufacturing Unit Manager, Cheetah Plant. “Key goals included highest labour productivity and plant efficiency (OEE) as well as lowest energy cost and water usage to name a few.” In order to achieve these business objectives, Cheetah plant needed easy-to-use operator interfaces, data analysis facilities, a ready link to ERP systems (specifically SAP), product traceability, plant visibility, the automation of bottling processes, remote access for support and query and in-plant information display. Two of the notable aspects of the project were the level of customer cooperation during its design phase and the enthusiasm of the operational staff who showed huge interest in its implementation. Solution Selection EOH Mining and Manufacturing, a Wonderware system integrator, was selected because of the company’s semi-independent nature and its track record in the same industry and accumulated industry knowledge. The software includedWonderware’s range of industrial automation and MES solutions. It was a perfect fit because the adjacent plant was already using Wonderware software solution for downtime analysis and it was also decided that theWonderware offerings provided the required functionality. 52 ActiveFactory software, InTouch HMI,Wonderware Operations, and Performance software,Wonderware System Platform. Food & Beverage Figure 1: Multi-level hierarchy of activities in a manufacturing enterprise.
  • 53. System Architecture The system architecture consists of the full Wonderware suite of products. In level 0, Siemens PLCs control the plant. In levels 1 and 2, the Wonderware System Platform provides the infrastructure on whichWonderware InTouch HMI (Human Machine Interface), Wonderware Operations software andWonderware Performance software (level 3) are implemented while also providing integration between levels 2 and 4 (figure 1). TheWonderware products in use are based on ArchestrA technology which provided the core infrastructure for the rest of theWonderware Operations software andWonderware Performance software. InTouch HMI is used as a universal workstation which provides process plant control and visualisation into the MES operations and the packaging line performance. The universal workstation concept allows InTouch HMI applications for three different vendors to be integrated into a single environment in order to provide a unified view into the entire plant. In excess of 20,000 tags are processed.There are two universal workstations with large LCD screens used for displaying line performance KPIs.The operational staff can control the plant as well as view historical process information and plant operational information such as product genealogy. Line performance (performance, availability and quality) is monitored with OEE on some equipment whereas only the availability parameter is measured on the rest. ISA-88 and ISA-95 standards were extensively used in the development of the process control and equipment models.The information from the production line was converted for visualisation using an OMAC / PackML standard. Of the extensive MES functionality available, production execution, inventory control, traceability, genealogy, quality states and yield control were implemented.“The ISA-95 activity models were used to define the production, inventory and quality requirements,” says Barnard.“The MES software provided the basis for the business logic and reporting functionality while the Graphical User Interface (GUI) was implemented using InTouch HMI in its role as a universal workstation.As the system requires minimal input from the operational staff to initiate and control production processes, some of the business logic transactions were implemented using custom ArchestrA objects.” (ArchestrA isWonderware technology backbone for all industrial, MES and ERP connectivity applications). The system is integrated with the company intranet on the reporting level, allowing multiple users to access production and line performance information using out-of-the-box reporting tools.Wonderware ActiveFactory software (trending, analysis and reporting software) andWonderware Information Server (aggregation and presentation of plant production and performance data over the web or company intranet) are used.The ActiveFactory software provides access to production process control information whileWonderware Information Server provides access to plant operation information.“The result of all this is that operational staff has full access to-real time and historical plant information,” adds Barnard.“From a system integrator’s point of view, perhaps the most outstanding feature of 53 ActiveFactory software, InTouch HMI,Wonderware Operations and Performance software,Wonderware System Platform. Food & Beverage Figure 2: MES system overview at Coca-Cola Fortune, Bloemfontein.
  • 54. the system is the ease with which applications, supplied by different vendors using the same standards and platform, could be integrated.” System Implementation Implementation started in December 2008 with a targeted sign-off date of end March 2009.The project was preceded by a URS development phase where the customer’s project team was enlisted to develop the URS by applying the full ISA-95 standard in mapping Coca-Cola Fortune’s MES requirements. “Some of the challenges that were thrown our way were the integration with non-OMAC compliant OEM equipment, time constraints, a tight budget and integration with Coca-Cola Fortune’s IT infrastructure,” says Barnard.“The whole system had to be developed, tested and implemented live and offline development was done usingVMWare technology with a simulation engine to provide the relevant data.” According to Barnard, use of the ISA- 95 standard provided an excellent framework for defining the MES requirements and working closely with the customer’s outsourced IT division ensured that all internal policies were adhered to with respect to the installation of network infrastructure, switches and fire-walls. “Something else that helped was the use of a unified standard on theWonderware System Platform and visualisation system which ensured ease of integration and a unified HMI experience for the operational personnel,” says Barnard. Benefits • Coca-Cola Fortune’s Bloemfontein plant now has a nearly paperless environment that will reduce administrative load and that, together with better management information, will drive efficiency up and costs down; •The plant now has great visibility into its equipment and process performance as well as a high level of process and information integrity. Conclusion By reconciling business needs with production realities, MES is the ‘information switchboard’ for a manufacturing or mining company. Where business processes are interested in financial and customer issues and the shop floor is interested in production and technical issues, MES handles the information in which the entire company is interested. And, as shown at this plant, by dealing with facts in real-time, MES can’t ‘fudge the books’ and provides the right kind of decision support information to the right people at the right time. This document was realised thanks to the support of: Deon Barnard, MES Business Development Manager, EOH Mining and Manufacturing. 54 ActiveFactory software, InTouch HMI,Wonderware Operations and Performance software,Wonderware System Platform. Food & Beverage Figure 3: OEE dashboard for a filler showing drill-down capability to pinpoint the reason for non-performance.
  • 55. Industry: Food & Beverage Elledi S.p.A. www.elledi.com “The solution we chose delivered consistent value-added benefits, especially thanks to the ability to differentiate. It has enabled us to fully monitor the entire manufacturing process, with data available at our enterprise system.As a result, despite our complex range of products, real operating data enabled us to maintain our competitive advantage.” Marco Carlon, Systems Engineer, Elledi Wonderware, a valuable choice in a Biscuit and Bread Plant’s Traceability System byWonderware Italy Goals: • Increase competitive advantage by improving process quality and reliability. Challenges: • Increased complexity of production lines; • Compliance with product traceability regulations; • Reduce operator interactions. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Equipment Operations Module; •Wonderware System Platform. Results: • Competitive advantage thanks to the availability of complete information supporting decision making processes at all enterprise levels; • Reduce production costs (reduce operators working on production lines); • Higher product quality (reduce operator interactions and improve process hygiene); • Full product genealogy; • Data availability to optimize maintenance scheduling. 55
  • 56. Galliera Veneta (PD), Italy – Elledi was founded in GallieraVeneta, a small municipality of 6,800 people in the province of Padua in 1968. Its wafer biscuits immediately found success thanks to the company’s high standards of manufacturing and ingredient selection. New lines for the production of lady finger biscuits and shortbreads were added in 1988, supplementing the original plant. A new plant was opened in 1995, alongside the historical headquarters, to produce a whole new range of pastry delicacies, that includes tarts, tartlets, doughnuts and soft cakes. Elledi currently manufactures its products - nine wafer biscuits production lines - in 13 plants, covering an area of 25,000 m2 .The company employs more than 130 people who produce an average daily output of around 800 tons of product. Elledi has remained competitive by keeping an assortment of products available in various sizes, placing special emphasis on packaging that ensures longer product preservation. To keep pace with the increasingly demanding market, Elledi focused on improving the general automation of its production proceses by carefully chosing solutions to adopt and working with technological partners. Automatize to Optimize Elledi decided to build a newWafer Cream plant, alongside an existing facility producing batter.The increased complexity of the production lines required the deployment of consistent and repeatable processes that provide quick and easy control over the lines. Product traceability was also a very important requirement and Elledi required a complete monitoring of the whole production process, in order to track information about the products, including its history and genealogy. To solve these requirements, Elledi chose a Wonderware software solution. Wonderware Italy supported Autoware, the firstWonderware ArchestrA-certified system integrator in Italy, to create the solution that would satisfy the monitoring and traceability requirements of the new plant. The installed solution consists of theWonderware System Platform, InTouch HMI (Human Machine Interface),Wonderware Historian, ActiveFactory software andWonderware Equipment Operations Module.TheWonderware System Platform is the heart of the solution. Its easy-to-use object-based features have enabled Elledi to reduce development time.Wonderware System Platform’s common-layer foundation enables different components of the manufacturing system to communicate.This includes the integration to Elledi’s business system and all the devices in the plant floor. “Using the Equipment Operations Module enabled us to reduce our engineering and development times and it has given us excellent results.The object-oriented programming and the genealogy functions are incredibly effective!” said Eng. Federico Di Prima,Autoware. The ability to analyze field data, making them available to the highest enterprise levels, has been crucial for the creation of a really smart decision support system. A Winning Approach Wonderware InTouch HMI software provides monitoring of all manufacturing information and control of the plant floor. Everything is constantly monitored by operators so that problems are easily detected.ActiveFactory enables Elledi’s plant personnel to analyze and report on historical information.At any moment it is possible to view production trends and this enables operators to proactively intervene in case of alams. On the other hand,ActiveFactory web portal software enables visualization of reports and inventory stocks. Every person in the plant is provided with most useful and relevant information.The high level of ActiveFactory software, InTouch HMI,Wonderware Equipment Operations Module,Wonderware System Platform. Food & Beverage 56
  • 57. control and access to information is a competitive advantage that enables faster decision making. From the Ingredients to the Recipe The production process involves different phases that includes ingredient storage, dosing, mixing and production. The production process starts when the ingredients are received and stored. In order to maintain high product quality, the ingredients must be mixed according to precise doses. Every work order is made of subrecipes - one for every machine or plant involved in the production process - contained in electronic records.TheWonderware Historian software records all variables involved in the process (weight, time and material selection) and creates a centralized recipe database.This enables all production managers to set machine set-points according to consistent and standardized metrics. TheWonderware solution developed by Autoware controls the mixing, refining and cream production, tank storage and dispatching to the respective lines. Data on ingredients used in every batch necessary for traceability are automatically collected by oil and powder dosing systems. TheWonderware sofware solutiuon supervises the manufacturing at the wafer batter plant. Recipe storage and recall for batch coordination is provided by theWonderware Historian software.The supervision and control system of the manufacturing facility directly communicates with the MES system, exchanging information on food production lines at every given moment.This enables the MES system to monitor the traceability of semifinished products, up to the manufacturing processes. Traceability Means Quality The capability to control the whole production process in real time offers many advantages. Every deviation from pre-set values is immediately detected, enabling timely actions at the exact point where the alarm occurred.The production-line monitoring enables total food traceability, helping to facilitate regulation compliance.All production phases and metrics are stored, providing full product genealogy. This includes the identification of single components, with the ability to trace back suppliers, batches and manufacturing date. In today’s competitive and evolving market, even maintenance management has strategic relevance in the success of every business. All shutdowns needs to be planned in advance in order to minimize the impact on productivity.TheWonderware System Platform enables constant reconciliation of production values with stored and field data, preventing sudden interruptions in production and any situation that could negatively affect product quality. “The solution we chose delivered consistent value-added benefits, especially thanks to the ability to differentiate. It has enabled us to fully monitor the entire manufacturing process, with data available at our enterprise system.As a result, despite our complex range of products, real operating data enabled us to maintain our competitive advantage,” commented Marco Carlon, Elledi System Engineer.Today quality is not only measured on finished products. It is measured on a company’s ability to choose solutions and technology partners able to create value. This document was realized thanks to the support of: Elledi S.p.A. and Autoware S.r.l.,ArchestrA-certified system integrator. 57 ActiveFactory software, InTouch HMI,Wonderware Equipment Operations Module,Wonderware System Platform. Food & Beverage Figure 1: Recipe list.
  • 58. Industry: Food & Beverage Frito-Lay www.fritolay.com AWonderware Solution Helps Frito-Lay Minimizing Cost on Energy andWater by EST (Enerji SistemTeknolojileri Sanayi) Goals: • Monitor electrical energy, gas and water consumption to minimize utilities cost; • Create consumption reports on all production area and products. Challenges: • It is difficult to collect information from monitoring devices spread out in a large area to a central location; • It is important to create a system that provides standardized reports to different people coming from different parts of the factory; •To save on energy costs, it is necessary to set the limits of consumption for the coming months. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: •TheWonderware solution makes it possible to monitor electricity, gas and water consumption based on the customer goals, actual spending and cost per product unit; •TheWonderware solution enabled people to act effectively thanks to web-based reports; •The system enabled plant personnel to focus on overspending problems that are easily corrected. 58 “Now operators show pride because of the savings they have reached”. Abdullah Biçer, Maintenance Manager,Tarsus plant, Frito-Lay
  • 59. 59 Tarsus and Suadiye,Turkey - Frito-Lay, established in 1932, is the world’s largest packaged food producer. The company owns or leases over 50 plants or production processing facilities all over the world. Its parent company, PepsiCo currently manufactures and sells a powerful suite of brands and distinct products that include Quaker Foods, Pepsi, Gatorade, Tropicana Juices, and of course, Frito-Lay chips. InTurkey, Frito-Lay aims to produce the best products on the market, reduce its enviromental footprint and create snack foods that appeal to cultural and local tastes. Factories inTurkey are located at Suadiye (Izmit) andTarsus (Mersin). Both factories decided to monitor their consumption of gas, electricity, water and other utilities in order to minimize their manufacturing costs while being environmentally friendly. The project was in line with PepsiCo’s strong environmental awareness policy and both factories adopted to watch their consumption level very closely. Plant Intelligence Frito-Lay evaluated different HMI/SCADA manufacturers and decided to useWonderware software.Wonderware System Platform is now used in theTarsus plant andWonderware Historian is used in the Suadiye factory. The consumption data coming from energy meters, water gauges and gas meters are collected by the Wonderware Historian. At theTarsus factory, two large screens display both historical and real-time consumption of the production areas. Also with effective utilization of the intranet, Frito-Lay managers are able to monitor the system from their offices transparently.The operators at the plant can examine their targets and observe if they are close to the planned level of consumption. Maintenance personnel and managers are able to track overall savings as well as over consumption. The improvement on the operating procedure is noticeable once the trends at the production area are set. The Maintenance Manager Abdullah Biçer fromTarsus plant reports a marked increased awareness about the utility consumption among the operators. “Now they show pride because of the savings they have reached,” comments Biçer. He also adds that the project had been realized with the close cooperation of the project team as a live demonstration of the famous PepsiCo motto ‘Take Others withYou’. Wonderware Information Server is likewise extensively used to obtain real-time energy utilization reports for Suadiye plant. Hakan Er, the Electrical Maintenance Supervisor of the Suadiye plant says “I can manage when I can InTouch HMI,Wonderware System Platform.Food & Beverage Figure 2: Reports (Tarsus plant). Figure 1: Utilities’ consumption (Tarsus plant).
  • 60. 60 measure”. He adds that in their plant they were able to save 30% on water after they started to use the Wonderware solution. Observing Details The Plant Intelligence system at theTarsus plant is integrated to the ERP (Enterprise Resource Planning).The production data from the ERP is connected to consumption data coming from Wonderware System Platform.TheTarsus plant’s application monitors the Potato Line, Dorritos Line, Cheetos Line, Packaging Area, Cogeneration Plant andWasteWaterTreatment Plant. Real time online consumption, as well as target consumption, are displayed in tables for each area where production, electric consumption, gas consumption, and water consumption’s graphics are monitored. Detailed alarms and reports provide real-time information to the people in charge, independently of their location in the plant, via web interfaces provided by theWonderware Information Server. In the near future,Tarsus plant will expand the system to include solar power, heat recovery, pressurized air and nitrogen. Savings from consumption create a real value for Frito-Lay and they are very happy with the Wonderware solution. This document was realized thanks to the support of: Frito-Lay. InTouch HMI,Wonderware System Platform.Food & Beverage Figure 3: Biogas area (Tarsus plant). Figure 4: Factory general layout (Tarsus plant).
  • 61. Industry: Food & Beverage HuysVoeders N.V. www.voedershuys.be “There are no compromises when it comes to product quality, food safety, safety on the shop floor and environmental matters.” Peter Bresseleers, CEO, INDEFF Wonderware improves production versatility byWonderware Benelux Goals: •To produce high-quality products offering food safety guarantees; • Optimal control of the production process; • Greater efficiency; • Uniform user interfaces at every level and in every production plant. Challenges: •To upgrade the automation environment; •To retain and consolidate their position on the market; •To streamline and automate the production process in the three plants; •To record in full all produced and delivered products. Wonderware Solution: • InBatch software; •Wonderware System Platform. Results: • A joint address and nomenclature list for all systems; • Out-of-the-box integration with various applications in production automation; • Easy configuration and maintenance of applications by means of graphic tools; •Total traceability of all products delivered and produced. 61
  • 62. Brugge, Belgium -Voeders Huys is a dynamic family business that has been active in the animal feed sector for several generations.The company is specialised in cattle, pig and poultry feed.The feed is produced at two production sites, namely in Bruges (on the industrial estate at the port) and in France. The production site in Bruges consists of two production units: one plant produces pig and cattle feed, and the other solely poultry feed, in order to avoid contamination. Cattle feeds are manufactured at the site in France, together with various raw materials mixtures in accordance with the customer’s demands. No Compromises There are no compromises when it comes to product quality, food safety, safety on the shop floor and environmental matters. Goal-oriented automation helps the Bruges-based animal feed producerVoeders Huys (Huys Feeds) to produce high-quality products offering food safety guarantees. The company recently decided to upgrade its automation environment, and opted for the Wonderware automation architecture. To meet the ever-changing demands of its customers,Voeders Huys has brought a wide range of animal feeds onto the market over the years.To retain and consolidate its position on this market, it is constantly optimising the product range and the production methods – a process in which the choice of a supplier able to provide a high-performance automation system is an important decision.This is whereWonderware came into the picture. According toVoeders Huys,Wonderware was chosen because it offers a complete package, thus affording the possibility of anticipating extensions in the future. The company chosen as system integrator was INDEFF, aWonderware Endorsed system integrator since September 2008. For the Benelux this company is the only ArchestrA-certified system integrator to have attained this level. Competitive Advantage To hold their own in the present-day production environment, successful companies have realised that operational excellence results in a competitive advantage. One of the decisive factors in operational excellence is integration of the entire supply chain, with manufacturing systems being linked to business solutions.“Wonderware offers a complete software package enabling companies to chart the entire production process and performance in real time.This means it is possible to step in where necessary and adjust the production process or production procedures to market requirements. Installing a soundly integrated automation system is a major step in building a reliable environment for attaining operational excellence.The Wonderware software makes it possible to give a real- time overview of both the production process and production data such as stock, goods movements, batch information, etc., in a very simple and transparent manner”, says Peter Bresseleers, CEO of system integrator INDEFF. Production Process According to the Company’s Own HACCP Plan Every feed-processing factory has to comply with certain standards and the ever stricter requirements in the field of food safety and health rules call for optimal control of the production process.Voeders Huys is GMP+ certified for this.This means that the products and services meet the requirements stipulated in the laws and rules and regulations concerning safety for persons, animals and the environment, and the specific requirements laid 62 InBatch software,Wonderware System Platform.Food & Beverage Figure 1: Setpoint.
  • 63. down by the customers in the framework of Integrated Chain Management. The implementation and enforcement of these GMP measures are supplemented by the company’s own HACCP plan. Peter Bresseleers:“The production process hovers between the required feed values and the cost price,as a result of which the various formulas have to be adapted almost every day.This means that efficient‘formula management’with effective mixing is essential.The company starts with the raw materials,which are stored in silos and are delivered for shipment in bulk or on pallets by ship or lorry.Then the various ingredients have to be dose-measured very accurately and (if necessary) ground according to parameters incorporated in the preparation method.Everything is therefore controlled on the basis of the formula. An interface applies the desired preparation method to the production process. After mixing (which must be optimal and in which the mixing time is vital) and if necessary the addition of liquids,fats,acids and other essential ingredients,the mixture is stored again or delivered,or undergoes further treatment (e.g.processing into granulate).” “The great advantage here is that work can be performed independently of an operator,and this is to the benefit of the quality of the animal feeds.Owing to a limited storage capacity and in order to be able to anticipate customer requirements (Voeders Huys also meets specific feed production requests),a smooth through-flow is important and the company also works according to the just-in-time principle.Loading and unloading,both in bulk and in bags,is also fully automated.This is done by means of an interactive interface with the lorry driver who automatically receives all necessary documents.This therefore rules out the need for an operator to be present” points out Bresseleers. All Products are Now CompletelyTraceable Peter Bresseleers:“The company used to work with several systems and needed greater efficiency and, in particular, uniform user interfaces at every level and in every production plant, for reporting, for the mixing process, for the preparation method, and so on. It was therefore our job to streamline and automate the production process in the three plants. On the basis of theWonderware System Platform, based on ArchestrA technology, we therefore developed an automation system for this customer, in whichWonderware Industrial Application Server constitutes the heart of the automation platform. By means of programmable controls, coupled with the high-performanceWonderware software, the company now has technical ingenuity, flexibility and transparency to increase the productivity of machines, industrial processes and infrastructures.” “Moreover, the system is conceived in such a away that all produced and delivered products are recorded in full and are thus always traceable.This traceability is particularly important if and when problems arise. Thanks to the modular and flexible architecture, Wonderware meets the needs of even the most complex projects within centralised and dispersed automation environments. Changes of applications on account of process evolution pass off smoothly thanks to the flexible installation and incorporation of hardware and software” continues Bresseleers. 63 InBatch software,Wonderware System Platform.Food & Beverage Figure 2: System overview. Figure 3: System overview.
  • 64. Loss of Capacity is aThorn in the Flesh of Every Production Company When processes are developed, automation naturally plays an important role.Wonderware offers software solutions ranging from very simple Human-Machine Interfaces to distributed SCADA solutions and Manufacturing Execution Systems (MES). Peter Bresseleers:“Loss of capacity is a thorn in the flesh of every production company.Tracing these losses and making them visible calls for efficient recording. One of the conditions for meeting these requirements is therefore the continuous inspection of real-time data acquisition and the storage of data on all batch procedures. In order to be able to guarantee this continuity,Wonderware InBatch software was chosen. InBatch software automates product issue. A rapid switchover from one product to another is possible. InBatch software implements the formula preparation procedures and verifies the correct order of the operators’ activities.This serves as a continuous guarantee of product quality from one batch to another. The operator is also given a perfect overview of what is happening and can follow every activity on one screen. By simply pressing on the screen, he/she can also consult and check more details per machine”. Solutions Extremely Flexible andVery Easy to Integrate The combination of possibilities enables the customer/user to work out solutions that are extremely flexible and very easy to integrate. Design, building, development and protection of the standardised applications for the integration of operational and enterprise applications, are easily done by the customer.This comprehensive approach considers critical business-to-manufacturing requirements such as, firstly, integration possibilities with various applications, ranging from small(er) sites to several sites, secondly, the necessary security provisions for foreign IT environments, and thirdly, support of the most common standards.And to give the customer even more support, a library of templates is provided for the integration of production planning and performance measurement systems with ERP, etc. And our interlocutor concludes:“The strategy of both Wonderware and INDEFF is to offer added value in the automation of our customers’ production process in the form of expertise and specialisation.TheWonderware System Platform manages all functional possibilities needed for industrial software.This platform is specifically designed for automation and information technology staff operating in their demanding real-time environments”. This document was realized thanks to the support of: HuysVoeders N.V. and INDEFF S.A.,Wonderware Endorsed system integrator. 64 InBatch software,Wonderware System Platform.Food & Beverage Figure 4: Scheme press.
  • 65. Industry: Food & Beverage Lotte SamKang www.lotteSamKang.co.kr “Wonderware InTouch HMI is much better than I had imagined.We can make decisions twice as fast.” Shin U-Infra, BusinessTeam Manager, Lotte SamKang An Integrated Production Management System for the Food Industry by Maha Net Co. Ltd. Goals: •To develop a new plant resource management system capable of supporting decision-making with real-time information and accurate reports of usage and operations. Challenges: •The calculation of accurate manufacturing costs was non-existent; •The old system wasn’t able to track claims; • Unable to collect operating and quality costs; •There are large losses from errors in manual operation; • Lack of accurate operation analysis data; •Yield, operation rate, productivity, etc. Wonderware Solution: • ActiveFactory software; • InBatch software; • InTouch HMI; •Wonderware Historian. Results: • Information on resources are sent to the ERP systems, with the additional ability of quality management tracking; • Accurate calculation of unit product cost for corporate strategic planning; •TheWonderware solution has enabled the effective planning of production activities. 65
  • 66. Seoul, Korea – Founded in 1958, Lotte SamKang is the market leader in the Korean food market for the past 40 years. In 1960’s, Lotte SamKang established Korea’s first sanitary facilities for the production of quality ice- cream with products such as the SamKang Ice Bar. Since then they have produced many popular ice- creams such as JjuJju Bar,Amatna, Daeji Bar, Goo- Goo products, Hazelnut Café,Turtle Bar and many others. Eventually, Lott SamKang ventured into the manufacture of other products like condiments to special restaurant sauces, instant meals, coffee, baby food, bread and cookies. Background and Objective Lotte SamKang required a new plant resource management system capable of supporting decision- making by transparently reporting information on usage and operation of all on-site resources. In addition to that, a real-time management system was required to strengthen the company’s competency and develop new growth engines. System Development Objective Although the information system allowed the accumulation of data and support for decision- making, there was a need for dynamic real-time information management for field-oriented decision support, tracking of various production resources, and quality management. Real-time Production Information System capabilities The capabilities of the integrated production information system included a real-time interface with the existing ERP, a human machine interface (HMI) connection to the automated production systems, an automated warehouse management system, and an enterprise asset management system. Integration with Utility SCADA All the PLCs at the Lotte SamKang plant are connected to the HMI where each unit operation equipment can be individually managed. AWonderware Historian collects all real time information. The accumulated historian data is processed for use by the enterprise asset management system (EAM) or to the manufacturing execution system (MES). The operating time data automatically extracted from the field equipment is transferred to the EAM so that the work orders can be automatically generated in accordance with the preventive maintenance strategy. 66 ActiveFactory software, InBatch software, InTouch HMI,Wonderware Historian. Food & Beverage Figure 2: Utility SCADA System Structure. Figure 1: HAVC Utility Screen Example
  • 67. Integration of all Production Data The information on all raw and semi-raw material input are collected by the HMI/ SCADA system and sent to the systems at the upper tier.They can be tracked for quality management. In addition, the utility usage information is recorded along with the actual production, both by personnel and by product, to get an accurate calculation of the unit product cost. The collected information will also be used for corporate strategic planning. Production Progress Monitoring In the past, an entire plant had to be patrolled in order to determine the actual production status. With the new system, all the necessary information is accurately displayed on the monitor in real-time. This makes production planning more effective and saves on personnel and operation cost. System Integration and Scalability Lotte SamKang has considered the information system right from the start of the construction phase of the new plant and has invested heavily to integrate all the components that make up the solution. The key feature of the solution is the dynamic configuration of the information system enabled by Wonderware.Any changes resulting from equipment or system addition can be easily adopted and deployed. This document was realized thanks to the support of: Lotte SamKang. 67 ActiveFactory software, InBatch software, InTouch HMI,Wonderware Historian. Food & Beverage Figure 3: Use of System OperatingTime by Enterprise Asset Management. Figure 4: Integration of all Production Data. Figure 5: Utility Usage Status Figure 6: Monitoring of Production Status in OneView.
  • 68. Industry: Food & Beverage New Belgium Brewing Company www.newbelgium.com Brewery with Progressive Reputation Makes the Most ofWonderware Software byWonderware Goals: • Install an Enterprise Manufacturing Intelligence and Manufacturing Execution System that will improve inventory management, increase production accuracy and improve quality control. Challenges: • Reduce time spent entering data and manually checking the movement of materials; •The PLC-based batching system was not operating at its full potential; •The clean-in-place (CIP) information was not readily accessible; • Quality control procedures were performed by hand. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware Production Event Module (PEM); •Wonderware System Platform. Results: • ‘Track andTrace’ capability enables tracking of any product within 30 minutes; • Key Performance Indicator (KPI) scorecards provide immediate information about performance; • Historical analysis enables optimization of energy use; • Faster trouble shooting; improved response times for corrections; • Early detection of product deviations; • Projected ROI for integration costs will be realized within two years. “From the administrative perspective, we save a lot of time. And from a people’s perspective, we save a lot of frustrations.That’s the number one benefit.” IgorValuyev, Chief Electrical and Automation Engineer, New Belgium Brewing Company 68
  • 69. 69 Fort Collins, Colorado –While many manufacturers today work to minimize their impact on the environment and meet green goals, few have been applying these practices for as long as the New Belgium Brewing Company. In addition to long-standing programs to reduce, reuse and recycle, in 1998 the company became the first wind powered brewery in the United States. Sustainability and utilizing innovative technologies are among the company’s core values. This tradition of progressive thinking extends itself into New Belgium Brewing Company’s manufacturing processes, but it did not start that way. In the beginning, Jeff Lebesch, inspired by the Belgium beers he tasted on vacation, began brewing beer in his basement. Soon after, friends and neighbors urged Jeff and his wife Kim to take their operation commercial. That was 1991, and the small company tracked most of its information on paper and with internally-developed databases. Early Success Brews Frustration It wasn’t long before the popularity of beers like Fat Tire spurred New Belgium Brewing Company’s growth.With reporting and compliance requirements increasing, the company found it difficult, time-consuming and sometimes even impossible to gather all of the production-related data they needed to generate reports using their early systems. Operators were frustrated by the large amount of time spent entering data and manually checking it again and again to track the movement of materials through the manufacturing process.The PLC-based batching system was not operating at its full potential and clean-in-place (CIP) information was not readily accessible. Quality control was performed by hand, slowing down an operation where the excellence of the product is the basis of the brand and can’t be compromised. IgorValuyev, Chief Electrical and Automation Engineer, explains,“Operators used to do double entry, which is double work. I’d say a lot of operators spent 30% of their time updating the paper.” There was no doubt that New Belgium Brewing Company needed better processes to trace each batch of beer through the manufacturing process. Management wanted to increase accuracy, decrease time for data input and reliance on paper documents, and reduce the time required to access and analyze information.The company was also looking for ways to improve inventory management and training.And the new system would have to be easier to use for both operators and management. A Plan for Innovation and Improvement The brewery contacted Orbis Information Systems of Dublin, Ireland – aWonderware system integrator with food and beverage industry experience – and shared this lengthy list of requirements. New Belgium requested their help to configure a system that would enable smoother, automated collection of data as well as more in- depth analysis and understanding of it. Additionally, the brewer hoped to see improvements in energy efficiency, quality assurance and throughput. Besides meeting these parameters, it was also important for the new Manufacturing Execution System (MES) to match New Belgium Brewing Company’s culture. The system’s scope is plant-wide – fulfilling New Belgium Brewery’s ‘grain to bottle’ quality-control requirements and providing valuable decision- making data from the arrival of raw materials through the bottling and shipping of the finished product. ActiveFactory software, InTouch HMI, Wonderware Production Event Module (PEM),Wonderware System Platform. Food & Beverage
  • 70. 70 Better Visibility Brings Increased Efficiency and Quality The new system usingWonderware software provides extensive ‘track and trace’ capability and is a natural fit with New Belgium’s conservation and performance goals.With the new solution, any bottle or tank of beer can be tracked back to all of its inputs – finding 100% of them within 30 minutes. It uses Key Performance Indicator (KPI) scorecards to provide immediate information about how each shift is performing as well as how the plant is doing on a monthly or yearly basis.This real-time visibility is critical because it enables operators to devote their resources to solving the right problems. In addition to providing more reliable and timely data, the system also aids in enhanced analysis, which has lead to increased quality control. Product deviations are caught much earlier, trouble shooting is faster and response times for corrections have improved. Control charts are used to predict the longer-term outcome of process changes. In a business where there is no scrap – low-quality product literally goes down the drain –Wonderware software is helping to make a significant difference in product consistency. Additional Operations Benefits Once tracked 100% by hand, vital stats such as temperature and pressure measurements were difficult to gather, hard to support and not easily analyzed. But not anymore.Today, New Belgium Brewery’s system employs Wonderware Historian software to collect and store real-time and historical production data. Plus Wonderware InTouch HMI (Human Machine Interface) software with its intuitive graphical interface makes running the plant easier than ever before. Wonderware ActiveFactory software also plays a key role. Because of its versatility, it is found throughout New Belgium Brewery Company’s operation: production departments use it to analyze and optimize energy use. Janitors use it to determine temperatures in the rooms, facilities usage and cleaning requirements. Even the accountants employ ActiveFactory software to extract batch data and alcohol content readings to meet Alcohol,Tobacco and Firearms Department reporting and taxation requirements. Beer brewing is an energy-intensive process, and with theWonderware system, energy conservation has improved too. Steam, water and electricity consumption is monitored continuously.The plant’s lighting system is automated; when no one is present, light sensors automatically dim the lights or turn off unneeded banks of lights. Bottom Line, It’s a Great Relationship With any new implementation, there are challenges along the way. AndWonderware has supported New Belgium Brewing Company throughout the entire project. Valuyev says,“I have usedWonderware for many years, and in my opinion they have the best technical support system in the world. People are prompt and people get back to you.”Wonderware knows that this kind of response builds strong relationships. As for return on investment,Valuyev speculates that ROI will come within two years for the combined software and integration costs.Which works well for a company that prides itself on environmental best practices and progressive use of technology, all while delivering a high-quality product and operating profitably. This document was realized thanks to the support of: New Belgium Brewing Company. ActiveFactory software, InTouch HMI, Wonderware Production Event Module (PEM),Wonderware System Platform. Food & Beverage
  • 71. Industry: Food & Beverage Orley Foods (Pty) Ltd www.orley.co.za “We found that the Wonderware solution was best suited as it had a proven track record in food and beverage (we spoke to their customers) and was used in many local and international plants involved with food production.” Henk deVilliers, Operations Manager, Orley Foods. Orley Foods - world-class chocolate manufacturing with a little help fromWonderware byWonderware Southern Africa Goals: • Full product traceability; • Seamless and transparent integration of manufacturing and business systems throughout the company; •Trend and trace process issues in order to speed up trouble shooting while conforming to regulatory requirements. Challenges: • Re-engineering of Orley Foods’ process control and information delivery infrastructure; •The plant model would have to be designed to handle the entire plant and not just certain aspects of the chocolate production facility. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: • Consistent batch sizes; • Raw material allocations tracked; • Better process control tracking; • Significant savings in fat usage; • Standardisation of batch processing times; • Minimised batch/formulation corrections. 71
  • 72. Background Orley Foods is fully HACCP (Hazard Analysis and Critical Control Point – an FDA programme) compliant and the company’s quality management system conforms to ISO9001. Compliance is audited regularly not only by Orley but also by the South African Bureau of Standards (SABS) and it is within this context of mandatory regulatory compliance that a material tracking solution was sought. The Orley Foods plant is made up of four main areas (Figure 1). From Raw Material Receiving to Finished Goods, tracking and traceability is key to regulatory compliance. This is especially true of the chocolate manufacturing facility which manufactures chocolate in bulk according to the specifications of downstream chocolate confectionery manufacturers whose products are found on the retail market. Project Objectives “Before this project, we were working with a failing system while our multinational customers demanded more traceability information,” says Henk deVilliers, Operations Manager, Orley Foods.“These large companies want certificates of analysis and conformity and can demand a full traceability report within two hours.They can also do flash audits on site without warning and ask any questions they wish about any batch. So we looked for a solution that would provide seamless and transparent integration of manufacturing and business systems throughout the company.” The manufacturing system would have to be capable of as yet undefined expandability, ease of integration and the ability to provide data in context for the benefit of more informed decision-making. All the important, relevant and contextual information was to be published to a portal for easy access by personnel who could make best use of it and it was imperative that the system have the ability to trend and trace 72 InTouch HMI,Wonderware System Platform.Food & Beverage Figure 1: Structure of Orley Foods, its chocolate manufacturing process, areas addressed by this project andWonderware System Platform model classification of functional groups. CapeTown, South Africa - Over the past 40 years, this proudly family-owned, Cape-Town-based business has produced a comprehensive range of quality ingredients for the South African food industry.The business has evolved into two distinct streams, one involving the ongoing innovation, manufacture and distribution of Orley Products and the other the highly collaborative, development- driven Orley Solutions service. Orley Solutions is a dynamic and extremely responsive service through which the company’s New Product Development division researches and develops food solutions for South Africa’s leading brand owners. Orley Products consist of a large range of successful packaged goods for wholesale distribution to the catering, confectionery and baking trade, as well as limited retail distribution to consumers. The company’s wide range of chocolate products (over 100 different formulations) include couverture chocolate made to international CODEX standards. Needing to know the quantities of the costly materials that make up a batch of raw chocolate, Orley Foods selectedWonderware technology and the capabilities it offers to allow for accurate consumption and production monitoring per batch and to never again having to wonder about the constituents of each batch.The merging of an effective production solution with their newly- implemented ERP system gives Orley full visibility on detailed manufacturing information per works order and more effective decision support.
  • 73. process issues in order to speed up trouble shooting while conforming to regulatory requirements. Project Requirements In order to achieve its objectives, Orley Foods would have to implement some far-reaching initiatives that included the re-engineering of its process control and information delivery infrastructure. Some of the considerations included: • Traceability of fat usage and additions against work orders - In the chocolate manufacturing process, the different fats used are incompatible with one another so it is vital to ensure traceability of the fat used at all times; • Monitoring / logging of process parameters - The chosen system would be used to monitor and track process parameters in the plant and for each recipe batch; • ERP integration with Syspro – Orley Foods needed one version of the truth for the Bill of Materials in order to minimise formulation failures and so needed this information to be fed directly from Syspro to the manufacturing system; • Overall system upgraded to latest technologies - As the company’s system could no longer cope, it needed to upgrade to the latest technologies that would address its Network andWindows / SQL Server environment as well as its SCADA and PLC system needs; • Ingredient management of recipes - As Orley Foods has over a hundred different recipes for liquid chocolate including different colours and fat combinations, the company needed a system that would be able to handle this variation seamlessly; • Introduction of expandable reporting infrastructure - With the new business environment and the need for key information, Orley Foods developed KPIs to which the manufacturing system had to respond so as to deliver reports from a central source. Solution Selection While realising that there were a number of potential technologies to address their needs, Orley Foods decided to step things up a notch and look for prospective solution providers who could use the technologies they though most appropriate to the task at hand. “We started the project by defining our needs and then drew up a tender process allowing various vendors and systems to be evaluated,” says deVilliers.“It was vital that we had a well-known system but it was equally important that we had a Cape-Town-based system integrator who needed to have experience in the development of PLC, SCADA and databases, especially SQL. It was also a prerequisite that the SI should have prior experience in a food and beverage environment and was well acquainted with the complexities of working in a HACCP environment.We chose AMR Automations because they met all these criteria.” Several prominent technology suppliers were considered but eventually Orley Foods selected 73 InTouch HMI,Wonderware System Platform.Food & Beverage Figure 2: InTouch HMI screen showing the fat storage and transfer process.
  • 74. Wonderware.“We found that theWonderware solution was best suited as it had a proven track record in food and beverage (we spoke to their customers) and was used in many local and international plants involved with food production,” says deVilliers.“We were also demonstrated examples of integration between Wonderware production and control systems with our chosen ERP system, Syspro. Lastly, there are numerous system integrators and solution providers with an extensive knowledge of theWonderware suite of solutions which meant that we wouldn’t be stuck in the case of an emergency.” Solution Architecture Wonderware System Platform, based on ArchestrA technology, was used to develop a model of the plant.“Although the project only addressed certain aspects of the chocolate production facility, we designed the model to cater for the entire plant,” says Stefan la Grange of AMR Automations. An important part of the project was the PLC upgrade where the previous PLC was replaced with an Allen-Bradley CompactLogix unit and Beckhoff EthernetTCP/ IP remote I/O units which AMR found to be a good and rapid solution for upgrading installations where PLCs could be kept out of harm’s way. “We design PLC programmes to run autonomously with no interference from the SCADA system,” says la Grange.“In this case, the PLC runs the recipe and handles the fat transfer route allocation. Obviously, processes for which the necessary raw materials (e.g. fat) are not available are not started.” Orley Food’s ERP system, Syspro, places the work orders into a ‘holding’ or intermediary Wonderware Historian production database from where they are picked up by the SCADA system.The works orders specify the raw materials to be used as well as the tank and equipment allocation / scheduling. Operators then use the dual-screen SCADA system (InTouch HMI - Human Machine Interface) to view the state of all the conches in the system and the works orders they are executing.“We use the SQL data grid from Wonderware to show the production plan which displays which work orders are queued or being processed and a simple click on the column headers will sort the display according to the chosen criteria,” explains la Grange. “Operators can modify the execution time of work orders or switch machines for a specific work order if authorised by production supervisors.This is useful for bypassing breakdowns or maintenance problems.” TheWonderware Information Server reports tabulate all aspects of work order status and production information such as temperature vs. pressure charts, process variations, timings and operator interactions for traceability purposes. Realised Benefits • Consistent batch sizes – Previously, this could be a hit-and-miss- affair with corrections having to be made for marginal or failed recipes.Today, that’s all in the past; • Raw material allocations tracked -What fat 74 InTouch HMI,Wonderware System Platform.Food & Beverage Figure 3: Orley Foods system topology for phases 1 and 2 of the project.
  • 75. goes where? Previously this was done manually and prone to operator error; • Better process control tracking – Alarming (e.g. motor trips) are now available at the SCADA level as is trouble-shooting information (temperatures, pressures, grinding times, etc.) as well as operator involvement; • Significant savings in fat usage - In the chocolate industry, Cocoa Butter is called Liquid Gold because of its high cost; • Standardisation of batch processing times – Allows for critical evaluation of plant performance reduced consumption or resources, especially electrical power; • Minimised batch/formulation corrections - Savings in having to add raw materials to batches which could result in batches that were larger than the customer ordered and were therefore wasted. Conclusion Phase 2 of this project will capitalise on the gains already made and extend functionality across the entire plant while closing the loop with feedback directly into the Syspro ERP system. Orley Foods has shown itself to be a prime example of adaptability in a more demanding world with a globally-competitive marketplace.There’s no doubt that the integration of information technology at the business and production levels is helping the company deal with the mechanics of sustained profitability. But it’s doing much more than that. It’s allowing Orley Foods to focus on its original mission of delighting all of us. This document was realised thanks to the support of: Henk deVilliers and Fiona Byrns, Orley Foods, and Stefan la Grange, AMR Automations. 75 InTouch HMI,Wonderware System Platform.Food & Beverage
  • 76. Industry: Food & Beverage OSM Piatnica SM www.piatnica.com.pl Wonderware MES solution supports packaging process of cottage cheese by Astor Sp.z o.o. Goals: •To create a consistent reporting system for production efficiency; • Real time monitoring of machine conditions; •To analyze productivity levels through OEE monitoring; •To analyze production potentials and material consumption. Challenges: •To detect and eliminate the most frequent reasons of packaging machines stoppage; •To improve the production management; •To replace paper work with electronic records. Wonderware Solution: • InTouch HMI; •Wonderware Performance software; •Wonderware System Platform. Results: • 8% OEE increase thanks to the detection of weaknesses in the packaging process and later optimization; • Quality and throughput increased; • Production order tracking enabled the quantitative and qualitative control of packaged products; • Available information for managers thanks to detailed reports. 76 “Thanks to the information about equipment efficiency and utilization provided by the reporting system, we are able to understand how to improve our packaging line performance and increase our productivity”. Andrzej Jacak Automation Service Supervisor, OSM Piatnica
  • 77. 77 Piatnica, Poland -Timely reporting and production efficiency analysis, based onWonderware Performance software, has showed the weakest points of the packaging machine and enabled the management to take the right decisions to optimize its work.Wonderware Performance software allows to control all machine components and monitor the operators’ work on every shift. OSM Piatnica offers a wide stock of dairy products and with 50% market share represents one of the market leaders in the food industry.They produce cottage cheese and other milk products which are distributed into different regions of Poland. A business operation under a strict technological and sanitary supervision is one of the key to explain an undisputed success. The company also adopted the most modern solutions to effectively manage and control the plant floor and production. Last section of cheese production line is equipped with one of the most efficient packaging machine in Eastern Europe. In order to optimize production management, supervision maintenance and the performance of their cottage cheese packaging machine, OSM Piatnica’s management team decided to implement a MES solution.They choseWonderware Performance software to address their production efficiency and stoppage analysis’ needs. Thanks to the open and scalable ArchestrA architecture, OSM Piatnica was able to integrate the new solution with the existing system. Moreover, the new system automatically tracks machine status and calculates its OEE (Overall Equipment Effectiveness). Thanks to theWonderware solution, it is possible to know the most frequent downtime reasons and therefore packaging operators, team leaders and maintenance specialists can react immediately and prevent future production losses.WithWonderware Performance software, it is possible to analyze the machine utilization and work cycles to implement predictive maintenance. Selected packaging machine parameters are recorded inWonderware Historian database. Existing visualization based onWonderware InTouch HMI (Human Machine Interface) was extended to enable order execution and production balancing. Thanks toWonderware Performance software, the customer have access to comprehensive product information, from recipes and raw materials to the packaging and ‘best before’ date printing. Key Effects of Implementation Unquestionably, the most reliable benefit from Wonderware software implementation is the common reporting system enabling maintenance staff and the top management to have access to real time and updated information from the shop floor. InTouch HMI,Wonderware Performance software, Wonderware System Platform. Food & Beverage Figure 2: Downtimes & Failures Analysis’ Report. Figure 1:Top 10 Downtimes’ Report inWonderware Information Server.
  • 78. 78 The new solution is a user-friendly tool: reports can be created quickly and contains useful data on the most frequent downtimes,work status,maintenance and balancing of the resources. “Thanks to the information about equipment efficiency and utilization provided by the reporting system,we are able to understand how to improve our packaging line performance and increase our productivity. We knew it was possible,but we didn’t imagine that improvements would have been so easy to reach.Now we know that a production increase will not create bottlenecks,” said Andrzej Jacak,theAutomation Service Supervisor in OSM Piatnica. Wonderware Information Server’s reporting system ensures the web-based access to the reports, as well as to basic and current parameters connected with packaged products. It is also possible to conduct different analysis, based on the real data from anywhere, not only from the production plant. It is worth to notice the easiness of application design and development thanks to the ArchestrA architecture and the simple management of production orders.Thanks to theWonderware solution, OSM Piatnica was able to minimize the time needed to add new orders into the system. By considering the results of theWonderware solution implementation, OSM Piatnica management team is taking into consideration the possibility to use the same equipment and software automation for packaging lines which will be installed in the future.“In the future we would like to add the reporting system to other machines and production lines, in order to analyze manufacturing process completely,” summarizes Jacak. This document was realized thanks to the support of: OSM Piatnica. InTouch HMI,Wonderware Performance software, Wonderware System Platform. Food & Beverage Figure 3:Work Order Summary at Operator Station.
  • 79. Industry: Food & Beverage The South African Breweries Limited www.sablimited.co.za SAB Maltings adopts latestWonderware technology for batch tracking and reporting byWonderware Southern Africa Goals: •Track products through the production process in order to get a complete view with respect to production variables applicable to each batch; • Reports detailing product transfer times and vessel occupancy times. Challenges: •The merging of production and process timelines into a single source of information with all the data in context for meaningful numerical and graphical reports regarding production KPIs; •The safeguarding of existing system investments. Wonderware Solution: • InTouch HMI; •Wonderware Equipment Operations Module; •Wonderware System Platform. Results: •The new system has highlighted operational and plant issues, which had previously been ‘hidden’ from view; •True vessel occupancies and transfer times can be determined; • Providing real-time data in the correct format now has made users more aware of true realities and they want more; • Meaningful information is helping SAB Maltings achieve its overall objective of continuous process improvement. 79 “All in all, for the first time, we now have an automated system giving us the information to achieve what everybody is striving for – continuous improvement.” Eddie Jordaan, IS manager, SAB Maltings
  • 80. Caledon, South Africa - SAB’s involvement in the barley and malting industries in South Africa stretches back more than a century but moving to more modern times, barley growing started in the Caledon, Swellendam and Bredasdorp areas in the Western Cape in the early 1970s. Southern Associated Maltsters (SAM) was established in April 1978 as a joint venture between SAB and two cooperatives. During the mid 1990s, a second barley growing area was established under irrigation in theVaalharts andTaung areas. In 2006, more than 800 farmers were planting barley for the malting industry. Caledon Maltings is now one of the biggest in the Southern Hemisphere with an annual capacity of 180,000 tons. Caledon Maltings runs a 24/7/365 operation. Every 14 to 16 hours, a 306-ton batch of malt is produced. Each batch is equivalent to nine rail wagons and will produce 7.8 million cans of beer. SAM is now called SAB Maltings. SAB Maltings at Caledon (Western Cape Province) is a wholly owned subsidiary of the South African Breweries Limited and has been operating since 1981.The company’s business is to turn barley into 180 000 tons of malt every year for the brewing industry and that’s why it’s the biggest producer of malt in the southern hemisphere.With malt batches exceeding 300 tons and taking nine days to complete, SAB Maltings decided to improve insights into its production with a batch tracking and reporting system fromWonderware. Project Goals “We needed a system that could track our product through the production process in order to get a complete view with respect to production variables applicable to each batch,” says Eddie Jordaan, IS manager, SAB Maltings.“From a user perspective, we wanted to supply a system that could generate a report per batch detailing the production KPIs numerically and graphically. In addition, we needed reports detailing product transfer times and vessel occupancy times.This information would assist us in optimising processes.” From this requirement arose the need for a batch tracking system for production and process data. Previously, the system consisted of an InTouch HMI (Human Machine Interface) andWonderware Historian providing process data and some trending but there was a lack of production information and no automated reports. So, the project objective became the merging of production and process timelines into a single source of information with all the data in context for meaningful numerical and graphical reports regarding production KPIs (Key Performance Indicators). Another project requirement was the safeguarding of existing system investments. Solution Selection This last project requirement mandated the use of the latest offerings from Wonderware and this meant growing the system by adopting theWonderware System Platform based on ArchestrA technology. 80 InTouch HMI,Wonderware Equipment Operations Module, Wonderware System Platform. Food & Beverage Figure 1: Batch tracking and reporting system topology at SAB Maltings.
  • 81. In addition,Wonderware Equipment Operations Module would be responsible for capturing the production data that would then be stored in the Wonderware Information Server while Microsoft Reporting Services would be used for the generation of the necessary reports. This choice of solutions would provide seamless integration with the existingWonderware investment. Wonderware Equipment Operations Module is designed to help improve the consistency and effectiveness of plant operations by helping to execute production activities consistently, as well as providing accurate visibility into the status of operations. It’s also used where there are demands for end-to- end traceability of materials, equipment and other resources across production processes. Compatible with the ISA-95 industry standard,Wonderware Equipment Operations Module includes genealogy functions for correlating events and information captured across multiple areas and process segments. “In view of the solution choice, we needed a Cape-Town- based and ArchestrA-certified system integrator that could provide a turn-key solution and that also had a local support infrastructure,” adds Jordaan.“AMR Automations was eventually selected after following a standard tender process.” Solution Implementation AMR Automations made a point of understanding SAB Maltings’ business requirements before starting any engineering effort.“Once we understood what was required, we drew up a functional specification which was agreed upon and signed off by everyone including the production personnel,” says Andrew Rennie, director,AMR Automations.“This also applied to the report layouts and content.” AMR Automations even went further through a Factory AcceptanceTest for a complete simulation of the solution before starting any implementation in order to make sure that the system complied with SAB Maltings’ requirements in every detail. It took approximately one month to establish the base-infrastructure on site. “Although this is a hybrid solution featuring a legacy InTouch HMI installation connecting to newer System Platform software, the integration is so seamless that you would never know it,” says Rennie.“Wonderware System Platform’s underlying ArchestrA technology allowed us to define and apply standards that reduce engineering effort and provide for its reusability. Notably, this is the first installation of theWonderware Equipment Operations Module in SAB.” 81 InTouch HMI,Wonderware Equipment Operations Module, Wonderware System Platform. Food & Beverage Figure 2:The display of KPIs in real-time areas together with alarm status, all within theWonderware Information Server framework.
  • 82. Delivering the Information •Wonderware Information Server provides for web- based delivery of information with security. Along withWonderware System Platform, AMR Automations had the opportunity to use the Microsoft SQL Server technology and this combination proved to be a really effective way of delivering the required information to those who need it while making use of the Microsoft security layers; • Microsoft Reporting Services’ reporting functionality was designed using Microsoft Reporting Services that provided interactive reporting with drill-down capability to view production and process data; • Dashboards and KPIs are visualised using published InTouch HMI graphics. Results •The new system has highlighted operational and plant issues, which had previously been ‘hidden’ from view; •True vessel occupancies and transfer times can be determined; • Providing real-time data in the correct format now has made users more aware of true realities and they want more; • Meaningful information is helping SAB Maltings achieve its overall objective of continuous process improvement. “The eventual solution exceeded my expectations,” says Jordaan.“The first version produced the desired reports with about 80% accuracy.The inaccuracies were traced to mainly operational and plant issues which were subsequently identified and which we are currently addressing.” This document was realised thanks to the support of: Eddie Jordaan, IS manager, SAB Maltings. 82 InTouch HMI,Wonderware Equipment Operations Module, Wonderware System Platform. Food & Beverage Figure 3: System Platform in action – ‘The model says it all’.
  • 83. Industry: Metal Products Alcoa Inc. www.alcoa.com “If I had to summarise all the benefits into one it would be that of migrating from a paper-based manual system to a mechanised, computer one.” Róbert Németh, OTC & MES Application Manager,Alcoa Alcoa automates plant process control usingWonderware solutions in the foundry section of Amorebieta facilities byWonderware Spain Goals: •To customize Comprehensive MES solution included in Alcoa Global Order to Cash initiative; • Schedule and work order management, Specifications and actual values management; • Downtime and OEE analysis,Traceability and Genealogy, ERP integration and Customized user interface, business rules, graphical analysis and customized reporting. Challenges: • Need to improve the efficiency; • Complete tracking of shop-floor operations and inventory; • Replace legacy shop-floor system; • Part of global Order-to-Cash initiative, involving the implementation of new ERP and shop-floor operation interface. Wonderware Solution: •Wonderware Operations Software; •Wonderware Performance Software. Results: • Complete tracking of the work orders on the shop-floor and inventory; • Ease of use regarding scheduling and work order management on the shop-floor; • Efficiency visibility, showing opportunities for process improvement; • Seamless integration with current systems (ERP, Control systems, Chemical Analysis systems); • Improvement of Quality management operations. 83 “If I had to summarise all the benefits into one it would be that of migrating from a paper-based manual system to a mechanised, computer one.” Róbert Németh, OTC & MES Application Manager,Alcoa
  • 84. Amorebieta (Vizcaya), Spain -Thanks to Wonderware technology, Alcoa has managed to align the commercial objectives of its Order-To- Cash platform with its manufacturing operations by deploying a Manufacturing Execution System (MES) in one key part of its production line. World Leader in the Aluminium Sector Alcoa is one of the world leaders in aluminium production and technology, with a presence in 35 countries and over 200 offices. It currently has eight production centres located in various Spanish regions from where it serves innovative solutions for its clients in major international markets. In particular, its plant in Amorebieta (Vizcaya) is Alcoa’s largest rolling plant in Europe and one of Alcoa’s largest in the world. It supplies both finished products to third party customers as well as semi- finished products to other Alcoa rolling plants in Europe. It manufactures sheets, levelled coils and trimmed coils for building & construction and industry applications and a great variety of other products to the European market. It also produces high-quality aluminium coils for the high value-added products manufactured by other Alcoa plants in Europe. i.e. foil, litho, closures and bright products. With the aim of optimizing all its aforementioned activities and facilities, Alcoa decided to implement a system to control in real time all factory processes. Although the aim at the beginning was to implement a MES throughout the plant, it has only been implemented in one of the factory’s two main sections: the foundry, where the blocks or ingots are produced as raw material for sheet operations, which is the second basic division of the plant. The company choseWonderware software to automate and monitor all plant processes, thereby obtaining absolute control of all operations being carried out. Integrated Solution into the Owned Global Platform As Alcoa OTC & MES Application Manager Róbert Németh explains:“We were looking for a solution that could be integrated into our global platform to manage Order-To-Cash (OTC) processes based on Oracle applications.” Given that the OTC platform encompasses all production activities, the company decided to deploy a Manufacturing Execution System (MES) solution that was able to respond to all manufacturing and plant quality requirements and could be integrated in a transparent manner with the Oracle system that will be implemented in the near future. Alcoa already had a MES system deployed as standard in some of its facilities in the USA.“This was how we chose theWonderware software as a global MES solution and began to work immediately on first covering the needs of the Amorebieta production plant and then later implementing the more global OTC project, a stage that has not yet been completed.” In order to carry out deployment in the Amorebieta plant, the aluminium manufacturer required the experience ofWonderware for the functioning and development of the application to manage the project, as well as dedicating its own resources at the development stage and relying on Sysmaker as Wonderware ArchestrA-certified system integrator. 84 Wonderware Operations Software; Wonderware Performance Software. Metal Products Figure 1: Production tab where the operator can see the work order’s production planning and respective attributes.
  • 85. Global Project Challenges Sysmaker is aWonderware ArchestrA-certified system integrator and has wide-ranging experience in the implementation ofWonderware’s HMI/SCADA, MES, EMI and SPC solutions. “We have been working withWonderware MES software since 2004 and this was one of our main reasons for participating in this project to help the end- client achieving operational excellence,” says Carla Costa from Sysmaker’sTechnical Department. As part of the Oracle-based OTC global strategy, the project required the design of a new interface to integrate ERP processes and manufacturing operations, with the final aim of optimizing efficiency, completing the monitoring of operations and inventory and replacing the management system of the inherited plant. After defining these parameters, the entire team, comprisingWonderware professionals,Alcoa developers and Sysmaker specialists, found themselves faced with certain challenges. The project included optimizing the MES solution, which was already operational in other Alcoa plants, and implementing it in the other facilities destined to have the same activity. “But there were differences between the factories in terms of work methods,” continues Costa.“And so one of the main challenges involved reconciling criteria to obtain a satisfactory solution for local managers at Amorebieta.” This difference in terms of process operations and methodologies triggered the need to resolve certain system control interface parameters “specifically relating to communication with the machines via OPC and obtaining information relating to inactivity times, the Overall Equipment Effectiveness (OEE) system and the carrying out of work,” points out Costa. Stages and Personalization Nonetheless, thanks to the great flexibility and personalization capabilities ofWonderware software, the challenges could be overcome as the different stages of the project progressed. Implementation was divided into various stages.The first comprised defining the specific requirements relating to plant operations, then the software specifications were established and next development and the different test processes began. After obtaining final approval from the plant manager and providing some training for the system users, the process moved on to the production and execution phase, encompassing a brief adaptation stage. The implemented MES solution includes the Wonderware Operations software and Wonderware Performance software, both based on ArchestrA technology. While the former provides consistent execution of operations by unit and line,Wonderware Performance software is a component of Wonderware MES and includes functions that make possible OEE (Overall Equipment Effectiveness) control via plant monitoring, encompassing an unlimited number of causes for equipment downtimes and calculations of their global effectiveness. As already mentioned,Wonderware’s MES platform was personalized to respond to the specific demands of the Amorebieta factory:“Covering agenda management and job orders, control of already existing specifications and values, OEE and inactivity times analysis, as well as process traceability and genealogy and future integration with the Oracle system,” stresses Németh, OTC & MES Application Manager at Alcoa. 85 Wonderware Operations Software; Wonderware Performance Software. Metal Products Figure 2: Downtime tab showing the list of latest working status of the machine and its duration, depending on the filter chosen.
  • 86. Therefore, the possibility of personalizing Wonderware Operations software and Wonderware Performance software not only affects user interface, but has also been extended to obtaining graphic analyses and reports on the basis of business guidelines. Main Benefits As Németh points out:“If I had to summarize all the benefits into one, it would be that of migrating from a paper-based manual system to an automated one.” This automation of MES processes affects different areas, encompassing major efficiency and easiness of use when it comes to schedule production tasks and calculating production needs, greater visibility and traceability and outstanding precision in inventory management and integration with control processes. Consequently, the Alcoa factory in Amorebieta has managed to achieve: • Full monitoring of job orders and inventory in the plant; • Greater ease in terms of task distribution and organization; •Visibility relating to efficiency, displaying the opportunities for process optimization; •Transparent integration with already existing systems (ERP, control systems, chemical analysis systems); • Improvement in the quality of management operations. Wonderware provided functional consulting at anytime and contributed to application development and integration with the remaining process control systems, working hand in hand with Alcoa professionals and Sysmaker experts. Speaking on behalf of Sysmaker’sTechnical Department, Costa concludes by adding:“Global performance has been very good, especially because we have been able to deploy a highly personalized solution to respond to the specific demands of the Alcoa factory, with smooth integration and without any major incidents.” This document was realised thanks to the support of: Róbert Németh,OTC & MES Application Manager, Alcoa, and Carla Costa, DepartamentoTécnico, Sysmaker,Wonderware ArchestrA- certified system integrator. 86 Wonderware Operations Software; Wonderware Performance Software. Metal Products Figure 3: Screen to schedule the slabs that are ordered by the clients. Figure 4: Screen showing how the operator can check which components are going to be used and the material’s availability for the specific alloy’s work order production.
  • 87. Industry: Metal Products Hoco ChromeV.O.F. www.corusgroup.com Wonderware System Platform gives clarity to Hoco Chrome production process byWonderware Benelux Goals: •To Simplify operation in the plant floor; • Enable the record of production history; • Make production data accessible to all plant personnel. Challenges: •The existing system uses traditional switchboards. This prevents plant personnel to get a clear view of what is happening in the plant. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: • Production information is easily retrieved in Microsoft Office tools; •TheWonderware solution is so easy to use that it is possible to be implemented by in-house technical service personnel; •With the object-oriented system it is easy to maintain and expand in terms of hardware and software; •The SCADA system can be remotely accessed. This provides transparency to the work floor at business level and allows maintenance to be supervised from different locations. 87 “Wonderware was selected due to our positive experience with Wonderware Historian. The system is both user-friendly and flexible. Furthermore, a solid foundation has been laid for our MES layer using ArchestrA technology. This open and object-oriented solution offers so much more!” René van Rij, General Manager, Hoco Chrome
  • 88. Velsen-Noord,The Netherlands – Hoco Chrome is a 50/50 joint-venture between Corus and the Canadian Court Holdings Ltd. Hoco Chrome repairs the surface of rollers used by Corus to produce pressed steel sheets. ‘We maintain rollers that are used to process steel into thin sheets,” explains René van Rij, Hoco, Chrome’s general manager.“These rollers need to be quickly returned to customers such as the Corus plants, otherwise the production process halts.”The stress placed on the rollers is great and Corus’ quality requirements are high. Rollers are often sent back again to Hoco Chrome after only a few hours of service, where an electrical spark process restores the correct texture to the roller surface.“A roller does not need to be smooth, instead it is slightly rough,” explains van Rij.“This ensures that the roller produces a sort of dotted pattern on the steel sheets.This makes them easier to process.” The original production process was controlled by outdated operating panels which did not allow the recording of process history. It was also not possible to remotely see what was happening on the work floor.This had all been solved with the implementation of theWonderware System Platform with InTouch HMI (Human Machine Interface) clients.This open and object-oriented solution also offers a connection to the ERP system and detection of Overall Equipment Effectiveness (OEE). The manufacturing process at Hoco Chrome is controlled by PLCs. A couple of small changes were recently made to plant operations. “The existing system still used traditional switchboards.This led to a lack of ability to have a complete overview of the plant. For example, we were not able to find out the process settings when investigating a customer complaint,” continues van Rij. This is similar to flying an airplane without a cockpit and black box. In order to give clarity to Hoco Chrome’s work floor processes, a new solution was required for operation, visualisation, and archiving process data. Data Historian Bases on a Highly-Accessible SQL Database This problem was solved by installingWonderware System Platform solution that incorporates the Wonderware Historian. “We are going to use the historical data to create quality reports for our customers,” explainsVan Rij.“They will then be able to check whether a roller has received the treatment that they requested. Furthermore, we can use the Historian to trace causes of malfunctions.This will not only benefit our delivery reliability, but it will also help us to free-up hidden production capacity. Expanding the machine park will only be required in two years time.” The activities on the plant floor can also be followed remotely by logging on to the SCADA system.“This is very convenient from my office, and it is useful during malfunctions.The maintenance of our installations is done by HTD, which is Corus’ technical service.We used to have to wait a long time if a technician had to come all the way from Den Helder during the night.This is no longer necessary, as I am now able to log on to the SCADA system from home using a secure connection,” explains Ko Dirkson, HTD’s senior technical assistant.“This proved to be particularly useful when there were problems with starting up the spark process. I was quickly able to see that the solution rested in a cold start on a PLC.” Wonderware was selected to supply the SCADA system due to the positive experience with theWonderware Historian in Corus’ central waste processing plant.“We already had experience of theWonderware platform at HTD, but at Hoco Chrome we implemented this package for the first time completely on our own.” 88 InTouch HMI,Wonderware System Platform.Metal Products Figure 1: Rollers to process steel into thin sheets.
  • 89. User-Friendly and Flexible System The system is user-friendly and flexible because the software is set up to be completely object-oriented. “You can design separate operating components, including visualisation, at the level of the Object Server. Object orientation allows you to easily change similar components in one go.You can also copy and reuse components which we used extensively when we put an additional production line into commission,” points out Dirkson.This flexibility is also important for future expansions.“You can easily add software and this makes the automatic registration of the Overall Equipment Effectiveness possible.” This is also echoed by Mark Satink, account manager atWonderware Benelux.“It is possible to make a pop- up screen for each object that informs the operator about the source of a malfunction.These notifications can then be used later for a Pareto analysis, in order to determine which problems occur the most.” Another future extension is linking the SCADA system to the Hoco Chrome and Corus’ ERP systems. “Each roller is treated separately for the required roughness,” explains Dirkson. “At the moment, this information is still entered by hand. It would be better if there was a MES layer that could automatically channel this information to the recipe data.Thanks to the present Wonderware technology, we have laid a solid foundation for this future component. Other future possibilities include sending quality reports to our customers electronically,” adds van Rij. “Handling questions and complaints can also be done through theWonderware MES layer.” Main Benefits 1.TheWonderware Historian enables production information to be easily retrieved in Microsoft Word, Excel or Internet Explorer; 2.TheWonderware solution is so easy to use that it is possible to be implemented by in-house technical service personnel; 3.The system is completely object-oriented.This makes it easy to maintain and expand in terms of hardware and software (e.g. for the latter, the addition of an OEE cockpit and a connection with the ERP system); 4.The SCADA system can be remotely accessed. This provides transparency to the plant floor at business level and allows maintenance to be supervised from different locations. This document was realized thanks to the support of: Hoco Chrome v.o.f. 89 InTouch HMI,Wonderware System Platform.Metal Products Figure 2: InTouch HMI clients.
  • 90. Industry: Metal Products Otefal S.p.A. www.otefal.it “Wonderware System Platform meets all engineers’ requirements, and object-based programming in particular allows to develop applications in a fast and consistent way, with the possibility to reuse content on new lines.And thanks to the excellent results obtained by the supervisory system of the liquid coating line, the same application will be reused in all production lines, taking advantage of its flessibility and scalability.” Luca Benedetti, Responsible for Automation Projects, Skyline The New Color of Aluminum byWonderware Italy Goals: • Increase competitiveness on the international market by improving efficiency and ensuring high quality standards. Challenges: • Production lines are composed of equipment provided by different vendors; • Heterogeneous supervisory hardware and software. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: •Waste reduction thanks to the possibility to detect nonconformity causes; • Increased competitiveness thanks to the reduction in production costs; • Increased productivity thanks to timely detection of causes and solutions to output failures; • On time deliveries thanks to detailed scheduling and reorganization of production. 91 “Wonderware System Platform meets all engineers’ requirements, and object-based programming in particular allows to develop applications in a fast and consistent way, with the possibility to reuse content on new lines.And thanks to the excellent results obtained by the supervisory system of the liquid coating line, the same application will be reused in all production lines, taking advantage of its flessibility and scalability.” Luca Benedetti, Responsible for Automation Projects, Skyline
  • 91. Bazzano (AQ), Italy - Otefal is a company operating in the finishing sector that has achieved success through continuous innovation in technology, as well as in commercial and marketing procedures. Otefal has specialised in aluminium coil- coating.The product is a perfectly flat, special aluminium alloy sheet coated with an even layer of long-lasting coating applied. Innovative Supervisory System Global aluminum demand constantly grew in the last decade.This material, in fact, ensures excellent machinability and has a long lifecycle, as well as weighing 30% less than steel. All these characteristics have been favoured by modern industry, not least because they comply with green regulations: aluminum is totally recyclable and this is one of the reasons why it has been so widely used. Thanks to these valuable properties, companies in the field of aluminum production and processing chose to invest in expanding or stengthening their productions sites, driving the best from existing plants. Otefal is a clear example of this trend: the company deployed the most innnovative automation and control technologies in the Bazzano plant, in the province of L’Aquila.This considerable investment involved embossing, liquid and powder coating.The company in fact used out-of-date automation systems, which have been growing without specific planning and often depended on vendors’ choices. The innovative supervisory system allows to uniform data collection and communications, monitoring coating processes in real time to prevent any deviation from optimum quality. Looking for Excellence The existing lines, which the company decided to keep, are composed by machines produced by different vendors, each with different supervisory and control systems.The existing automation system was based on different and often off-market hardware, without any documentation about components. Such a situation involved high workloads since careful visual checks and continuous adjustments were necessary to ensure the high quality standards which characterize Otefal products. Furthermore, obsolete assets compromised the reliability of the whole system, which risked sudden failures. In order to increase competitiveness on a global scale, under the direction of Sabino Morra, ICT General Manager, last year Otefal chose a partner able to contrbute in increasing production efficiency while ensuring quality standards. Otefal chose to work with Skyline, combining typically IT expertise with specific industrial automation knowledge. A Common Language The wide range of hardware and supervisory softwares “represented one of the main challenges in the development phase,” explains Marco Anzovino, Skyline owner. “Even though this is a common situation in Italian manufacturing companies, where rarely there are unified automation solutions and every single vendor offers its own supervisory systems.” In many cases, proprietary systems 92 InTouch HMI,Wonderware System Platform.Metal Products Figure 1: Shopfloor.
  • 92. work perfectly on specific applications, but are difficult to interface with plant HMI systems, since they are not based on international standard protocols. Furthermore, suppliers use different hardware according to market opportunities. This leads to overlaps increasing complexity and making the whole system unstable and unreliable. These limits are not compatible with modern operational activities, where there is no room for delays, mainly because they would affect the whole logistic and production chain. In this scenario,Wonderware System Platform has proved winning, and has been used by Skyline engineers to develop the supervisory operating station with InTouch HMI (Human Machine Interface), allowing vector graphics visualization to create realistic plant representations. Real PlantView “In aluminum coating processes, which are characterized by multiple variables,” explains Luca Benedetti, Skyline responsible for the automation project “besides the automation phase, supervisory operations has a fundamental role. For this reason we choseWonderware System Platform, enabling to create logical representations of the physical processes.Wonderware solutions provide better performances than systems by other vendors, and this is the reason why we’ve been working with them for more than twenty years. And we can confirm this thanks to our experience in the IT field. Wonderware System Platform meets all engineers’ requirements, and object-based programming in particular allows to quickly develop consistent applications, with the possibility to reuse them for new production lines.And thanks to the excellent results obtained by the supervisory system of the liquid coating line, the same application will be reused in all production lines, taking advantage of its flessibility and scalability.This way was created a business system which automatically collects and analyzes field data, avoiding problems arising from manual data collection, with the advantages of operating in real-time and eliminating any manual error.Total plant monitoring allows all authorized personnel to be always informed about any unusual situation. Line operators immediately understood the potential of this solution, both enabling to prevent inefficiencies typical of a system developed without specific projects, and the risk for irreversible damage, very likely in heterogeneous and not backed up systems.” Smart Supervision “Through the smart supervisory system developed by Skyline – explains Luca Centi, EDP Manager – all field data is collected in real-time andWonderware InTouch HMI advanced graphic capabilities enable perfect management of all activities. In this context, the intuitive graphic interface allows operators to be timely informed in case of problems, with the possibility to analyze every single detail”. “Data connection and real-time operator interactions – explanis Anzovino – are possible thanks to the innovativeWonderware technology, enabling to integrate ‘intelligence’ in the control systems, transforming raw data into useful information.The system immediately detects downtimes and is able to notify output falls, indicating possible causes and solutions, in order to quicken maintenance interventions.All these capabilities allow to maximize efficiency, since they prevent any issue that could affect production times. In a process where 93 InTouch HMI,Wonderware System Platform.Metal Products Figure 2: InTouch HMI screenshot.
  • 93. any detail is planned, any delay negatively affects the whole organization, with the risk to pay penalties to the customers. On the contrary, a smart system timely notifies any disfunction, supporting managers in planning or reorganizing production, in order to keep to the schedule, without causing logistic problems. Data communication is quite useful also in maintenance activities.The system, in fact, is able to notify the need for interventions scheduled by machine builders, upon reaching of a certain amount of working hours. But what is especially crucial is the capability to detect production falls or unusual trends, clear indicators of problems to be solved before they lead to urgent interventions which negatively affect productivity.” High Readiness Wonderware System Platform satifies all Otefal quality requirements. Choosing to invest on high quality production, second quality is inacceptable, and every nonconforming piece is rejected. In order to ensure high quality standards, operations must prevent waste. For this reason, Otefal needs a system able to monitor every single workpiece in real- time and to timely intervene on nonconformity causes, thus allowing for economic advantages.Waste is drastically reduced, mainly because this smart system allows to detect negative trends, notifying maintenance managers about the need for actions to prevent nonconformities. This operational approach also improves efficiency and productivity, allowing to reduce costs linked with every single workpiece.This feature allows to increase competitiveness thanks to lower product prices, all the while keeping satisfactory profit margins. This document was realized thanks to the support of: Otefal S.p.A. and Skyline s.r.l. 94 InTouch HMI,Wonderware System Platform.Metal Products Figure 3: InTouch HMI screenshot.
  • 94. Industry: Mining AngloGold Ashanti Limited www.anglogold.co.za “The fuzzy logic rules can be and are implemented remotely from South Africa or anywhere else, saving time as well as transportation and consultation costs. The benefit of fuzzy logic rules will increase in parallel with the increase in unit run time, as well as compound its improvement as variability is decreased.” Corné Lourens, Metallurgical Manager, Geita Gold Mine Enabling intelligent operations at a gold mine byWonderware Southern Africa Goals: • Applying the corporate standard; • Standardising the control philosophy; • Improving the alarming and alarm logging for analysis; • Maintaining a history of production data; • Providing for real time and scheduled reporting and the production of those reports; • Implementing an Expert System based on fuzzy rules to reduce process variation and improve production. Challenges: • Remoteness of the site; • Extreme ease of operation; • Sophisticated expert control that also had to be transparent and easy to understand. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware System Platform. Results: •The implementation of corporate standards; • A new roadmap for future projects; • A state-of-the-art control system with best support and training infrastructure; • Greatly improved alarming – ensuring safety and logging the triggers; •The right information allows the right people to improve plant performance even when not on site; • Identification of bottlenecks (e.g. problems with the discharge dilution density); • Full remote support and fuzzy logic rule changes promote rapid improvements. 95
  • 95. Johannesburg, South Africa - In 2008,AngloGold Ashanti produced 4.98 million ounces of gold from its operations – an estimated 7% of global production – making it the third largest producer in the world.The company has 21 operations and a number of exploration programmes in both the established and new gold-producing regions of the world. Geita Mine, based inTanzania, is one of AngloAshanti’s production site. Geita first came into prominence as the site of a German colonial gold mine. A German gold prospector discovered the mineral in the early 1900s in the hills surrounding modern-day Geita town. This and other discoveries triggered a gold rush in the surrounding area, attracting German and native prospectors alike.The colonial government established a mine to exploit ‘Bismarck Reef’. Mining activities significantly declined, however, when Germany ceded control of its colonies to the British after their defeat inWorldWar I. Geita regained its prominence in the mid to late 1990s when theTanzanian government opened the mineral sector to foreign investment. A number of medium to large-scale mining houses, including Ashanti and Anglo American, conducted extensive exploration activities in the surrounding areas. The most significant outcome of these developments was the construction of the open-pit Geita Gold Mine, now owned by AngloGold Ashanti and the largest gold producer inTanzania. The deployment of plant and technology at remote sites in Africa is prone to logistics complications, delivery delays and support problems yet; AngloGold Ashanti’s Geita Gold Mine inTanzania is becoming a model of productivity in spite of these challenges. Background In 2006, decreasing production at the mine prompted AngloGold Ashanti to investigate and to make some hard business decisions.“The loss of skills at all levels throughout the process plant necessitated the implementation of automated control as far as possible to reduce variability and increase control expertise,” says Corné Lourens, Metallurgical Manager at Geita Mine. AngloGoldAshanti decided to call in system integrator SystemsAnywhere who had previously successfully addressed such problems for the company. “One of the first things we found was a control system installation that required significant improvement in order to handle the higher level of automation that the client was looking for,” says Systems Anywhere MD, AndréVuilleumier.“Some areas, like switch gear configuration, did not conform with AngloGold’s normal practices; an example in this plant was that a running motor was shown in red because it indicated a hazard but a stopped motor was green because it was in a safe mode.This contradicted Anglo’s normal standard indicators. With the skills shortage and high staff turnover the mining industry is experiencing, a standardised control philosophy would be key to consistent control and smoother operations.” While upgrading the control system and improving the SCADA, the project goals included: • Applying the corporate standard; • Standardising the control philosophy; 96 ActiveFactory software, InTouch HMI, Wonderware System Platform. Mining Figure 1: Geita Gold Mine system topology.
  • 96. • Improving the alarming and alarm logging for analysis; • Maintaining a history of production data; Providing for real time and scheduled reporting and the production of those reports; Implementing an Expert System based on fuzzy rules to reduce process variation and improve production. This was to be implemented using the latest technology while also providing for a maintenance plan and 24/7 support of the control system software in spite of the remoteness of the site. Solution Implementation The software solutions chosen for the Geita Mine included an Expert System to be developed by Systems Anywhere which would run with Wonderware Information Server, ActiveFactory software as reporting tool, InTouch HMI (Human Machine Interface) andWonderware Historian, all hosted byWonderware System Platform, based on ArchestrA technology. Seventeen Allen Bradley PLCs would be upgraded to cope with the new environment. “In order to make sure the customer got what was needed and to clarify the system design, we spent a lot of time on the User Requirement Specification,” says Vuilleumier.“We addressed everything from colour coding to access levels and implementation deployment schedules during planned maintenance stops to avoid unnecessary downtime.This was followed by a thin-slice simulation which was approved by the client.”Part of the design was to keep all display screens as uncluttered as possible while providing operators with the drill-down facilities necessary to view any level of detail.“This is especially true of the alarms,” saysVuilleumier.“With ArchestrA technology, alarm groupings and the alarm tree are automatic and we only show the alarms that are relevant to the section being monitored, such as the ball mill. Then, using a Pareto chart, only the top ten alarms that must be serviced are displayed and the system logs who acknowledged each alarm. Previously, the unscreened flood of alarms meant that they were largely ignored.” According toVuilleumier, a discipline whereby the maintenance team effectively and regularly attends to the top three alarms in the Pareto chart can result in significant improvements in plant productivity. Details on analogue alarms and values can be accessed using the same drill-down facility and performance trends can be examined through historical analysis to help predict potential problems on various items of plant – a key feature when spares availability is limited because of the remoteness of the site. Expert System An expert system can be defined as an operator who is always present, adheres to a control philosophy and maintains it at all times. In this case, such an expert operator needs to monitor the mill load, mill feed, power consumption, trends, etc. and then make a decision on whether to increase or decrease the input feed rate. In other words, this is a multi-variable control system which is quite different from the standard PID configuration. The Expert System takes over the responsibility of changing the set points from the operator and brings the mill to peak performance by: • Filtering the process variables individually through a moving average and checking them against their parameters; 97 ActiveFactory software, InTouch HMI, Wonderware System Platform. Mining Figure 2: InTouch HMI screen showing a ball mill gearbox’s lubrication details (left) and the view from inside the ball mill powered by the two 4MW motors shown in the graphic.
  • 97. • Comparing the result of each variable against the rules that are stored in the database and analysing the result to determine whether the set point needs to be increased or decreased; • Applying a time interval that determines how quickly it needs to react to the rule to ensure that production is kept consistent. It’s important to bear in mind that, in this environment, quick reactions times are essential but then processes need some time (10 to 30 minutes) to settle before any further corrective action is taken. “One of the benefits of this approach is its transparency and simplicity,” saysVuilleumier.“Complicated mathematics could be difficult to manage at site level whereas the fuzzy-based rules are more easily traced so that operators can understand the control philosophy of the system.” Information Delivery TheWonderware Information Server facilitates the aggregation of large amount of plant data into highly informative production reports tailored to AngloGold Ashanti corporate requirements.This allows management to access the information from site and contribute towards improving their performance.TheWonderware Information Server is integrated with the company’s existing IT infrastructure and web portals and has helped connect plant personnel so that they can access the entire plant record. Lab data can be manually entered when results are received and it is synchronised in theWonderware Historian at the time the sample was taken.“The Wonderware Information Server gets the right people the right information at the right time so that they can improve plant performance even when not on site,” saysVuilleumier. Individual users at Geita Mine have been assigned access to different views/areas beyond their normal scope to allow them to do their jobs more effectively. Displays include KPIs, production reports, trends and published InTouch screens and any information is available in one or two seconds.“Reporting options are unlimited,” continuesVuilleumier. Benefits The project spanned 12 months and the changeover occurred on a live plant during maintenance shutdowns. Realised benefits include: •The implementation of corporate standards; • A new roadmap for future projects; • A state-of-the-art control system with best support and training infrastructure; • Greatly improved alarming – ensuring safety and logging the triggers; •The right information allows the right people to improve plant performance even when not on site; Identification of bottlenecks (e.g. problems with the discharge dilution density); • Full remote support and fuzzy logic rule changes promote rapid improvements. “The production rate of the plant will benefit significantly from the upgrade,” addsVuilleumier.“Other AngloGold Ashanti sites have benefited similarly in the past and by identifying the bottlenecks at Geita, we are aiming to improve recovery time and throughput.” This document was realised thanks to the support of: AndreVuillemier, Systems Anywhere cc. 98 ActiveFactory software, InTouch HMI, Wonderware System Platform. Mining Figure 3: Expert System in action.The set point to the feed belt (yellow) ensures optimal mill performance while the ability to predict overloads allows the system cut back on feed before they occur (light blue and green).
  • 98. Industry: Mining Assmang Limited www.assmang.co.za “The standards enforced by Wonderware System Platform are allowing us to describe plant objects and their behaviour to reflect our experience and needs.” Marius Malan, Control Systems Supervisor,Assmang ‘Proof of the pudding’ in action at South Africa’s newest iron ore mine byWonderware Southern Africa Goals: •The monitoring of the new mine’s processes and production infrastructure. Challenges: • Fast track implementation in a massive greenfields project that included nothing less than the creation of a mega iron ore mine from the ground up. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware System Platform. Results: •The definition and enforcing of standards means that less engineering effort will be involved in the mine’s planned extension phases; • ArchestrA technology provided a multi-user development environment that allowed engineers to focus on complex applications rather than low- level operations. 99
  • 99. Johannesburg, South Africa - Assmang Limited is a South African company that supplies raw material to the world’s steel mills and alloy plants. Most of the group’s production is exported to the Far East, Europe and the USA. Originally namedThe Associated Manganese Mines of South Africa Limited, the company changed its name to Assmang Limited in 200. Assmang, which is owned equally by African Rainbow Minerals and Assore, currently has three operating divisions structured to handle its three commodities of chrome, manganese and iron ore. The Khumani iron ore mine is situated in the Northern Cape Province of South Africa and close to Sishen.Assmang’s Khumani iron ore mine is an ambitious undertaking by any definition. Completed in just two years from a foundation of Kalahari sand, Khumani is well on the way of becoming a principal player on the global and competitive world of primary metal production. Background Assmang’s new Khumani iron ore mine is situated in the Northern Cape Province of South Africa and close to Sishen.The Khumani deposits are among the best iron ore resources in the country in terms of quality and quantity. Based on current reserves, a new mine producing 8,4 million tons annually would have a life in excess of 40 years and at double that capacity, a life in excess of about 25 years. By any standards, the Khumani mine is a gigantic project. Starting in June 2006 with a budget of R4 billion, 60 000 cubic metres of structural concrete, 10 000 tons of steel, 3250 tons of plate work and 650 kms of instrumentation and electrical cabling were forged together to form this mega iron ore mine in just two years. The Khumani mine project was to be implemented in two phases: • Phase 1 was to be completed in September 2008 and would have a capacity of 8.4 million tons of iron ore per year. Phase 1a, to be completed in December 2008, would have a capacity of 10 million tons per year; • Phase 2 will have an annual production level of 16 million tons and is scheduled for completion in late 2010 / early 2011; • A possible further expansion to 22 million tons per annum is presently at the feasibility study stage. The iron ore is mined from a series of open pits by conventional drilling and blasting before being loaded onto trucks for hauling to the primary and secondary crushers. From there, the ore is 100 ActiveFactory software, InTouch HMI, Wonderware System Platform. Mining
  • 100. transferred by conveyor to stockpiles ahead of the beneficiation plant.The run-of-mine ore is stockpiled on blending beds in two categories,‘on-grade’ and ‘off-grade’. The on-grade ore is crushed, washed and graded according to four size categories.The off-grade ore goes through an identical crushing, washing and screening process, followed by a jig beneficiation plant to match its chemical composition with client specifications.There are 8 Geoscan on-line analysers installed at critical locations in the plant to monitor the chemical composition of the ore in real-time, so that immediate remedial action can be taken if the ore deviates from the chemical grade requirements. Products are stockpiled ahead of a rapid load-out station, which has the capability to load 342 x 100- ton wagons in 8 hours – that’s one 100-ton wagon every 90 seconds. From there, the product is railed 860 kms to the port of Saldanha Bay for export. Solution Selection DRA Mineral Projects were appointed as the Managing contractor for this project and EPCM contractor for the plant and infrastructure. DRA Mineral Projects is an engineering company that specialises in project management, engineering design and implementation and has implemented successful projects on five continents. DRA appointed system integrator Iritron for the Wonderware System Platform’s implementation portion of the project. Iritron was actively involved in the systems engineering, instrumentation design and PLC control systems aspects of the scheme. This was a natural choice since African Rainbow Minerals and Assmang have standardised on Wonderware industrial automation solutions for all their SCADA, historian and plant web portal requirements and Iritron is aWonderware ArchestrA-certified system integrator that has providedWonderware solutions and support to Assmang since 1999.“To effectively monitor this huge complex, we implemented Wonderware System Platform which is based on ArchestrA technology and includesWonderware real-time Historian, theWonderware Information Server web portal,ActiveFactory software, real-time production performance analysis and reporting software and InTouch HMI (Human Machine Interface) for the SCADA/HMI applications serving some 44 000 I/O tags,” says Iritron director Johann Pienaar.“In addition, we used theTopserver I/O Servers from SoftwareToolbox to communicate between the PLCs and the System Platform as well as MDT Software’s AutoSave for the change control management of all 63 Allen-Bradley ControlLogix PLCs.” “These solutions were chosen to give us comprehensive data analysis facilities so that we could check production status and identify potential problems at any time,” says Marius Malan, control systems supervisor,Assmang. “We also need continuous operation without loss of control or data as well as web access facilities and links to our planning and ERP systems. Most importantly, it all has to work through a user-friendly and intuitive operator interface. But these are all things we need to do now.This is a brand-new mine with a long future and we will need to adapt production to meet with market demands.That means we’ll have to expand the system as and when required and we’ll also have to do it quickly and at minimal cost.” 101 ActiveFactory software, InTouch HMI, Wonderware System Platform. Mining Figure 1: Part of the system topology at the Khumani Mine.
  • 101. System Implementation Allowing for the expansion of systems at minimal cost is a cornerstone of ArchestrA technology and one of the ways this happens is through the development of standards. Standards allow companies to define, apply and enforce their engineering criteria so that everyone works from the same page. Standards also mean that plant objects are built from templates and that changes to a single master template can be propagated to every instance of that object throughout the plant. “The standards enforced by ArchestrA technology are allowing us to describe plant objects and their behaviour to reflect our experience and needs,” says Malan.“Being Assmang standards, they reflect our best practices and can be used by other companies in the group.The enforcement of standards ensures that all future development conforms to the norms already developed and this will save engineering time in the future, especially with the planned extensions to the plant.” Standards do not only apply to plant objects but also to the whole plant and to integration with other disciplines in the company. One of the key standards that help businesses build a coherent organisation is ISA-95.“Khumani’s plant model is based on the ISA-95 standard which was facilitated byWonderware System Platform and its best practices guide supplied by Wonderware Southern Africa,” adds Pienaar.“This standard was implemented and adhered to throughout the project and will greatly facilitate integrating the system’s information with Assmang’s planning and ERP systems.” Another importantWonderware System Platform attribute that safeguards expansion at minimal cost is that of scalability.At Khumani, they know they will have to double their capacity in two years and, in ordinary conditions, this could mean some expensive system rework.“When the time comes to expand the system, the initial work done on standards means that defining new capability will be a matter of hours rather than weeks or months,” says Pienaar.“In addition, Wonderware System Platform has been proved to handle more than a million I/O tags and we’re currently looking at (only) about 44 000.This, together with a self- configuring historian, makes system expansion painless.” Assmang’s Khumani mine, a major contributor to the company’s financial well-being, can’t afford unplanned production delays during its lengthy and productive life.The mine has to produce quality products that will be accepted worldwide in an extremely competitive market and to do that, it needs industrial information and automation equipment equal to the task. “Wonderware System Platform’s management of dual redundancy procedures not only guarantees delivery of data to the Historian but has saved us a significant amount of complex software engineering to resolve this 102 ActiveFactory software, InTouch HMI, Wonderware System Platform. Mining Figure 2: Load-out stacking and Load-out mimic (dual screen).
  • 102. critical issue,” says Malan.“In fact, we no longer think ‘redundancy’ but rather of decisions that have to be made given the wealth of available information – in other words, forget the technology and focus on the business.” Apart from standards, scalability and system availability, Assmang needs a few more key attributes from a system in charge of one of its primary wealth-creating facilities and these are security and architectural freedom – which don’t mean much if said quickly but are key to versatility and freedom of choice. “In a situation such as ours, it’s important that only authorised personnel has access to various levels of the system to make changes to set points and other parameters,” says Malan.“WithWonderware System Platform, security and alarming are uniform across the entire system and we don’t have to make provision for discrete sub-systems. Of equal importance is our ability to change our mind with respect to the structure of our system and its interaction with others. ArchestrA technology gives us that choice. For example, we had to integrate with a number of third party stand-alone InTouch HMI applications incorporated into the Metso crushers, the Bateman load-out station, a QMastor stockpile management system and a CCLAS LIMS system.Well, it all just ‘happened’”. Conclusion “For us, the most significant aspect of this project was that ArchestrA technology gave us a multi-user development environment that allowed us to design, develop, implement and maintain a large project in one year,” says Pienaar.“Wonderware System Platform’s integrated development environment gave us the tools to develop complex applications without bothering unnecessarily about the details of interfacing with PLCs at one end of the spectrum and ERP systems at the other while providing the functionality to do both.” From the start,Assmang’s Khumani mine is a winner, not only in terms of its rich deposits but also in terms of how it will process them.Today, no enterprise can survive without efficiency and a major contributor is how well processes can be measured and controlled.Wonderware System Platform will be providing Khumani mine’s managers and operators the plant intelligence they need for efficient operation far into the future. This document was realised thanks to the support of: Johann Pienaar, Managing Director, Iritron. 103 ActiveFactory software, InTouch HMI, Wonderware System Platform. Mining
  • 103. Industry: Oil & Gas Chevron Oronite Company LLC www.chevron.com/products/oronite/ Wonderware System Platform makes it easy to connect to an ERP application while monitoring the production of additives for oil and gas byWonderware France Goals: •To implement a SCADA system for a new additive production unit; •To facilitate information sharing between shop applications and the SAP ERP application; •To be able to use thin clients to connect to the SCADA servers; •To determine standards that make it easier to reuse and update applications. Challenges: • Adding different types of equipment to the ERP application; •Taking the terminology used up to this point and standardizing it; • Meeting very short implementation deadlines; • Adopting the ISA-95 standard to define data sharing between the shop floor and the ERP application. Wonderware Solution: • InTouch HMI forTerminal Services; •Wonderware Equipment Operations Module; •Wonderware System Platform. Results: •Terminology for different products and measurement units were standardized; • Information sharing between the ERP application and production units no longer require manual intervention; • Launching a new product and adding new items is done simply without jeopardizing the existing product; •Through the object concept, modifications to an object are immediately transferred to all of the graphic displays, enabling us to save a significant amount of time compared to what was being done until now. 105 “We were looking for a SCADA system that would be easy to connect to our ERP application and we also wanted to implement the ISA-95 standard.The Wonderware System Platform meets our expectations.The capability to connect to thin clients and create objects also weighed in this solution’s favor...” SergeTalleux, Director of the industrial IT department at the Gonfreville site (France). “We were looking for a SCADA system that would be easy to connect to our ERP application and we also wanted to implement the ISA-95 standard.The Wonderware System Platform meets our expectations.The capability to connect to thin clients and create objects also weighed in this solution’s favor...” SergeTalleux, Director of the industrial IT department at the Gonfreville site (France).
  • 104. Gonfreville l’Orcher (Le Havre), France – Upon entering the vast chemical manufacturing site in Gonfreville l’Orcher (France), a stone’s throw away from the port of Le Havre, it is easy to become disoriented.The simplest way to maintain your bearings in the factory of the Chevron Oronite Company is to think of it as theVatican! Both places have a similar surface area (54 hectares instead of 48) and population (approximately 650 people); of course, the comparison ends after these geographical similarities. Chevron Oronite is a subsidiary of the Chevron Corporation, one of the largest oil companies in the world (in the United States it is second only to Exxon).The company specializes in the production of additives for fuels and lubricants. It is due in large part to these additives that you can make it almost the entire way across France on one tank of gas and drive 40,000km between oil changes.A production volume of 300,000 tons per year makes the Gonfreville l’Orcher factory one of the company’s largest manufacturing units, along with Oak Point (United States) and Singapore, which has four, more modest sites.These three production sites are able to manufacture all of the core products in the company’s portfolio (there are approximately thirty, which break down into more than 600 products). However, their primary role is to meet the needs of the area in which they are located (the Gonfreville l’Orcher site basically covers the markets in Europe, Africa, and the Middle East). Each geographical area has its own sales force and significant autonomy. This autonomy exists even when it comes to technical choices.However,certain decisions are made at the corporate level,and can have a significant local impact. This is precisely what happened when corporate management decided to deploy integrated ERP (Entreprise Resource Planning) management software from SAP on all of the manufacturing and commercial sites. The objective, as it always is in this type of decision, was to improve the management and control of all of the company’s operations, costs and deadlines.To do this, the ERP application sends manufacturing orders to the equipment concerned with the specifications to be applied. In turn, supervisors provide the ERP application with manufacturing reports, raw material volumes, finished product quantities, and inventory status. Two Simultaneous Operations: Connecting to an ERP System and Implementing a New SCADA Application The announcement about the implementation of an ERP application was made at a time when the factory also had to set up a new reactor. “This was a lot to handle at once!We realized how beneficial an ERP application would be for the company; we had studied the entire situation, both existing applications and the new one to be put into place.We did this all on our own. Frankly, we have always developed our own applications and kept up with the state of the art in technology” stated SergeTalleux, director of the industrial IT service (seven people) in the new works department (which includes 250 people with numerous construction trades). If the site’s only need had been to connect the existing systems to the ERP application, the problem would have been approached differently. In this case, however, a new control application also had to be implemented, which prompted a higher, broader approach to the problem. In terms of hardware, it was quickly decided that a programmable logic controller (PLC) should be used because controllers were already part of the factory’s environment, which includes sixty controllers managing approximately 15,000 inputs/outputs. ISA-95, a Key Advantage for the Wonderware System Platform The remaining tasks were to choose the supervisory control software for the new equipment and to connect all of the control systems to the ERP application.This task was difficult given the factory’s previous experience in this area. A few years ago, a relatively basic ERP application was installed and the industrial IT department developed a program to enable communication between control systems and this ERP application. Guillaume Labadie, who is part of SergeTalleux’s team, and more specifically involved in ERP connection, has a bad memory of the experience: “The connection program that we had developed had several thousand lines! And it only included a few of our supervisory servers. In addition, it was a nightmare to 106 InTouch HMI forTerminal Services,Wonderware Equipment Operations Module,Wonderware System Platform. Oil & Gas
  • 105. maintain because for any new item to be manufactured (or an existing item to be modified), you had to make some sort of change to the program... It was out of the question to do the same thing again because we have better things to do than align program lines!” The SAP ERP application has brought with it a standard that has changed everything.This standard, the ISA-95 (known better under its former name, S95), began in the United States and is now a widely adopted international standard (ISO/IEC 62264 and Afnor NF62264, in particular).This standard has the major advantage of standardizing exchanges between the production system and the ERP application.“For the supervision of our new reactor, we decided to go in a new direction and use the latest in computer technology. More than anything, we wanted a software program that was compatible with ISA-95 because it guaranteed the simplification of exchanges between the control system and the ERP application.We were also looking for a solution that accepts the connection for ‘thin client’ workstations.And finally, and this was a very important aspect, we wanted a software program that enabled us to design ‘objects’. In our eyes, there was only one solution for all of these criteria: the Wonderware System Platform,” stated SergeTalleux. A Major Project – StandardizingTerminology To deploy theWonderware System Platform, the Chevron Oronite Gonfreville industrial IT team began by becoming familiar with the ISA- 95 standard. It consists of terminology and models that describe both the structural (products, materials, production facilities, and human resources) and operational (capability, production) aspects of the production systems used to support information sharing. It also defines data attributes and structures, production operation management models, and transactions between management and the shop floor (ISA-95 is continuously updated and will soon establish guidelines for storing production information). It is currently 400 pages.“It is well-structured and detailed, but as with many new standards, it takes a major effort to absorb it all.To better understand it, and to ‘pick out’ what was most suitable for our situation, our team attended a two-day training session on site given by the Control Chain Group (CGC). This help was very valuable to us”, commented Serge Talleux. Implementing the ISA-95 standard involved a major effort to standardize internal terminology.As is often the case on manufacturing sites with a long history, several different names and labels that mean the same thing emerge over the years, and several measurement units may be used to quantify one parameter. In addition to this standardization work, routines had to be created to calculate the parameters required by the ERP application.Thus, we had to create new counters that would enable us to upload all of the consumption information that we need to the ERP application.A previous decision to reduce the number of control systems installed on site (carried out by local engineering) had already led the industrial IT team to undertake a similar standardization project.Thus, having to develop ISA- 95 terminology and models was not a new experience for them. However, this work was no picnic either, recounts Guillaume Labadie:“We knew that it would take time, but not that much! But once everything is standardized, the connection between the Wonderware System Platform and the ERP application is very fast because the two databases have the same structure.And if we want to add a new model or parameter later, it can be done immediately, nothing is affected”. 107 InTouch HMI forTerminal Services,Wonderware Equipment Operations Module,Wonderware System Platform. Oil & Gas Figure 1: Quality test of lubrificant.
  • 106. Objects andThin ClientWorkstations, a Bonus for the SCADA System In choosing theWonderware System Platform, the simple connection with the SAP ERP application was not the only basis for our decision. Being able to work with thin clients was also one of our criteria; in particular, this enabled us to maintain a certain consistency between the two systems.To access information on the supervisory servers installed up to this point, the Gonfreville site is working with thin clients; in other words, very basic workstations, with no hard drive or operating system.This approach has the advantage of using more robust (no moving mechanical parts) and cost-effective workstations, which do not require updating. Wonderware already offered this option with Windows workstations.“We were delighted that the company expanded this option and that we can now use Linux workstations. In terms of update frequency and anticipated computer security, we will have a lot less work!” states SergeTalleux. Redundancy was also a strong argument for choosing theWonderware System Platform.To ensure high data availability, the data acquisition system natively integrates a redundancy feature using simple configuration.You can put some applications on one server and others on a second server. If one of the servers fails, the applications on the failed server are automatically transferred to the second server. And the supervisory feature of the platform?This is Wonderware software’s strongest suit! Gonfreville’s industrial IT department wanted to take the initiative in this area as well, as indicated by Oliver Godard, who focuses on supervision (SCADA):“We monitor technological developments, we wanted to progress to the object concept.Acquiring theWonderware System Platform enabled us to reach this next level.There too, we had to challenge ourselves because the object concept means a profound change in habits”.To do this, Chevron Oronite Gonfreville was able to count on skilled advice fromWonderware France, who “cautioned us against rushing forward with new software developments, and advised us to attend training session for our current products and to spend more time creating standards instead”. Advice followed to the letter, but which still created a few worries. SergeTalleux remembers:“Normally, when we develop supervisory applications, we obtain the first graphic displays very quickly. For a department director, this is reassuring because he sees that the work is progressing.With the object concept, it’s better not to think about it.You wait impatiently for months without seeing a single diagram! However, once the basic objects (valves, regulators, display devices, pumps, etc.) have been created, everything goes very quickly.” And in the long run, you save time. It is very easy to modify both the graphics and attributes (variables) of an existing object; modifications are immediately made on all of the display diagrams containing the object in question. In fact, even a child can create these supervisory displays. Olivier Godard remembers a high school student on a discovery internship was able to create block diagrams from the very first day! Normally with SCADA applications,an effort is made to not interfere with the procedures of the operators stationed in the control rooms.Here however, operators were directly involved in the improvements made to their control interfaces.The SCADA designers avoided the overuse of color on the screen displays.Instead,they used more neutral colors (dull even) and only used bright colors for important information so that it stands out better.Major work was also done on alarm display.Banners with endless lists of alarms are gone,and only the alarms used for the operator are displayed on the screen. The design of theWonderware System Platform supervisory system has also enabled Chevron Oronite Gonfreville to turn a new corner. This document was realized thanks to the support of: Chevron Oronite. 108 InTouch HMI forTerminal Services,Wonderware Equipment Operations Module,Wonderware System Platform. Oil & Gas Figure 2: Storage tanks.
  • 107. Industry: Pharmaceuticals, Chemicals Cambridge Reactor Design Ltd. www.crduk.com “InTouch HMI is a ready-made software solution that is easy to implement even for complex processes.This is a far cry from the traditional route of trying to write code using complex high-level languages.” Dr Bashir Harji, Managing Director, Cambridge Reactor Design Wonderware software improves integrated high throughput solutions and robotic platforms byWonderware United Kingdom Goals: •To create a homogenous machine visualization and vision system using robotic assistants for monitoring of downstream unit operations in the chemical and pharmaceutical industries. Challenges: • Cambridge Reactor Design had to find a way to streamline its design process, they needed a system that would communicate with various control and monitoring systems and thereby provide a solution that would be easier to implement, support and expand. Wonderware Solution: • InTouch HMI. Results: • Using a product-based solution,Wonderware InTouch HMI, Cambridge Reactor Design was able to integrate many disparate devices into one system, reducing business risk, development and support costs; • Standard solution for future applications. 109
  • 108. Cambridge, England – Cambridge Reactor Design (CRD) is a producer of integrated high throughput solutions and robotic platforms for the pharmaceutical industry and other businesses. CRD was founded in Cambridge in 1989 with the objective of producing customised engineering projects for Cambridge and other UK universities. Services were expanded to UK and European companies when CRD became a key developer of high throughput technology for Shell International and AvantiumTechnologies.Today, CRD is firmly established and has a growing global customer base that includes the Energy Research Centre of the Netherlands, Dow, ICI, Nestlé,The Royal Institution of Great Britain, andTotal. Machine vision is a good example of combining state-of-the-art technology, where the latest improvements in camera capabilities, including memory and resolution, offer research chemists access to new analytic methods for improving product quality. CRD realised new applications of intelligent vision meant that investigations of downstream processing operations within the chemical industry would become more manageable. The four most fundamental downstream processing operations in the pharmaceutical and chemical industries are filtration, extraction, distillation and crystallisation. Of these, both filtration and extraction are amenable to machine vision using the Robot Assistant system manufactured by CRD. Its IntelligentVision capability is made possible through the application of InTouch HMI (Human Machine Interface) software. “Our basic philosophy is to make our clients’ lives as easy as possible by offering a multidisciplinary skill-set that deliver solutions,” says Dr Bashir Harji, CRD’s Managing Director. A Robot Assistant for Repetitive Processing Operations Robot Assistant is a mechanical organic chemistry device capable of performing a variety of repetitive processing operations.The unit works 24x7, has a load carrying capability of 3kg, moves repeatedly and reliably to within 0.1mm, recognises motion and takes video images. Machine vision is used in a variety of ways within the system. It captures images of key procedures and generates information on rate of change.The data gathered is then used for critical real-time decision making. A Comprehensive Solution for Integration and Control Wonderware InTouch HMI (Human Machine Interface) is a comprehensive solution used in the Robot Assistant. It easily integrates with all the required input/output hardware. It offers a guaranteed method for controlling articulated robot arms and enables users to interpret their downstream process using a variety of graphical representations. For example, variability in temperature, time, mixing, pH control and solvents used in the downstream process can is displayed visually with the intelligent vision elements fully incorporated. Dr. Harji points out that the applications created using InTouch HMI are Federal Drug Administration 110 InTouch HMI.Pharmaceuticals, Chemicals Figure 1: Machine vision.
  • 109. (FDA) compliant. It will recognise information supplied from the Robot Assistant’s log, and is designed to be tamper proof.The log is fundamental to the system because it tracks the robot and what it is doing at any moment in time, giving it a secure audit trail. Method ofWorking “InTouch HMI is installed in the master computer.The slave computers control the intelligent vision systems and analytical sample preparation workstations,” says Dr Harji.“The workstations take samples and offer the right level of dilutions so the samples are ready to be analysed by the appropriate analytical system e.g., gas chromatography (GC) or high pressure liquid chromatography (HPLC).” “InTouch HMI is a ready-made software solution that is easy to implement even for complex processes.This is a far cry from the traditional route of trying to write code using complex high-level languages,” says Dr Harji. “Also the availability of intelligent icons to reflect the ongoing performance of a real-time robotic process makes it easy for users to interpret where they are during the course of continual processing.All that is needed is one Ethernet connection to the control system; one cable does it all.” UsingWonderware software with CRD’s hardware and machine vision application makes downstream processing operations in the chemical industry more manageable. Wonderware software facilitated CRD’s robust and highly innovative approach to solving difficult issues in the chemical and pharmaceutical industries. This document was realized thanks to the support of: Cambridge Reactor Design Ltd. 111 InTouch HMI.Pharmaceuticals, Chemicals Figure 2: InTouch HMI screen. Figure 3: Robot in action.
  • 110. Ample and affordable power to 2 million people. T H A N K S T O Powerful Open Wonderware The powerful and openWonderware System Platform software enabled a Pacific Northwest power utility to supply electricity during peak hours and help them avoid skyrocketing wholesale prices.Forty megawatts of power delivered to millions of homes and businesses with just a click of a mouse.Put some POW into your operation. GetWonderware.www.wonderware.com ©2008 Invensys Systems, Inc. All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners.
  • 111. Industry: Power, Energy, General Process Manufacturing Bodycote plc www.bodycote.com “Since getting Wonderware, we’ve noticed a decrease in product run-wrongs and parts that need re-processing.” Shawn Crawford, Plant Engineer, Bodycote HIP Wonderware Software Helps HIP Plant ProfitThrough Improved Process Control and Proactive Maintenance byWonderware Goals: • Improve control and consistency of furnace temperatures; • Enact a proactive maintenance program to save equipment costs; • Provide better tools to increase operator efficiency and accuracy; • Reduce product re-runs. Challenges: • Existing data system did not provide historical information or useful reports; • Uniformity of temperatures difficult to control between furnace units of different sizes; • Maintenance scheduling based on calendar dates, not run times or performance data. Wonderware Solution: • ActiveFactory software; • InTouch HMI; • SCADAlarm software; •Wonderware System Platform. Results: • Proactive maintenance program enabled steady productivity and better planning of capital expenditures; • Recipes have increased run-over-run product consistency and customer satisfaction; • Operator efficiency improved; fewer operators accomplish more work with better accuracy; • Reports provide more visibility and help facilitate better decision making. 113
  • 112. London, Ohio – No doubt, most everyone in manufacturing today knows what it feels like to be under intense pressure. But how about 30,000 pounds per square inch (psi)? For Bodycote, a plant that provides hot isostatic pressing (HIP), that’s business as usual. The plant processes parts for jet engines, gas turbines, automotive assemblies, medical components such as replacement joints and other items which must be made as strong as possible. In the HIP process, the parts are subjected to extreme heat and pressure, which makes them less porous and more resistant to stress fractures. Control is Critical At Bodycote, multiple furnace units serve the plant. Customer parts are placed in a furnace, which is filled with argon gas.Then the unit is pressurized and heated from room temperature to approximately 2,000ºF, which takes about two hours.This high temperature is maintained throughout the process, then the furnace is cooled and the parts are removed and inspected. HIP quality depends on consistency and repeatability. Bodycote’s customers rely on the plant to provide a uniform process, so discrete batches of product show consistent strength and density characteristics, run after run. Keeping the plant’s units in top condition is very important. If a furnace were to malfunction, Bodycote would be forced to re-run the batch of parts.Worst case, Bodycote might have to replace the parts completely, which would have a severe effect on profitability. Another factor is that Bodycote’s furnaces are physically different in size. Each unit heats and cools on a unique schedule, which must be controlled carefully in the HIP process and supervised by plant operators. Additionally, Bodycote has to monitor its use of argon gas carefully.The pumps and valves on each unit control the pressurization of the gas, which is very expensive. So maintaining the units in good working condition to prevent leaks is key to saving money. Strengthening the System These challenges – providing consistent processes, maintaining the varied equipment and conserving resources – mean that Bodycote is always on the lookout for the right operations management software solutions that can help the company succeed. The plant also needs these systems to help maintain its ISO 2001 certification. Wonderware Cincinnati, the regionalWonderware distributor, worked with American Isostatic Presses, a localVAR and System Integrator, to recommend additions to Bodycote’s data systems. Their goals were to help Bodycote implement a preventative maintenance system, get improved visibility to operations data and increase operator efficiency and accuracy. Shawn Crawford, Bodycote Plant Engineer, appreciates the teamwork that went into the effort,“Everyone did a great job of using theWonderware software to produce a user-friendly system that’s quite outstanding.” 114 Figure 1: Bodycote control room. ActiveFactory software, InTouch HMI, SCADAlarm software, Wonderware System Platform. Power, Energy, General Process Manufacturing
  • 113. A BetterWay to Manage Maintenance With the newWonderware software, Bodycote made a significant change to the way it schedules maintenance for the furnace units and supporting pumps, valves and components. Before, the plant managers used a calendar to plan upcoming maintenance. For instance, vacuum pumps were estimated to need repair or replacement every six months.At that time, the pump would be taken off-line for inspection, regardless of whether it exhibited any signs of wear and tear or sub-standard performance. But withWonderware System Platform and InTouch HMI (Human Machine Interface), accurate real-time data on the operation of all of Bodycote’s equipment is available.This has enabled operators to monitor valves, pumps 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.TheWonderware 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. Superior Process, Superior Product Before addingWonderware 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 theWonderware 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, andWonderware SCADAlarm™ software alerts operators to equipment that needs attention, or triggers an automatic shutdown if a pre-determined threshold is exceeded. Best Feature: User Interface When asked, Crawford is quick to point out that the most important feature of the newWonderware 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 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 that 115 Figure 2: InTouch HMI screen showing manufacturing process. ActiveFactory software, InTouch HMI, SCADAlarm software, Wonderware System Platform. Power, Energy, General Process Manufacturing
  • 114. operators can learn how to best react. And these exercises can be accomplished without taking the plant systems offline, so there’s no impact on productivity. Versatility under Pressure TheWonderware 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 theWonderware software’s capabilities. He hopes to implement new ideas he has been developing for utilizing 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. This document was realized thanks to the support of: Wonderware Cincinnati. 116 Figure 3: Bodycote plant floor showing control of kiln. ActiveFactory software, InTouch HMI, SCADAlarm software, Wonderware System Platform. Power, Energy, General Process Manufacturing
  • 115. Industry: Power, Energy Eskom Holdings Limited www.eskom.co.za “Through the Wonderware solution platform and ArchestrA technology, the PDS system has succeeded in bringing the plant automation and information technology worlds within generation together.” JohnViljoen, Corporate Consultant for Generation Business Engineering, Eskom Eskom’s PDS project is helping the company see the light! byWonderware Southern Africa Goals: •To merge the plant information world with the company’s information technology environment; •To turn plant data into useful information that would be openly available; • Improved performance indication; • Improved incident response. Challenges: • Structuring a data model in compliance with Eskom’s Generic Plant Breakdown Guide and the ISA-95 standard; • Conforming to Eskom’s structure adjustments half way through the project. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: • Real-time plant data; • Standardization facilitated the reduction of engineering effort, rapid adaptability to changes and elimination of disparate information solutions; • Significantly highlighting the benefits that can be derived from open access to real-time and useful plant information; • Closer relationship between plant and IT and the different needs of both disciplines; • Numerous applications are now using the PDS data and all the information is available anywhere to any qualified person; • PDS is a business enabler that improves the ability of people to conduct their business more effectively. 117
  • 116. Johannesburg, South Africa - Eskom Holdings Limited is a vertically-integrated operation that generates, transmits and distributes 95% of the electricity used in South Africa.The company is among the top seven utilities in the world in terms of generation capacity and among the top nine in terms of sales. Eskom Enterprises, the wholly-owned subsidiary of Eskom, together with its subsidiaries, serves as a means by which all the non-regulated activities of Eskom, both inside and outside South Africa, are carried out. Eskom Enterprises’ core lines of business are infrastructure development, energy business operations, specialised energy services and the pursuit of key opportunities in related or strategic businesses, such as information technology and telecommunications. The operations of Eskom are located in South Africa. Eskom Enterprises has operations on the African continent, with its head office being located in Johannesburg, South Africa and other offices in Uganda, Nigeria and Mali. Oil and electricity are the 21st century’s energy hot potatoes.At the start of 2008, South Africans had a small taste of what life without electrical energy would be like - intolerable.That’s why Eskom is investing a great deal of energy, finance and technology into understanding the behavior and status of its complex grid and generation facilities on a national level with an initiative that is known as the Plant Data System or PDS. Background - Plant Information Issues “The drive for increased reliability and efficiency of operation requires better plant information in real time,” says JohnViljoen, Corporate Consultant for Generation Business Engineering at Eskom.“The plant condition is deteriorating due to ageing which prompts the need to get a better handle on condition monitoring information and since electricity supply must match the demand at all times, accurate production information is critical.” Traditionally, process automation solutions provide operating information to help operators manage their plants more effectively but, according to Viljoen, this is only one aspect of the information spectrum necessary for Eskom to be more effective. “Engineers, for example need asset information for asset lifecycle management. It’s not as if we lack the data, we have masses of it at plant level but useable information is not readily accessible.” InformationTechnology Issues While Eskom’s IT infrastructure focuses on improved business performance and efficiency, it is nevertheless a transactional environment not suited to the real-time world of plant production.“As far as IT is concerned, plant control systems are black boxes that we don’t understand,” saysVicki Naudé, Senior Advisor for Generation Information Management at Eskom. “Our integration and storage methods focus on transactional systems in a fragmented and outsourced IT infrastructure that isn’t suitable for the real-time plant environment. So the intention is to broaden the scope of IT to include plant information while providing for the necessary levels of security.” This left Eskom with the challenge of managing the escalating complexity of merging its plant 118 InTouch HMI,Wonderware System Platform.Power Figure 1: Eskom’s “shop floor”. Each of the coal-fired units typically consists of a boiler and a 600MW generator - although this can vary.
  • 117. information world with its information technology environment. Project Objective The Plant Data System project goal is to make plant data openly accessible, in a standardised format, to every area of the business that can use it to improve the bottom line. In order to do this, plant data would have to be readily transformed into useful plant information in order to meet the specific information needs of personnel at different levels. Hopefully the more effective use of plant information would have ultimately resulted in more refined performance indicators, better plant optimisation and better resource allocation. Plant data could also be delivered to specialist engineers in order to improve incident response. Project Requirements Any solution must meet the need of real time information to support both operational and business decisions while also addressing the issue of standardisation.“Each power station is unique and in the past, there had been no attempt at standardisation so that they all had different control and operational systems,” saysViljoen.“Since the natural tendency is for people to improve their information systems, we didn’t want a proliferation of different solutions with each power station implementing their own ideas. So, a primary requirement was standardisation that would eliminate duplication of engineering effort, interface development, solution deployment, etc.” Eskom would select a solution based on the least cost but that would provide the required functionality.“Such a requirement would indicate a centralised solution rather than the far more expensive alternative of multiple and diverse information systems,” addsViljoen.“Another advantage of basing solution selection on cost is that one of the major cost components of such systems is licensing, which is based on tag volume. By purchasing half a million tags for the whole of Eskom, we spent significantly less than if each power station bought, say 50 000 tags of its own. So, according to our structure, buying technology that would meet these requirements was seen as establishing a platform enabling the various parts of the business to improve their performance. In other words, we have installed a business enabler.” Solution Selection Eskom issued an open Request For Proposal to the market and theWonderware solution was deemed to offer the best cost / functional performance ratio. The ArchestrA framework was ideally suited to the rapid deployment of a standardised solution across all the power stations and web based viewing enabled a cost effective method of managing a large number of simultaneous users.The combination of Wonderware System Platform,Wonderware Historian, InTouch HMI (Human Machine Interface) and theWonderware Information Server met all the specific requirements for real-time data management. Eskom selected ArchestrA-certified system integrator BytesTechnology Group because of the company’s track record of implementing large and small PDS-like solutions on-time and in budget, its existing knowledge of Eskom solutions and its numerous awards for the successful implementation of integrated ArchestrA-basedWonderware solutions. Plant Data System Project Description With the project goal of providing a standard platform in order to obtain Generation plant data 119 InTouch HMI,Wonderware System Platform.Power Figure 2: Topology diagram showing the relationship between head office (Megawatt Park) and power stations – only the Matla power station is shown here.
  • 118. via a single interface, Eskom structured the system as shown by the topology diagram in figure 2 (only Matla Power Station shown).“While each power station has its own Historian, we replicate the information we need at head office in a central Historian so as to minimiseWAN access,” says Naudé.“We also have a firewall between the business LAN and the process LAN for security purposes and to ensure that only the PDS has access to process data.” Eskom spent a lot of time and effort to structure the data model so that it would conform with Eskom’s Generic Plant Breakdown Guide and the ISA-95 standard, an exercise which would soon prove to be extremely worthwhile.“Halfway through the project, Eskom changed its structure and we had already built our (Wonderwre System Platform / ArchestrA) galaxy,” says Naudé.“Instead of a train smash, we were confronted with a simple drag-and-drop exercise before once again being on track.This could not have happened without a properly designed data model.” The design of master templates for such plant items as furnaces also greatly reduced engineering time and facilitated deployment since only specific attributes needed be changed to cater for different furnace types. The initial target for the PDS is 80 super users (ActiveFactory software) and 500 web users. Since the generic training on theWonderware components of the PDS would take approximately six weeks with the risk of users losing interest along the way,Wonderware Southern Africa structured a condensed three-day training course specific to the PDS. Since it was deployed, the PDS has been of such value that users have wanted more and motivated for the expansion of this valuable information commodity.Although the PDS is only part of Eskom’s overall information strategy, it is nonetheless the real-time portion that provides decision makers a vital window into the realities of their power generation initiatives. Realised Benefits • Real-time plant data is now a reality and available to anyone who can make best use of it; • Standardisation facilitated the reduction of engineering effort, rapid adaptability to changes and elimination of disparate information solutions; •The approach taken towards the PDS project was definitely cost effective and proved the economies of scale that can be achieved with the right solution; •The PDS project has significantly raised the visibility of the benefits that can be derived from open access to real-time and useful plant information; •The project has fostered a closer relationship between plant and IT and the different needs of both disciplines; • Numerous applications are now using the PDS data and all the information is available anywhere to any qualified person; • PDS is a business enabler that improves the ability of people to conduct their business more effectively. Conclusion Eskom bears an awesome responsibility – the continuation of our way of life - while its ‘shop floor’ consists of nothing less than Southern Africa. Eskom now has the tools to understand and control its vast and complex power generation machine and to improve the quality of life of more than 50 million people. This document was realized thanks to the support of: Vicki Naude and JohnViljoen, Eskom. 120 InTouch HMI,Wonderware System Platform.Power Figure 3:ActiveFactory software screen showing a typical 7-day load profile at Lethabo Power Station.
  • 119. Industry: Power, Energy S.T.E. Energy S.p.A. www.ste-energy.com Different Plants, Single Control Centralized management and control over intake works and hydroelectric dams enable reduced costs, increased efficiency and optimized production byWonderware Italy Goals: • Ensure quality, performance and efficiency of hydropower plants. Challenges: • Environmentally friendly plants; • Minimized operating costs. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware System Platform. Results: • Maximized energy generation; • Reduced maintenance costs thanks to preventive and scheduled maintenance. 121 “In order to build a unique and highly effective plant, we chose to collaborate with Wonderware, a specialist with high expertise in this sector, delivering products able to integrate innovation and ease of use.” Mario Arquilla, President and Managing Director, STE Energy
  • 120. Padua, Italy –With more than two hundred systems implemented over the past years in Italy and abroad, and with its branch offices located in various countries, STE Energy today is one of the major operators in the field of energy and plant engineering. STE Energy was established in 1995 in Padua, Italy. It develops, designs, builds and manages energy production plants, especially the hydropower type and electrical and thermotechnical systems, as a general contractor. It also builds wind, solar and biomass cogeneration systems and electric energy production, transport and distribution plants all around the world. Quality, performance and efficiency are the key factors in energy generation. Companies in this market constantly seek for solutions enabling to optimize production, by leveraging the latest technologies on the market and always keeping environmental issues into consideration. In this scenario, traditional hydropower plants, which in recent times were neglected in favour of apparently more efficient methodologies, are back in use and now developed according to innovative principles. STE Energy, based in Padua, specializes in this activity and deploys innovative hydropower plants on a global scale. “In order to be competitive on the international market,” explains Mario Arquilla, President and CEO, STE Energy, “it is necessary to offer solutions enabling to optimize the whole production process, providing measurable and demonstrable results. For this reason we chose to apply modern automation technologies even to hydropower plants, especially for production control and monitoring.” Leveraging Every Single Drop Traditional hydropower plants were based on big dams having high environmental impact and effective only if deployed on high discharge rivers. On the contrary, the current vision prefers run-of-river power stations, able to leverage even the smallest drops.This way it is possible to reduce development times, minimize environmental impact and, most of all, ensure high efficiency levels.The sum of the energy produced by different dams in succession is higher than the one produced by a single big plant. Power companys need to take into account administation costs in their total budget. Having dedicated operators in every single plant implies considerable costs, contrasting with the need to minimize expenses. Furthermore, some plants are situated in almost unreachable places, and determine high costs for moving operators. In the light of such requirements, STE Energy engineers chose to leverage a similar control technology as in the field of industrial automation: collecting all data locally from the different power plants and centralizing them in a single control point, where activities are automatically managed and supervised by specialized engineers. ‘Telemetry logic’, explains Arquilla, “provides producers with a highly efficient control system, delivering real-time 122 ActiveFactory, InTouch HMI,Wonderware System Platform.Power, Energy Figure 1: Inside hydropower view with a close-up of the alternator.
  • 121. operating data of every single component in the hydropower plants. In this way engineers can intervene accurately and timely to solve problems, avoiding unuseful interventions and optimizing activities.This opportunity is particularly useful in daily management and allows to optimize operator activities. In order to differentiate from the competition, we were seeking innovative technologies to provide our customers with a real competitive advantage. Finally, we evaluated the benefits offered by the MES technology, knowing that only a perfect knowledge of production processes could allow us to optimize our activity”. STE Energy chose to collaborate withWonderware, market leader in real-time operations management software. “In order to build a unique and highly effective plant,” continues Arquilla, “we chose to collaborate with Wonderware, a specialist with high expertise in this sector, delivering products able to integrate innovation and ease of use.” Preventing Failures The choice of investing in such an innovative technology is determined by the fact that STE Energy also takes care of maintenance activities. Perfect maintenance of power infrastructures, which need to work without interruptions, requires high competence levels both in practical activities, and in preventive actions. Operating only upon customers’ request, in fact, means always working in ‘emergency’ conditions, since interruptions in power production cause loss of income. STE Energy therefore chose to implement preventive and scheduled maintenance: “a similar method,” explains Arquilla, “has been adopted in the most innovative manufacturing companies and this is why we chose to apply it to our market.” All data collected in the control rooms of the single plants are sent to STE Energy headquarters in Padua and saved in real time in theWonderware Historian database, then constantly monitored through specificWonderware applications. These smart solutions enable to immediatley detect any decrease in performance and the presence of unusual conditions thanks to cross-comparisons of data. “In the most banal of cases,” continues Arquilla, “on equal discharge dams present a reduction in power generation. In this case, the supervisory system, which was programmed to optimize system efficiency, sends an alarm notification.The engineers can analyze the single values collected by the local monitoring systems thanks to the extremely intuitive graphic capabilities based on the HMI and SCADA systems, we developed by leveragingWonderware InTouch HMI capabilities.” This operating method allows STE Energy to undertake preventive actions, so that STE Energy experts are able to notify to local engineers the presence of unusual conditions, also indicating suitable intervention to restore the optimal situation. Simple One Click Historization All data which are collected and stored by Wonderware Historian allow you to know all the statistical and analytic data of specific streams and dams. Wonderware solutions allow to leverage such a huge amount of data in the best possible way, in order to optimize production activities. It is possible to know a river’s dispatch throughout the year, according to specific weather and environmental 123 ActiveFactory, InTouch HMI,Wonderware System Platform.Power, Energy Figure 2: Plant synoptic of teh turbine - generator group.
  • 122. conditions, in order to plan specific maintenance activities and to satisfy the demand in the different periods of the year. Furthermore, engineers are constantly informed about the amount of electricity produced according to weather and environmental conditions and the events that occurred with time. It is possible to immediately detect inefficiency causes, distinguishing problems connected with different kinds of failures. Always connected Leveraging industrial technologies for civil and geographically distributed works determined the need to exploit all the available telecommunications technologies. Data collected in the single dams must in fact be sent to the control room in real-time.And this could be a complex task, especially if there are no telecommunications networks. From this standpoint,Wonderware integrated solutions are the best solution to interface with any communications technology. This means that, in case there is no traditional telephone network, data can be exchanged via mobile phones, satellite or radiofrequency communications, thanks to the scalability of Wonderware management systems which, at an early stage, had been implemented only in the new plants.This way the project could start with low initial investment and pilot functions, then progressively expanding the control system according to the excellent results that were obtained. The constant monitoring of the activities in the hydroelectric plants enabled to optimize the efficiency, but also delivered an useful tool for the operators in the different control rooms. Operators are constantly informed about performance and real-time production of the single power plants, thanks to common handheld computers, with the possibility to analyze single values and historical data in detail. Energy looking into the future The availability of such an amount of data, which are automatically and efficiently processed, enabled STE Energy engineers to improve projects for new power plants. In the development stage, engineers can leverage a database containing all the data coming from dozens of plants on a global scale. “The information, processed byWonderware analysis tools, enables to understand the factors which allow maximizing efficiency and reducing maintenance costs – with the purpose of progressively improving plants, making them more and more efficient and reliable,” concludes President Arquilla. This document was realized thanks to the support of: STE Energy S.p.A. 124 ActiveFactory, InTouch HMI,Wonderware System Platform.Power, Energy
  • 123. Industry: Process Engineering Meteng Pty Ltd. www.meteng.com.au “We found enormous differences in data transfer and operator response rates with other systems, but we have not yet found any limitation on what we can do with Wonderware software.” Jim Groutsch, Managing Director, Meteng Pty Ltd Wonderware and Meteng Combine for Innovative 3D Process Modeling and Simulation System byWonderware Australia Goals: • Enable an accelerated design process so that plants can begin to generate income more quickly; • Provide an interactive simulation environment that saves time and money by testing plants and processes before they are constructed; • Facilitate more effective learning by enabling operators to make mistakes and practice responding to emergency or out-of-compliance conditions without negative consequences. Challenges: •The complexWalk-Through Interactive Simulated Environment (WISE) system has enormous power requirements and integrates Apple,Windows and Wonderware technology with very large, high- resolution displays; •The system had to be built with components that would ensure easy and cost effective expansion to meet the needs of many different clients. Wonderware Solution: • InTouch HMI; • InControl software. Results: • Improved system performance. Increased data transfer rates and response to operator interactions on the various systems that make up the simulation system; • Software platform enabled development of functionality Meteng required for its simulation systems; • Developers could concentrate on task of process modeling and simulation instead of focusing on complex program code; • Software offered opportunity for Meteng to develop methods enabling re-use and standardization, resulting in tremendous savings in engineering costs. 125
  • 124. Brisbane,Australia – Imagine a realistic tour of a minerals processing plant that has not yet been built, where you can not only see the entire facility, but also adjust the valves, read the meters, walk up and down stairways and even practice responding to a fire or explosion. If this sounds like a video game, it’s meant to. And it’s also an inventive new way to save plant design costs and safely train operators for real-world scenarios. Brisbane is known for its natural resources, especially metals and minerals, and Australia’s mining industry is concentrated in the region. So it’s a no surprise that Meteng Pty Ltd, an engineering consultancy specializing in process modeling and simulation, would have expertise and customers in this segment.What may not be as expected is that the firm would take such a novel approach. TechnologyThat Capitalizes on Human Nature Meteng started by studying cognitive science and learning. Research shows that humans have tremendous ability to process and analyze massive amounts of data, and that we retain knowledge best in interactive training, when we experience the results of our actions.Therefore, people discover how to make better decisions when they can practice scenarios and make mistakes without negative consequence. Some call it ‘learning by doing’. Meteng translates this to the engineering world.The firm’s goal is to help their customers plan and design plants more efficiently, maximizing the value of their physical assets and their people, so they can increase profits, empower employees and enjoy sustainable growth and success. The result is theWISE system, orWalk-Through Interactive Simulated Environment. Using powerful computers to process dynamic mathematical data models along with several large, high-resolution screens,WISE is a 3D spatial experiences set in a ‘cave’ with surround sound. It is like being within a video game, but rather than an imaginary setting, WISE simulates an actual processing plant, including a prototype SCADA and control system. It’s NoWorries withWonderware As Meteng brought theWISE system to life, a major concern was that its complex processing requirements would cause performance or functionality roadblocks. But whenWonderware Australia, the localWonderware distributor introducedWonderware software to Meteng, they found an easy-to-configure solution that met their needs and enabled the firm to develop unique solutions. While the main requirement was high performance with functionality, ease of installation and updates plus excellent technical support were other factors in the decision to integrateWonderware software into the sophisticated system. Wonderware software serves as the main control center, opening the 3D models, loading dynamic processes, and initiating or saving training scenarios. Specifically,Wonderware InTouch HMI (Human Machine Interface) adds a versatile, intuitive GUI for theWISE SCADA system, whileWonderware InControl software provides easy-to-integrate, expandable control and scripting that supports the system’s interlocks and logic control. Meteng applies its process engineering skills when it comes to analyzing workflow and developing efficient processes.Wonderware software supports them with its 126 InTouch HMI, InControl software.Process Engineering Figure 1: Meteng 3D Process Modeling and Simulation System.
  • 125. powerful standardization and repeatability capabilities. Groutsch says,“Once a module is designed, it’s easy to rapidly spin off other versions and tailor them to specific operator and plant requirements. It helps us to be smart and efficient, plus we can do it at a fraction of the cost.” Changes and re-work to control systems and graphics are also facilitated smoothly. Meteng can respond quickly to client comments and requests for revisions.And when clients are participating in the continuous development of their plant, they are actually seeing theWonderware software at work in their environment. Wonderware has also been a capable partner for support. Groutsch is complementary of the association formed between Meteng, Martin Halsey and theWonderware Australia team. He elaborates, “The best thing about it is that the software is so trouble-free, the need for support almost doesn’t exist!” The Key is ROI Meteng has grown up in the mining and minerals processing industry, but as these plants have become more complex, they have incorporated simulations for power stations and chemical plants.They believe the application of theWISE system to new technologies, such as renewable energy processes and carbon reduction projects can significantly help overcome problems in getting new technologies off the ground. But no matter what the segment, return on investment is critical – for Meteng and their customers. Since it can cost up to ten times more to fix a design problem onsite than when it is solved in simulation, and since programming errors that delay production can cost millions of dollars, the Meteng solution is proving its worth to the firm’s customers. Meanwhile,Wonderware software continues to make solid contributions to Meteng’s high- performance system. Groutsch says it best,“It allows us to do what we want, and do it well.” This document was realized thanks to the support of: Meteng Pty. 127 InTouch HMI, InControl software.Process Engineering Figure 2: Meteng interactive screen.
  • 126. Take the Wonderware and watch efficiency take off. The powerful and open Wonderware System Platform software has enabled the largest ecosystem of system integrators and third-party providers in the industry to deliver solutions that help their customers’ businesses with faster, real-time collaboration and decision support. Over 3,000 SI organizations around the world are leveraging the power and ease of Wonderware in record time, while helping their customers achieve operational success. Put some POW into your operation. Get Wonderware. www.wonderware.com ©2008 Invensys Systems, Inc. All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners. T H A N K S T O Powerful Open Wonderware
  • 127. Industry: Pulp & Paper Lenzing AG www.lenzing.com “The performance of the facility was doubled – and that is a success.” Harald Schlader, System Administrator and Product Coordinator, Lenzing Modern AutomationTechnology for a Cellulose Fiber Manufacturing Plant byWonderware Austria Goals: • Efficient production; • Increase production capacity; • Seamless flow of information; • Reliable production technology. Challenges: • Modernization of production automation system. Wonderware Solution: • ActiveFactory software; • InTouch HMI; • InTouch HMI forTerminal Services; •Wonderware System Platform. Results: • Increased efficiency; • Higher productivity. 129
  • 128. Lenzing, Germany –The Lenzing Group, based in the Austrian city of Lenzing, is successful worldwide in the internationalTextile and Non-Woven market for the past decades. Lenzing today is market leader in many Business-to-Business markets: from special cellulose fibers to high-quality plastic-polymers. To produce effectively in a high wage country like Austria, it is only obvious that state-of-the-art manufacturing plants are the keys to profitability. Seamless flow-of-information and digitalized production management are as fundamental to Lenzing engineers as functional tools for diagnosis, data collection and archiving.They rely on efficient hardware as the basis for automation architectures, and combine that with software products specifically modified for the different production divisions.This was also the case during the modernization of an existing cellulose fiber manufacturing plant, where perfectly integratedWonderware software solutions allowed for a considerable increase in efficiency and a consequent boost in productivity. Looking back on 70 years of experience in the fiber production, the Lenzing Group is the only manufacturer worldwide with expertise in all three generations of the so-called ‘man-made cellulose fibers’ - from classic viscose to modal- and lyocell- fibers. Lenzing’s success is based on consistent customer-orientation combined with leadership in innovation, technology and quality. Next to the core business in fiber and synthetic material, Lenzing is also experienced in machine building and engineering. A high level of automation ensures an efficient production, in which the company invests continuously. In order to update the automation system and adapt the production capacity to an increased level of incoming production orders, the existing hardware (Simatic S5) was replaced by more efficient Simatic S7 CPUs. Also, the automation system was to be integrated into the production area and to allow remote diagnosis. “In the past, our production assistants had to be on site to collect data from meters and to manually put the data into the production database,” says Harald Schlader, Lenzing System Administrator.“Also, the electrical staff had to be on-site to evaluate a problem. Remote diagnosis was not possible.” Since Wonderware InTouch HMI (Human Machine Interface) software has been used for the visualization of the cellulose fiber production area for approximately 10 years and a large, continuously grown, object-library already existed, it was decided to put the modernization of the production area into the hands ofWonderware.“Our experience with InTouch HMI is very positive. Especially InTouch HMI for Terminal Services software has proven to be perfect for us,” mentions Harald Schlader with reference to the advantages of the visualization system. Automation Solution Structure Due to the unrivalled openness of the Wonderware software, regular PCs running withWindows XP operating system can be used as user stations in the control room.They are automatically connected to theTerminal Servers in the distribution room with InTouch HMI for Terminal Services. Based on the ArchestrA technology, this technology provides the user with a unified environment in which the information coming from different data sources can be integrated. The environment offers a common infrastructure plus a unified set of services. 130 ActiveFactory software, InTouch HMI, InTouch HMI for Terminal Services, Wonderware System Platform. Pulp & Paper Figure 1:Thanks to the deployment of InTouch HMI, now production assistants in Lenzing can optimize production processes directly from their offices.
  • 129. Lenzing also standardized the use of the Wonderware Historian as a production database. It is based on Microsoft SQL Server and allows access to real-time information for the analysis of plant and equipment data.The complete production data are automatically collected from various data sources, e.g. industrial OPC-Server or one of the +600 different I/O Servers. Lenzing also uses the Wonderware Historian to export production data into a higher-level ERP System. For data trending, analysis and reporting, Lenzing choseWonderware ActiveFactory software.This software offers tools for an optimal utilization of data stored in the Wonderware Historian. Functional point- and-click dialog boxes facilitate the retrieval of production and process data and simplify troubleshooting, in case of potential process inefficiencies, eliminating time consuming error localization. With DASSIDirect, Lenzing takes advantage of the powerfulWonderware DAServer for the communication with Simatic S7 PLCs based onTCIP/IP.A customized ‘SFCWizard’ enables the automated import of up-to-date information from the ‘S7-Graph’ from Siemens into InTouch HMI. Otherwise the display of current information would not have been possible. Advantages & Benefits of the Wonderware Solution InTouch HMI forTerminal Services was mainly chosen because of the long distance between the cellulose fibers production area and the rest of the production plant. The maintenance staff can now solve minor problems directly from their workstations. And production assistants can now carry out certain production process optimization activities directly at their PC. “Since InTouch HMI isWindows-based and Windows is our standard operating system, PCs in the production area can be maintained by our internal IT department,” states Harald Schlader.“Also, InTouch HMI gives us full flexibility regarding the choice of server - unlike otherTerminal Server Solutions suppliers.The open OPC interface of the I/O Server is another advantage.” The implementation of the InTouch HMI application was short and smooth, thanks to the vast 131 ActiveFactory software, InTouch HMI, InTouch HMI for Terminal Services, Wonderware System Platform. Pulp & Paper Figure 2:Total transparency: with the perfectly integratedWonderware software solutions Lenzing obtained considerable increases in efficiency and therefore higher productivity in the cellulose fiber production. Figure 3: Thanks to the InTouch HMI forTerminal Services,all process parameters can be easily visualized and customized with simple mouse click from standard office PCs.
  • 130. experience of the Lenzing engineers, but also the reusability of the SmartSymbols’ Library: the SmartSymbol technology allows the reusability of graphic templates. Object-oriented graphics include graphic-, script- and tag management tools, necessary for the appropriate use of application objects in a production environment. New applications are created based on standards, that way ensuring the compliance with company procedures. Existing applications can easily be adjusted by changing the SmartSymbol template. “We gradually enlarged and improved our library to make sure that the integration of new equipment is done as fast as possible.The SmartSymbols we used had to be changed only a little to fit the individual processes,” says Harald Schlader. He also compliments Wonderware Support:“The support agreement withWonderware provides a continuous software upgrade of our software. The technical helpline staff is competent, quick and is of a great help.” All-in-all, the Lenzing Group realized a vast improvement regarding product-control and material usage thanks to the use of InTouch HMI for the production of special cellulose fibers.“We doubled equipment performance – and this is a pretty big success,” concludes Harald Schlader. 132 ActiveFactory software, InTouch HMI, InTouch HMI for Terminal Services, Wonderware System Platform. Pulp & Paper Figure 4: A proprietary SFCWizard providing the automatic import of Data in InTouch HMI is deployed for the visualization of actual information of Siemens S7 Graph.Without this software, a specific application for the visualization of real-time statuses would have been necessary. This document was realized with the support of: Harald Schlader, System Administrator and Product Coordinator, Lenzing.
  • 131. Industry:Transportation Tecnositaf S.p.A. www.tecnositaf.it “We invested in the deployment of the most modern safety systems available on the market today, developing solutions enabling us to go far beyond international standards.” Giuseppe Celia Magno, Sales and Quality Manager, Tecnositaf S.p.A. SCADA: an Important Help for Managing the Road Infrastructure byWonderware Italy Goals: • Ensure the highest safety levels through the deployment of maintenance and infrastructure management systems. Challenges: • Limit maintenance costs while ensuring maximum safety. Wonderware Solution: • ActiveFactory software; • InTouch HMI; • InTouch HMI forTerminal Services; •Wonderware System Platform. Results: • Reduced maintenance and energy consumption of the tunnel lighting and venting systems; • Deployment of a fire-fighting system meeting highest safety standards. 133
  • 132. Bussoleno (TO), Italy –Tecnositaf, an integrated engineering company founded in 2001, is a SITAF S.p.A. company (A32 motorway,Torino – Bardonecchia and FréjusTunnel operator) that designs, develops and manages systems and tools for the mobility control and road (urban and extra- urban, outdoors and in tunnels), rail and industrial safety. An Experience Along A32Torino – Bardonecchia Motorway Wonderware andTecnositaf experience and technologies have been put together to ensure maximum safety along the whole A32Torino – Bardonecchia motorway infrastructure. Everyone of us, when driving on a motorway, is especially concerned about traffic and road conditions. But actually our safety depends on almost invisible technological infrastructures, which need to be perfectly working. Managers of big infrastructure networks are fully aware of this issue and, in recent years, have been investing in strengthening those systems, providing them with the most efficient management and control tools. Maintenance and management of the road infrastructure, in fact, are not only the main goals, but also the highest costs for the contractor. Highways must be always open and ensure constant safety levels; any maintenance intervention involves organizational challenges and the need to open building sites, causing dangerous road narrowings. In order to improve service levels, ensure safety and limit maintenance costs through an exact scheduling, SITAF (Società ItalianaTraforo Autostradale del Fréjus), as contractor of A32Torino – Bardonecchia motorway, recently invested in the expansion of the technological infrastructure ensuring the safety of this major road connecting Italy to France.This choice has been also influenced by the fact that 18 of the total 73Km are tunnels, a potentially hazardous environment for vehicles and the place where rescue interventions are really difficult, as testified by recent dramatic news. Tecnositaf (specialized in integrated systems for road safety) has been therefore involved in this project, due to the expertise of its collaborators and the experience with other companies managing street and motorway systems. Air Quality Control “In the light of this,” as explained by Giuseppe Celia Magno, Sales and Quality Manager,Tecnositaf, “we invested in the deployment of the most modern safety systems available on the market today, developing solutions enabling us to go far beyond international standards.” In such a project, constant event monitoring and automatized management systems are key factors provided thanks to the collaboration with Wonderware System Platform, combined with InTouch HMI (Human Machine Interface), represented the ideal solution for supervising the whole road section.This solution is among the most innovative on a global scale, since it leaves the freedom of customizing the application in order to develop all necessary controls Sitaf aimed at, and to reach the integration levelTecnositaf expected, all the while providing a reliable solution. The project, personally followed by Andrea Ballatore,Wonderware certified system designer, aimed at replacing the pre-existent and out-of-date SCADA system, using the most efficient control technologies, especially for tunnel ventilation. Inside highway tunnels, under particular weather or traffic conditions, there could be a high concentration in exhaust gases, affecting visibility and, in the severest of cases, the health of passengers.These are the reasons why the venting 134 ActiveFactory software, InTouch HMI, InTouch HMI forTerminal Services, Wonderware System Platform. Transportation Figure 1: Central control headquarters A32 motorway.
  • 133. system must ensure suitable air makeup. Non-stop ventilation implies high energy consumption, along with rapid deterioration of fans, and makes periodic and expensive maintenance necessary. Manual management proved demanding and inefficient, mainly because personnell operating locally cannot have full visibility into the complete system. Gas concentration is not only influenced by traffic and passage of trucks or highly polluting vehicles, but also by external factors, such as weather conditions at the entrance end exit of the tunnel. It is possible to foresee almost exact traffic conditions in some timeframes, allowing to set the venting system up according to forecasts. Wonderware solution has been customized to interact with 86 PLCs controlling the single local plants which are based on a master/slave logic and able to work autonomously, according to the information retrieved from field devices and historical archived data. An optical fiber 1Gb/s network, 73Km long and suitably backed up, allows centralizing all the information in the central control room in Susa, where all emergency actions are coordinated. CO2 concentration monitoring is ensured by sensors which start only the necessary fans in the longitudinal venting system, at the required speed, in case the concentration exceeds preset values. Furthermore, according to the natural speed of the airflow detected by the anemometers installed at the entrance and inside the tunnels, the system sets the number of fans which would be enough to keep the air in tunnels always fresh. This management system drastically reduced maintenance, extending the operating life of mechanical systems and, most of all, reducing electricity costs. All the Light Needed Tunnels are critical passages in every travel. In case of sudden lighting changes, human eyes require more then one second – the so-called ‘adaption time’ – to focus images back. Considering that hen driving at 120Km/h, in one second you cover more than 30 meters, it is immediately clear that the driver’s sight is temporarly and dangerously limited for quite a long distance.This is why lighting at the entrance and exit of tunnels must be particularly intense in the daylight and weak during the night. For this reason,Tecnositaf engineers leveraged Wonderware solutions’ capabilities to create an intelligent management system based both on seasonal timetables and on the brightness detected by twilight sensors.This smart management system allows limiting costs and extending the operating life of the installed lamps. The same control system is able to constantly monitor the status of all switches and lamps, offering the operators in the control room real-time visibility into all the plants and enabling immediate remote or local intervention in case of need. AValuable Help in Event of Fire However important, venting and lighting management does not always require real-time intervention and can tolerate partial delays. In event of fire, every second can make the difference for people trapped in the tunnel. For this reasonTecnositaf, not least to comply with 135 ActiveFactory software, InTouch HMI, InTouch HMI forTerminal Services, Wonderware System Platform. Transportation Figure 2: Longitudinal and roof venting system telecontrol.
  • 134. severe international regulations, invested in the creation of a particularly robust and effective system. The need to ensure highest quality standards contributed to the choice of a SCADA system based onWonderware System Platform, combined with a proprietary system. The SCADA system itself, in fact, constantly diagnoses the status of the fire-fighting system, notifying any disfunction and activation. Perfect efficiency and timely activation of the plant represent two crucial factors engineers took into consideration upon development of the plant. Perfectly working pumps and valves must also be automatically activated, with no room for error. For this reason, the SCADA system analyzes CO2 concentration levels and air opacity, constantly comparing them with historical data and values retrieved in tunnels.This way the plant can easily distinguish initial fires linked with sudden increases in values detected by sensors in a limited area, from the passage of particularly polluting vehicles, thanks to the integration with videosurveilance systems carrying out smoke detection functions, too. In this case, afther the activation of fire-fighting systems, smoke extractions systems come into operation according to pre-set schedulations, in order to facilitate evacuation and rescue procedures to the rescuers called by the Centralized Control Room. All these solutions allow ensuring the highest safety levels as today possible, improving safety of drivers on the A32 highway. This document was realized thanks to the support of: Tecnositaf S.p.A. 136 ActiveFactory software, InTouch HMI, InTouch HMI forTerminal Services, Wonderware System Platform. Transportation
  • 135. Industry: Transportation Transports Publics de la Région Lausannoise (tl) SA www.t-l.ch “The simplicity and flexibility of Wonderware makes it a user-friendly solution par excellence” Laurent Arn, Director, Mauerhofer & Zuber Wonderware and Mauerhofer & Zuber join forces for the safety of Lausanne’s M1Tramway byWonderware Switzerland Goals: • Relocate and consolidate traffic management; • Revamp the entire remote control system in order to improve traffic visibility; • Archive all of the events needed for maintenance and scenario reconstruction. Challenges: • Implementing a new system without disturbing current line operation; • Meeting the safety requirements of the ‘Office Fédéral desTransports’ (OFT – Swiss Federal Transportation Office); •Tailoring graphic representations to the customer’s wishes. Wonderware Solution: • ActiveFactory software; • InTouch HMI; •Wonderware System Platform. Results: • Successful implementation without traffic (very dense) interruption/disruption; • 7.8 km of M1 line fully monitored with one ergonomic, advanced application; • Real time and historical access to all types of information (alarms—safety—traffic). 137
  • 136. Lausanne, Switzerland –The Mauerhofer & Zuber Company Entreprises Electriques SA (MZ) is based in Renens (VD) and has a subsidiary in Martigny (VS). It conducts most of its business in Romandie, Switzerland, but operates throughout the rest of Switzerland and internationally as well. MZ was established in 1905 and has deep roots in the region’s economic base. In 2000, it was bought by the Atel InstallationsTechniques Corporation, providing it the advantage of the flexibility and responsiveness of a small business combined with the stability of a large company. MZ’s primary fields of business are: railway safety systems, Road traffic monitoring, overhead electric lines and low, medium, and high tension cables optical telecom and fibers, electrical grids and electrical engine inspection. MZ can study, build, and maintain systems in all of the fields listed above. In addition, MZ designs, develops, and manufactures its own line of products for road traffic management and railway safety systems.The company has 150 employees who have a high-level of training and motivation. More than one third of its employees work in the research department. In addition to offering the best services at the best price, MZ is committed to quality and sustainability, as proven by its internationally recognized ISO 9001 certificate (quality), ISO 14001 certificate (environmental management), and OHSAS 18001 certificate (health and safety in the workplace). TheTSOL -Tramway du Sud-Ouest Lausannois, (Lausanne SouthwestTramway), which was renamed M1 in 2000, began running on June 2, 1991. It connects the center of Lausanne [Switzerland] with major universities and Renens.The total cost of operation (infrastructure, equipment, station, rolling stock) rose to 192M CHF (Swiss francs).The Canton of Vaud invested 47%, the [Swiss] Confederation 30%, municipalities 11%, theTSOL Corporation invested 7% andTL (Transports Lausannois – Lausanne PublicTransportation Company) invested 5%. M1 is a light, single-track above-ground system that serves as the backbone of public transportation in southwest Lausanne, Switzerland. In addition to 95% exclusive right-of-way, the 1984 preliminary design study shows that the line provides service to 33,000 inhabitants and 32,000 jobs, not including universities.The route is 7.8 km long and has fifteen stations. It is connected to the rest of the public transportation network by four connecting stations: Flon, Bourdonnette, the EPFL (Swiss Federal Institute ofTechnology) station, and Renens, which is the only direct connection between the M1 and Swiss Federal Railways (CFF). The Lausanne Southwest tramway currently transports 10 million travelers per year with 17 electric railcars and more than 300 trains per day. One train runs in each direction every five minutes during rush hour. A Delicate Move Because of transportation growth and the construction of M2, the Lausanne public transportation company (TL) decided to consolidate traffic management into one location at their headquarters in Perrelet. The M1 control desk was located at theTSOL station and therefore had to be moved.This task was entrusted to MZ which specializes in engineering and railway safety, and designed the current 138 ActiveFactory software, InTouch HMI, Wonderware System Platform. Transportation Figure 1:The different levels of the remote control system’s architecture.
  • 137. system.The MZ remote control system was initiated in 2004 and built between 2006 -2008. It was first installed and tested in Ecublens, then transferred to Perrelet. The system has two control stations that each covers the entire line. Only one person is needed for monitoring and handling special events or breakdowns, as well as conducting a series of system tests, for switches in particular, before the first trains begin to run in the morning. MZ Remote Control System The MZ remote control system meets the need that railways have for a cost-effective remote control and SCADA system based on open-ended, high- performance technology. Normally, safety systems are operated manually through control boxes or desks.The MZ remote control system replaces these manual systems without affecting the level of safety guaranteed by the interlocking signal boxes. It has only one software program (Wonderware System Platform), regardless of the type and size of the system to be installed. The system includes the following components: • Siemens S7 type programmable logic controllers for the interface with the interlocking signal box; • An Ethernet /TCP-IP communications system. Industrial, redundant equipment, which increases network availability; • Secure servers for hosting the remote control application and a server that records events and alarms; • High-availability monitoring stations with two PCs and four screens. Another advantage of the system developed by MZ is that it allows to make subsequent changes to the IT infrastructure by adding hardware, without having to modify any of the software. Servers andTheir Software For security reasons, the servers are installed in two different locations in the Perrelet station. The following software solutions are installed on these servers: •Wonderware System Platform, a complete software solution for automation applications and industrial information systems. It marks the beginning of a new era for operating and updating current industrial applications more effectively and provides the best methods for designing and implementing new technical systems; • AlarmDBlogger, a data acquisition software engine that can retrieve alarms and events generated by the system and store them on a history server; •Wonderware Historian, a software program based on the Microsoft SQL Server which stores all data from the infrastructure managed by the Wonderware System Platform software. Customized reports can then be created through Microsoft SQL Server Reporting Services; •Wonderware Industrial Application Server 3.0.This software is the remote control source program. Its application is stored in an SQL database and protected by a password. It can run the operating modules for the object-oriented application; •The traffic management centers are installed in the central control station.They are equipped with a Windows XP Pro operating system,Wonderware InTouch 10.0 supervisory control software, and the Wonderware Industrial Applications Server 3.0 software platform. 139 ActiveFactory software, InTouch HMI, Wonderware System Platform. Transportation
  • 138. Operating Principle The SCADA system makes it possible to send commands through the communications network and programmable logic controllers to the safety system, which will in turn accept or refuse the command.The SCADA system shows the status of the safety system in real time.This provides repetition status.The role of servers is as follows: •The primary server hosts the remote control application •The secondary server hosts the same application as the first. If the primary server malfunctions, the secondary server takes control of the system. •The third server hosts the SQL database that records all of the system’s alarms and events. The function and graphic objects library created by Mauerhofer & Zuber is absolutely vital to the development of future applications.With the reference library (switches, signals, safety, etc.), designing a new application consists of logically organizing objects, modifying them, and bringing them into production. This object-oriented software capability has enabled Mauerhofer & Zuber to deploy the Metro M1 stations in just a few days, rather than the several weeks needed with the software used by MZ in the past. Remote Control and System Monitoring Remote control and system monitoring ensure that the entire system is working properly. In case of breakdown or failure, the remote control system becomes inoperable and the interlocking signal box stops responding to commands from the remote control systems. In addition, statuses are invalid and the block diagrams display a system default. System alarms and events are recorded in a 2005 SQL database server (Wonderware Historian) with different levels of severity being assigned to the items. Alarms are acknowledged via a mechanism and cannot be deleted from the database. Users can manage alarms, look up alarm and event history, and print reports from the management center. Moreover, the system includes features for managing user rights: access rights are managed by user name while tasks on the system are recorded with the computer’s name. This document is realized thanks to the support of: Mauerhofer & Zuber SA. 140 ActiveFactory software, InTouch HMI, Wonderware System Platform. Transportation Figure 2:The M1Tramway at EPFL station.
  • 139. Industry:WaterTreatment Comunidad de Regantes de Motril-Carchuna y Cota 2000 www.icr-sa.com Motril-Carchuna automates & remotely manages irrigation thanks toWonderware technology byWonderware Spain Goals: • Promote Agricultural development through an exhaustive control of irrigation; • Immediately detect irregularities in the system; • Apply more efficient irrigation programming by centralizing all processes. Challenges: • It is difficult to supervise a large facility.The irrigation area of Motril-Carchuna-Cota 2000 (Granada) covers an area of 2,535 hectares. It includes 3,000 parcels and 2,400 water users. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: • Remote control has been achieved in the entire irrigation distribution network without affecting the operators; •TheWonderware solution helps monitor the state of the network in real time, making the detection of breakdowns faster; •Wonderware’s ease of use makes it possible to easily change, add or delete any parameters; • Consumption is optimized in accordance with water resources and demand. 141 “We use Wonderware technology because of its great versatility, robustness and ease-of-use.” José Rodríguez, President, Irrigation Community, Motril-Carchuna
  • 140. Motril, Spain -The community of Motril-Carchuna has implemented a complete solution based on Wonderware technology that manages its irrigation by remote control.All the control functions are automated and this provides great reliability and major saving in costs. Making the Most of Natural Resources As a result of the global climate change during the last few years, the state of the environment greatly worries society today. Spain has a semi-arid surface area and over two- thirds of these are great extensions of irrigated land. However, there is a lack of water resources in Spain and supply is irregular. Increase in water consumption, inadequate management and prolonged periods of drought have led to the implementation of control measures to manage water supply.This was done in order to stop low water supply from having an even greater impact on the agricultural and service sector economies. Many of the irrigation communities in Granada had ‘extremely precarious’ irrigation networks in 2007. This made the government activate projects that would modernise the irrigation system in communities like Motril-Carchuna-Cota 2000.The irrigation area of Motril-Carchuna-Cota 2000 (Granada) covers an area of 2,535 hectares. It includes 3,000 parcels and 2,400 water users. It recently adopted a wireless consumption network supplied byWonderware to control and manage the irrigation system. The automation and management of irrigation systems is one of the measures that many companies are adopting to enable optimum water resource management in agriculture.This helps to optimise the recording and distribution of water usage.The establishment of pressure irrigation networks supervised through centralised remote control systems helps to provide a balance in work conditions.This makes irrigation-on-demand possible in areas with sufficient water resources. Complete Remote Management Solution The irrigation community of Motril-Carchuna decided to implement a HIDROBUS-RF system, which is a complete solution for irrigation.The system involves the design of remote irrigation terminals usingWonderware software. Communications are carried out through an optimised wireless network (ULP). Low-cost alkaline batteries power the remote terminals. TheWonderware System Platform was used with Google Earth 3D visualisation.This combination provided great precision in the supervision and control of the facility. It also provides a flexible visual environment for geographically distributed applications with high number of nodes. The HIDROBUS platform is comprised of the following elements:Wonderware System Platform at the core. It also includes theWonderware Historian. Clients, with whom the operators interact, receive updated and historical information from the Wonderware System Platform andWonderware Historian.The OPC server (OLE for Process Control) helps sending the information to the other control and management programs. The implementation of this system achieves three main goals: 1.To promote agricultural development through an irrigation control system; 2.To immediately detect possible irregularities in the systems; 3.To apply more efficient irrigation system by centralising all the processes. In the words of José Rodríguez, president of the irrigation community of Motril-Carchuna:“We opted forWonderware software because of its great versatility, robustness and ease-of-use.” Implementation Challenges Motril-Carchuna is a collective network making system implementation very difficult. To overcome all obstacles, it was necessary to establish a centralised management system to remotely 142 InTouch HMI,Wonderware System Platform.WaterTreatment
  • 141. supervise and control the water connection on thousands of parcels based on the needs of users, the availability of water resources and crop type. Manuel Morales, secretary of the irrigation community of Motril-Carchuna, comments:“It is essential to use solutions like those fromWonderware in modern and environmentally sustainable systems today because it helps to manage the extensive irrigation networks”. Remotely managed irrigation systems require the establishment of communication between the control centre and the thousands of nodes in greatly dispersed irrigation points. Each node reads consumption, pressure, volume and the control of valves. Ingeniería y Control Remoto (ICR) S.A. is the company in charge of responding to all these challenges. AsTechnical Director, Lucas Galán explains:“We already had experience inWonderware software. Before beginning implementation, we still had to conduct tests on new specific parts of the solution such as the integration of Google Earth.” Main Benefits The benefits were realized not long after system implementation. Remote control has been achieved in the entire irrigation distribution network without affecting the operators. TheWonderware solution also helps monitoring the state of the network in real time, making the detection of breakdowns faster. Moreover, it is now far easier to make changes to the solution.Wonderware’s ease of use makes it possible to easily change, add or delete any parameters. Remote control and updates of the software and firmware of all the elements making up the control system can be made without much difficulty. José Rodríguez, president of the irrigation community of Motril-Carchuna, confirms this and notes that:“Added to all these advantages are cost savings in pump operation. We are able to optimize consumption in accordance with water resources and demand.” There are huge advantages provided by Wonderware technology for Ingeniería y Control Remoto, S.A. According to Galán,“Wonderware provides great flexibility and this makes it easier to do changes in the future.There is greater integration with other systems and the driver development tools are easy to use.The software helps in standardisation as well.” This document was realized thanks to the support of: José Rodríguez, President of Comunidad de Regantes de Motril-Carchuna, Javier Fernández Lorca, Managing Director, and Lucas Galan,Technical Director, Ingeniería y Control Remoto, S.A. 143 InTouch HMI,Wonderware System Platform.WaterTreatment
  • 142. Proof positive why thousands of the world’s water and wastewater facilities depend on Wonderware. ©2008 Invensys Systems, Inc. All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners. With over 28,000 software licenses in use,Wonderware knows water and wastewater operations.Wonderware software enables the integration of applications across all departments and functions.You get real-time operations management capabilities for your modern municipality or industrial water operation. Rely on the leader in water and wastewater software. For a FREE white paper on overcoming your top challenges, go to wonderware.com/water.
  • 143. Industry:WaterTreatment GlobalWater Management, LLC www.gwresources.com “…we can address problems before they occur. It’s the big picture we need to fine tune and solve complex problems.” JamesTaylor, Operations Manager, Global Water Management, LLC Wonderware Software Solution HelpsWater Utility Meet Quality, Efficiency and Profitability Goals byWonderware Goals: • Provide ample water and meet county, state and federal quality standards; • Use less power, conserve energy and operate more profitably; • Reduce operator time spent driving to remote locations to save fuel and vehicle costs; • Improve measurement of treatment processes and gather historical and real-time equipment data for better preventative maintenance. Challenges: • Aggressive timeline required the new system to be operational within a few weeks; • Operations cover a 100-square-mile territory with eight separate facilities. Wonderware Solution: • ActiveFactory software; • InTouch HMI; • SCADAlarm software; •Woderware System Platform. Results: •TheWonderware software solution’s standardization and repeatability resulted in quick development time; • Historical data and trending reports now are available to management for improved decision making; • Preventative maintenance has extended equipment life; power use is minimized and operations are more profitable; • Remote visibility saves operator travel time and has improved efficiency while reducing fuel and fleet maintenance costs. 145
  • 144. Phoenix,Arizona – As the fastest-growing private water company in Arizona, GlobalWater Management, LLC has a dual purpose: to deliver clean drinking water to residential and commercial customers throughout the state, and to provide reclaimed water to irrigate parks, schools and golf courses. The utility considers both the citizens and the environment as its customers.This is especially imperative in the desert where it’s possible to supply enough water for everyone – as long as this precious natural resource is carefully conserved. And that’s where GlobalWater makes its greatest contribution.The company is known for the progressive implementation of leading-edge systems that enable it to provide ample water as well as meet county, state and federal water quality standards, plus save energy and operate profitably. The GlobalWaterWish List One of the important factors in this reputation for innovation comes from the company’s continuous evaluation of its operations. Not long ago, GlobalWater’s management team developed a list of desired, additional capabilities. They wanted improved measurement of their treatment processes, better ability to recognize and correct possible quality problems before they occurred, and more comprehensive historical data to assist with management decisions. They recognized that if they could save power, they could also save money. Plus, because GlobalWater operates eight facilities in an approximately 100- square mile territory, they envisioned decreased time driving between their locations, which would save on vehicle wear and tear, fuel costs and operator hours spent on the road. GlobalWater contacted the local authorized Wonderware distributor,WonderwareWest and CP ControlTechnologies, LLC, an Arizona systems integrator.The three entities formed a team that would work together to meet GlobalWater’s list of needs. Rapid Development and Deployment Not only did GlobalWater have a clear vision of what they wanted theWonderware software solution to provide, they also had an aggressive timeline. Four of the utility’s sites needed to be deployed at the same time, and CP Control was asked to complete the project within weeks. TheWonderware System Platform gave the system a firm foundation, including patterns to follow for standardization of the system design. I/O configuration from the PLCs, object modeling and graphics, tags and naming conventions were set from the beginning.Then they were also used by the developers and engineers who took responsibility for the system post-deployment. Jeromy Peterson, CP ControlTechnologies’ Chief Operating Officer, says,“After the upfront investment in development, you get great time savings. It has allowed us to build in more features that GlobalWater wanted and still finish on time. From a developer’s standpoint, it made us look pretty smart!” He continues,“We did triple the work in one-fourth of the time becauseWonderware software’s repeatability and deployment of objects makes development so easy.” On the strength of this standardization, the first site was completed in about a month, and the additional three sites came online within a week. And, as GlobalWater’sWonderware software system has continued to evolve, the solution’s store- and-forward capabilities have provided stability. When adjustments are made, store and forward safeguards data and helps prevent losses. Seeing the Big Picture Now that the system was in place, it was time to see if it could help GlobalWater’s management to better process data for planning and performance measurement. In the past, historical data was not gathered at all, and the amount of current information that was collected provided a mere snapshot of the complex operations. Engineers used hand-written log sheets 146 ActiveFactory software, InTouch HMI, SCADAlarm software,Wonderware System Platform. WaterTreatment
  • 145. and entered results into a monthly report.This made it difficult for management to identify trends and make forward-looking decisions. ButWonderware software changed all that.The new solution gives GlobalWater engineers the ability to track multiple points of input and hundreds of data points in real time.Wonderware Historian and InTouch HMI (Human Machine Interface) screen graphics organize this information and make it easily understandable, which has made operators more efficient and proactive. And the data can be trended over long periods of time to create better decision- making input for management. According to JamesTaylor, GlobalWater Operations Manager,“The greatest benefit from our system is trending.We can understand what’s going to happen, and we can address problems before they occur. It’s the big picture we need to fine tune and solve complex problems.” The accurate reporting and trending that comes from the newWonderware software enables Global Water operators to make use of KPIs, standardize their best practices, adhere to EPA standards – and do it all efficiently. For example, data from the Wonderware solution shows when filters will need to be replaced. Backwashing and change-outs can be planned so that the system’s performance is not disrupted. Reports also prove that water remains within EPA compliance standards for quality. COO Peterson explains,“Previously, we affected our KPIs with man hours, but now we can affect them with technology.” ‘Powerful’ Cost Savings Now and in the Future Power is another central consideration since it’s a significant operational cost. For GlobalWater, the Wonderware software solution monitors the energy usage of all pumps, identifying those that may be malfunctioning. By performing preventative maintenance more quickly and improving the efficiency of the pumps, equipment life is extended, power use is minimized and GlobalWater realizes more cost savings and operates more profitably. Taylor says that this is the basis for GlobalWater’s future plans for theWonderware system.“We’ve decided to implement power quality monitoring with Wonderware software in all of our facilities on a fast track.We will have it throughout our operations within the next year,” he predicts. This will give GlobalWater the ability to monitor and track power usage, compare it to water supply and pump speeds, and track true metrics.Taylor 147 ActiveFactory software, InTouch HMI, SCADAlarm software,Wonderware System Platform. WaterTreatment
  • 146. continues,“The substantial cost savings go along with the ability to ensure compliant operations and maximize the ability to monitor our operations.” Compliance is the Key The ability to track trends and monitor operations is essential for planning and proving compliance, but remaining within strict compliance guidelines at all times is also aided by theWonderware solution. Wonderware SCADAlarm software capability enables GlobalWater to set alarms for customized conditions, see visual indications of system performance and notify operators of current conditions, no matter where they may be. This means that the company can enforce stringent EPA mandates for water quality. Peterson says that, above all else, compliance is GlobalWater’s mission and thatWonderware SCADAlarm software is his most useful tool for ensuring it. It enables the utility to affect changes immediately and maintain constant control, plus the solution is also easy to use. The alarm set points can be quickly updated whenever standards change, whether they come from the EPA, the state or the county. RemoteVisibility Provides Environmental Benefits With theWonderware solution, GlobalWater enjoys better visibility to its widespread operations and has made additional operational improvements. Screens in the control room of the main facility show all of the equipment, so the need for operators to drive out to pumps and stations is minimized, saving time as well as fuel, maintenance and wear on GlobalWater’s fleet of service vehicles. And these results align with the company’s environmental goals. Successfully Fulfilling Multiple Missions With this deployment, both GlobalWater and CP ControlTechnologies have achieved their objectives. As the developer, CP ControlTechnologies has built a new system that addresses the critical needs of the customer, including meeting the deployment schedule and the operational goals for improvement. And GlobalWater is benefiting from the Wonderware software solution’s capabilities that facilitate the utility’s pledge to provide clean, safe water to citizens, to meet environmental and compliance standards, and to do it all efficiently and profitably. This document was realized thanks to the support of: GlobalWater Management, LLC. 148 ActiveFactory software, InTouch HMI, SCADAlarm software,Wonderware System Platform. WaterTreatment
  • 147. Industry: WaterTreatment Ontario CleanWater Agency (OCWA) www.ocwa.com “The reliability we have with the Wonderware Historian is phenomenal. Because of the store and forward feature, it eliminates any loss of data.That’s critical to the whole system because we have to report that information to our regulatory body.” Robert Simpson, Manager,Asset Management and Operational System Support, OCWA Ontario Citizens Enjoy Consistent, CleanWaterThanks to aWonderware Software Solution byWonderware Goals: • Provide consistent high-quality water and wastewater treatment services; • Build in scalability and standardization to improve efficiency; • Control costs; do more work with fewer staff in less time; • Provide the highest levels of regulatory compliance. Challenges: •Vast service area; wide-ranging customer types and sizes; • Strict quality/compliance regulations must be met while delivering cost-effective service; • Provide continuity plus accommodate future technology integrations. Wonderware Solution: • ActiveFactory software; • InTouch HMI; • SCADAlarm software; •Wonderware System Platform. Results: • Scalable; ideal for wide area installations and communications; • Adding new customers costs less and is accomplished in hours rather than days; • Increased location support without increase in staff; • Real-time reports have improved analysis and proof of compliance; • Changes required for regulatory compliance can be tested and deployed in one day. 149
  • 148. Toronto, Ontario – Just as water is always in motion, so is the Ontario CleanWater Agency (OCWA). Since 1993, OCWA has operated in a competitive market, providing a comprehensive array of water and wastewater services to municipalities, private sector companies and First Nations throughout the vast province that is twice the size ofTexas. Each day, OCWA produces over 700 million liters of drinking water and treats about 1.2 billion liters of wastewater at 502 facilities all across Ontario. Of course, when it comes to water, delivering a clean, consistent and safe product to all citizens is paramount.After protecting public health and the environment, priorities turn to delivering value through outstanding service and cost-effective operations. OCWA has kept these goals in sight as it has made strategic moves forward for its customers. In 1999, the agency developed the first Supervisory Control and Data Acquisition (SCADA) system in Ontario. Called Outpost 5, it was designed to work across large geographic areas providing monitoring, reporting and security. Outpost 5 is still in use at over 750 OCWA locations and is the largest such system in the North American water and wastewater industry. Riding theWave of the Future But OCWA’s commitment to innovation did not stop there. In 2003, the agency recognized an opportunity for progress.What if Outpost 5 could be transitioned to a new system that would integrate an off-the-shelf solution with the current network base? Blending Outpost 5 with such a resource would provide the best of both worlds and carry OCWA and its customers into the future. It would enable the agency to operate more efficiently by taking advantage of templates and redundancy scenarios to roll out new locations more quickly with fewer staff. As envisioned by OCWA, the right solution would also improve their competitive advantage. Customers who choose OCWA as their provider today would have the option to take control of their system – without re-engineering – if they wished to do so in the future.They would simply purchase the necessary licenses to continue to run the application. And finally, this new approach would also provide greater continuity of service and quality control to meet regulatory requirements across the province. TurningVision into Action The research and development and IT departments at OCWA converted these ideas into specifications and sought out possible partners.Through the process of evaluations and presentations, it became clear thatWonderware offered critical advantages based on similarities it shares with the Outpost 5 model.A transition to aWonderware software solution would be eased because of scalable configuration and template structure as well as strong web-based capabilities. Plus,Wonderware Canada East, the localWonderware distributor for the project, added applicable experience and outstanding service capabilities. The Importance of Standardization For OCWA, economies of scale are imperative. With over a million square kilometers of territory to cover, the agency’s teams are highly coordinated. Skilled technicians travel to remote locations for installations.Then they rely on colleagues working at theToronto office to perform the programming, and still other groups in OCWA hubs around the province monitor and maintain the systems. None of this would be possible without a versatile solution that enables standardization. OCWA’s Instrumentation,Automation and SCADA Group is responsible for deploying all of the installations.This team found that the highly flexibleWonderware System Platform and InTouch HMI (Human Machine Interface) could be integrated with Outpost 5 as well as OCWA’s existing asset management system and Process Data Collection (PDC) database. Plus, withWonderware software’s template capabilities, 150 ActiveFactory software, InTouch HMI, SCADAlarm software,Wonderware System Platform. WaterTreatment
  • 149. the system could be replicated consistently and quickly at new installations. Ciprian Panfilie, SCADA DeveloperTeam Lead, explains,“It’s easy because everything is developed as a template.We have a template structure at the Wonderware System Platform level, the reporting level, the security level, the graphic level, and we have templates that integrate with other packages as well.We have them all here in our lab so everything is fully tested and we maintain our standards.” This brings a major advantage when new stations are added. Before integrating theWonderware solution, OCWA required a complex, interdisciplinary team to work for six months to a year on new deployments. Now, they can do the same work with one person in about three months. And in the case of installations where the hardware is already in place, projects are even faster; bringing the system online in large plants has gone from months to days. Calculating Compliance Along with these deployment advantages, the new solution also provides extensive measurement capabilities that are necessary for regulatory compliance in Ontario. Both OCWA work teams and emergency response teams rely on the system for real-time data about pump pressures, power consumption, piping systems, chemical levels and other performance factors.The data is used to respond to immediate needs, but also to compile reports that are required by the Ministry of Environment. GeorgeTerry,Vice President of Operations and Maintenance, says,“It’s not enough just to do an excellent job in ensuring compliance at all times.What you have to ensure is that you are recording and documenting that work.” It is also critical for OCWA to be able to defend its reporting.The agency is required to provide regular information to the Ministry of Environment.This data, collected from numerous sources such as the pumps that deliver the water, the regulators that manage the chlorination and the labs that test the effluent, is reviewed, checked and rolled up into quarterly reports to prove compliance. Robert Simpson, Manager,Asset Management and Operational System Support, elaborates,“We have to do this so that people are aware that they have a system that’s working properly and providing them with clean, safe drinking water and properly treated wastewater. It’s a continuous process.” That’s where theWonderware Historian comes in. It enables each hub to record data in real time and converts it into reports that are submitted to the Ministry of Environment. And because of the extensive communications connections built into the system, staff throughout the operation can access the data instantaneously. In eastern Canada, where severe weather is part of the picture, protecting OCWA’s data is another area whereWonderware can help. Wonderware Historian forward is a sophisticated capability that maintains system data even if communications lines are temporarily down. Performance measurements – some taken as frequently as every five minutes – are stored locally, if needed, then forwarded to the central database once communications are reestablished. Previously, OCWA had been hampered during power outages because remote staff members were not able to access records when connections were interrupted. Now access is optimized and data is protected. Proactive Maintenance Promotes Quality of Life As the data is being collected, it is being monitored by OCWA’s maintenance management system. Programmed with guidelines and allowable ranges for operations, the system automates the generation of alerts and work orders. Of course this benefits customers because it helps OCWA deliver a consistent product and a high level of service. But it also brings advantages to the agency’s workers.The work orders enable crews to be proactive, since they can highlight budding problems before they progress. 151 ActiveFactory software, InTouch HMI, SCADAlarm software,Wonderware System Platform. WaterTreatment
  • 150. Additionally, management can better utilize personnel throughout the province.While there are hundreds of OCWA locations in Ontario, there are not hundreds of staff. So the Wonderware solution’s web-based desktop capabilities mean that maintenance can be performed remotely. Simpson puts it this way, “You can be ahead of problems before they happen. Wonderware enables you to respond in a timely manner using a remote desktop.The last thing you do is physically go there.” So it saves fuel costs, vehicle costs and operator time. The wide-area SCADA system also provides better work-life balance for OCWA’s maintenance staff members.Because most corrections are made remotely,workers don’t have to travel as much.And when system adjustments are needed, they usually can be addressed during the normal working day,eliminating more-expensive,on-call hours.But if alarms do come in overnight,staff can log on to the internet,make a correction and go back to sleep. Flowing into the Future The OCWA system incorporating the Wonderware software solution is considered cutting edge in North American water and wastewater management, but the agency is driven to implement further innovations. Plans include expanding web-based capabilities so that customers and partners can log on and see how their systems and services are operating, including performance information and quality measurements. Plus, OCWA envisions expanding its work with small- and medium- sized utilities so that all municipalities in Ontario have access to the latest technology for clean water service. OCWA is also partnering with First Nations in Ontario.The agency hopes to be a resource for high-quality water and wastewater services as well as emergency capabilities. Simpson sums it up by saying,“The most important benefit is that it provides a scalable system for our clients whether they are small or large. It incorporates the best technology and software available and gives us the total solution to meet their needs, and meet all regulatory requirements to provide safe, clear drinking water throughout the province of Ontario.” And withWonderware, that’s sure to continue. This document was realized thanks to the support of: Ontario CleanWater Agency. 152 ActiveFactory software, InTouch HMI, SCADAlarm software,Wonderware System Platform. WaterTreatment
  • 151. Industry:WaterTreatment Puerto RicoWater and Sewage Authority www.acueductospr.com “Using Wonderware software has made this plant the role model for the Metro region. It has helped us improve and maintain the quality of the water produced in this facility – which is excellent!” Nancy Caceres, Plant Manager-Guaynabo,Autoridad de Acueductos y Alcantarillados Puerto RicoWater and Sewage Authority Delivers Increased Customer Satisfaction withWonderware Solution byWonderware Goals: • Maintain high quality standards for EPA compliance; • Increase efficiency of management for one of the world’s largest system platform installations; • Enable better visibility and troubleshooting for over 1,500 sites; • Provide higher capacity output while controlling costs. Challenges: • More than 120 different platforms to be integrated; • Needed faster deployment of new installations; •Tough terrain with areas where radio and DSL communications can’t reach. Wonderware Solution: • ActiveFactory software; •Wonderware Industrial Computers (InTouch HMI embedded); •Wonderware System Platform. Results: • Output has increased from 12 million gallons to 20- 30 million gallons; • Cost savings estimated at $15 million over seven years; • Fewer shutdowns and improved customer satisfaction due to proactive trouble shooting; • Island-wide standardization for faster installations and increased operator ease-of-use; • Clean, EPA-compliant water. 153
  • 152. Puerto Rico – Since being discovered by Christopher Columbus in 1493, Puerto Rico has lived up to its name as a ‘Rich Port’. But since the island lacks a source of fresh water, inhabitants have always had to be wise with this precious resource. During Spanish Colonial times, the military built five large cisterns beneath the Main Plaza to collect rain water. But today, with a population of almost four million people, the nation’s needs for clean drinking water and waste water treatment are much more extensive.The system that serves them has grown to over 10,000 miles of water mains and aqueducts and 2,000 miles of sewage lines. This large operation is managed by the Puerto Rico Water and Sewage Authority (Autoridad de Acueductos y Alcantarillado de Puerto Rico).The agency supervises over 1,500 sites that provide service to all five regions of the island. More than 120 platforms have been deployed, making it one of the largest System Platform implementations in the world today. Investing in Progress The Puerto RicoWater and Sewage Authority’s strength is not just in its size.The agency is committed to advanced technology that enables it to provide the highest-quality services.Wonderware distributor iMiS has been a key partner, working with the Authority to meet its aggressive objectives. The latest updates were deployed so that the Water and Sewage Authority could increase water output, maintain EPA compliance, improve efficiency and also control costs.And while these goals may sound contradictory, with iMiS and theWonderware solution, they were all possible. To do it, iMiS recommended the addition of a state- of-the-art security system, high-speed historical data collection and components that would enable centralized management of 100% of the agency’s critical facilities. Improving Efficiency and Quality The first step was to transition to a fully automated system. By eliminating as many manual operations as possible, theWonderware solution enabled the Authority to reliably control all aspects of the water and waste water treatment system – and to be proactive about it. Jose Luis Muñoz, President of iMiS, explains,“TheWater Authority has changed from a reactive system to a proactive system with the Wonderware solution.We know what’s going on now, rather than having users tell us.” With real-time diagnostics, operators monitor the quality of the water and the treatment processes, plus they can make timely changes that help prevent compliance violations.Also, with the addition of Wonderware Historian, data can be gathered and organized easily and quickly for the monthly reports required by the Environmental Protection Agency. This means that the quality of the water is maintained consistently and theWater and Sewage Authority is meeting compliance regulations. The agency has gained better troubleshooting capabilities as well. According to Muñoz, with system-wide data at their fingertips, decision making is much more rapid and efficient. Hector Sanabria, InformationTechnology Director, agrees,“You have all of the information in front of you.Therefore, once you see different alarms within the software interface, you can make decisions.You do not have to go directly to the facilities because you can see the information on the screen.” Communications Across the Island Increased visibility and reduced travel to the many system sites is critical. Because the agency serves 154 ActiveFactory software,Wonderware Industrial Computers (InTouch HMI embedded),Wonderware System Platform. WaterTreatment
  • 153. the island’s entire diverse and remote terrain, the Wonderware solution also needed to provide better communications.Various technologies combine to solve this challenge, including frame relays, radio, DSL and satellite links.Time and money are saved because trips to remote sites are minimized. MoreWaterWithout Increased Costs With a growing population and brisk tourism, the demand for more water in Puerto Rico is constantly growing.This is another area where the new Wonderware solution has solved an important challenge. Because, even though more water is needed, the ability to provide it cost effectively is also a requirement. The new solution has enabled system-wide consistency in monitoring and allocating resources and overall output has steadily grown. Sanabria says, “We’ve usedWonderware software to analyze our processes and capacity.And based on this data, we’ve realized that we can, in fact, increase our output.”The Authority now produces 20 to 30 million gallons of water, up from 12 million gallons before the Wonderware solution was implemented. And the increase has been accomplished without taxing the Authority’s budgets.The agency estimates that within about seven years, the new system will save Puerto Rico close to 15 million dollars. Customer Satisfaction is the Ultimate Goal With theWonderware solution in place, the Authority is realizing substantial benefits: • Facilities in all five regions operate consistently and maintain the same, high quality of water and waste water treatment; • Standardization, enabled by theWonderware System Platform, allows resources to be allocated among the regions as needed; • New stations can be deployed faster, also through standardization; • Automatic fault detection of remote PLCs, pumps, sensors and instruments minimizes the need for manual inspections, saving time and money; • Real-time monitoring and alarms improve control of the operation and prevents sewage overflows and water distribution faults. But the most important result of the new solution is that the customers of the Puerto RicoWater and Sewage Authority are experiencing better service. Thanks to the dedication of the agency’s management and staff along with a valued distributor partner and advanced automation technology fromWonderware, the island’s citizens are enjoying abundant, clean water delivered consistently and cost effectively. This document was realized thanks to the support of: Puerto RicoWater and Sewage Authority and iMiS. 155 ActiveFactory software,Wonderware Industrial Computers (InTouch HMI embedded),Wonderware System Platform. WaterTreatment Figure 1: Guaynabo water treatment plant.
  • 154. Industry:WaterTreatment Tragsa (Empresa deTransformación Agraria, S.A.) www.tragsa.es “Each remote control system for irrigation management is a new example of optimization and improvement.The technology helps make efficient use of Spanish natural resources” Félix Díaz de Rada, Director, Department of Irrigation Modernisation,Tragsa. Balearics Optimises theWater Resources of itsWater Users Irrigation Using remotelyWonderwareTechnology byWonderware Spain Goals: •To reuse and optimize water resources; • Create a system that is self sustaining; • Simplify integration and make it available to future irrigation communities. Challenges: • Include various elements differentiated from each other: waste-water treatment plant, a intermediate water storage reservoirs systems, its associated hydraulic system and remote control system; • Control the water from crops. Wonderware Solution: • InTouch HMI; •Wonderware System Platform. Results: •With the integration of theWonderware System Platform, the irrigation communities have a simple tool that stores water user administrative data; •The solution optimises water consumption and distributes water fairly based on farmers’ requests; •The system helps make consumption forecasts based on demands. 156
  • 155. 157 Balearics, Spain -The Ministry of Environment and Rural and Maritime Affairs (MARM) committed itself in 2008 to modernise various irrigation systems on the Balearic Islands in order to create a productive, sustainable and high quality agriculture system. The main goal of this Project is to reuse waste water for irrigation by modernising and optimizing various irrigation communities. A Project Aimed at Sustainability Reusing wastewater is important part of sustainability.This is especially true in Balearics where demand increases considerably in the summer when droves of tourists arrive at the island at the same time that the crops need for water is at its greatest.This is why the optimisation of water resources has become one of the main goals. The project includes various elements that include a wastewater treatment plant, an intermediate water storage reservoirs system, its associated hydraulic system and a remote control system.The different irrigation systems have their own local control centers with a general control centre located in Palma de Mallorca. MARM, throughTragsa, is responsible for carrying out this project. It is managed by Adasa, an Engineering company specializing in technological solutions relating to the management of the integral water cycle and the environment andWonderware ArchestrA-certified system integrator. ChoosingWonderware Wonderware System Platform was chosen after a thorough evaluation.The solution, based on ArchestrA technology, includesWonderware Application Server,Wonderware InTouch HMI (Human Machine Interface) andWonderware Historian for data control, visualisation and storage, respectively.The complete solution has been installed in the seven local control centres and in the central control room.TheWonderware System Platform provided huge improvements in productivity and scalability for the distributed automation applications. The data acquisition, alarm and event, data handling and development makes it a great solutions for simplifying, maintaining and managing any distributed application. The solution provides the necessary flexibility for possible extensions with new equipment and requirements.This is possible in the future when the integration of ultraviolet treatment systems, meteorological stations, desalination plants and other systems needs to be implemented. “One of the matters that concerned us was the difficulty of individually controlling the quantity of water supply. The remote control system helps to control the water consumption from each of the different communities, making it possible to regulate consumption,” Félix Díaz de Rada, Director of the Department of Irrigation Modernisation,Tragsa. Efficiency, Effectiveness, Easy Implementation and Use Ensuring water supply quality for all users and facilitating decision-making for system managers improves irrigation system efficiency. The implementedWonderware solution places vital importance on the four main points that make up the control system: 1. Communication architecture: Grouped in two blocks: a. Local control centres:Thanks to Wonderware System Platform software, the equipment can be supervised locally; b. Central control centre: •TheWonderware System Platform application provides important information to 10 concurrent users at the same time (via mobile, PDA,ADSL or 3G, for example); •Website application: Helps to monitor and manage the system’s irrigation terminals. Users can access information from anywhere in the world via a computer or mobile device. InTouch HMI,Wonderware System Platform.WaterTreatment
  • 156. 158 Moreover, they can follow any changes in consumption and export the displayed data to an excel spreadsheet for greater comfort and ease of use; 2.Watering control units:The remote unit used is the aquaReg system, manufactured and supplied by Adasa. It is responsible for closing and opening the electrovalve and the reading and transmission of counter’s pulses; 3. Control automation: it manages pump operation and communication using the local control centre; 4. Control centre:The SCADA system in the local control centre is responsible for supervising and operating all local equipment. Information from all the pumping and irrigation is also transmitted to the control center. “The remote system not only helps having control over the water resources, but it also makes operation very easy for users who are not accustomed to this type of technologies”, points out Enrique Santarrufina,Works and Projects’ Coordinator at Balearics, MARM. Better Control, Less Costs “Although it is too early to provide specific data, it did not take long for us to evaluate a return on investment for the project, as the result of more efficient water management and connection with the invoicing systems of the irrigation communities”, affirms Gloria Cabot Batlle, Project Manager,Adasa. The benefits of the irrigation automation are quickly seen once the system was implemented. With the integration of theWonderware system, the irrigation communities have a simple tool that stores water user administrative data. It optimises water consumption and distributes water fairly based on farmers’ requests. It also helps make consumption forecasts based on demands. This document was realized thanks to the support of: Félix Díaz de Rada, Director of the Department of Irrigation Modernisation, Tragsa, Enrique Santarrufina,Works and Projects’ Coordinator, Balearics, MARM, and Glòria Cabot, Project Manager,Adasa,ArchestrA-certified system integrator. InTouch HMI,Wonderware System Platform.WaterTreatment Figure 1: Irrigation SCADA System.
  • 157. 160 NOTES
  • 158. 161 NOTES
  • 159. EUROPE Austria, Hungary Wonderware GmbH www.wonderware.at Belarus Wonderware Belarus www.wonderware.by BeNeLux (Belgium, Netherlands, Luxembourg) Wonderware Benelux www.wonderware-benelux.com Czech & Slovak Republics Pantek (CS) s.r.o. www.pantek.cz Denmark Wonderware Scandinavia AB www.wonderware.dk Estonia Wonderware Estonia www.wonderware.ee Finland Wonderware Finland www.wonderware.fi France Wonderware France www.wonderware.fr Germany Wonderware GmbH www.wonderware.de Greece Control System Ltd. www.controlsystem.gr Iceland Tölvusalan HF Email: olafur@tolvusalan.is Ireland Wonderware Ireland www.wonderware.ie Italy Wonderware Italia S.p.A. www.wonderware.it Latvia Wonderware Latvia www.wonderware.lv Lithuania Wonderware Lithuania www.wonderware.lt Norway Wonderware Scandinavia AB www.wonderware.no Poland Astor Sp. z o.o. www.astor.com.pl Russia & CIS Wonderware Russia www.wonderware.ru Portugal SA, Soluções em Automação, S.A. www.sa.online.pt Serbia & Montenegro ACE – Automatic Control Engineering www.ace.co.yu Slovenia, Croatia WW Engineering www.wweng.com Spain Wonderware Spain www.wonderware.es Sweden Wonderware Scandinavia AB www.wonderware.se Switzerland Wonderware Switzerland SA www.wonderware.ch Turkey EST (Enerji Sistem Teknolojileri Sanayi) www.estenerji.com Ukraine Wonderware Ukraine www.wonderware.ua United Kingdom Wonderware United Kingdom www.wonderware.co.uk AFRICA South Africa Wonderware Southern Africa www.wonderware.co.za ASIA & SOUTH PACIFIC Australia Wonderware Australia www.wonderware.com.au China Wonderware China www.wonderware.com.cn Wonderware Guangzhou www.guangzhouwonderware.com.cn Beijing BlueBird Automatization Technology Co., Ltd. www.bluebirdme.com Qingdao Gaoxiao Information Industry Co.,Ltd. E-mail: zxpmile@163.com Chongqing Runfeng Science & Technology Co., Ltd. www.cqrfkj.com Shanghai BlueBird M&E Co., Ltd. www.bluebirdme.com Shanghai EastDream Automation Control Tech Co, Ltd. www.eastdream.net Utitech Technology (Beijing) Co. Ltd. www.utitech.com.tw Xi’an king-mount Automation Co. Ltd. www.king-mount.com.cn Yunnan Summit Technology Co. Ltd. www.summittech.com.cn Zhuhai Telead Mechanical & Electronic Co. Ltd. www.telead.gd.cn Hong Kong Tecoford Ltd. www.guangzhouwonderware.com.cn India Wonderware India Email: info.india@wonderware.com KLG Systel Ltd. www.klgsystel.com 162 WONDERWARE REPRESENTATIVES
  • 160. Indonesia PT Trimaxindo Adimitra www.trimaxindo.com/wonderware Japan Wonderware Japan www.wonderware.jp Canon IT Solutions, Inc. www.canon-its.co.jp Nittetsu Elex Co. Ltd. www.ns-elex.co.jp/index.htm Korea, South Wonderware Korea Ltd. www.wonderware.co.kr INO Technologies Inc. www.ino.co.kr Maha Net Co. Ltd. www.maha-net.co.kr Sammi Information System Co. Ltd. www.sammicomputer.co.kr Macao Tecoford, Ltd. Email: tecoford@netvigator.com Malaysia IAM-Wonderware Sdn Bhd www.iamgroup.com.my New Zealand Process Software Ltd. Email: info@prosoftware.co.nz Pakistan Agatos Pakistan (Pvt.) Ltd www.agatos.com.pk Philippines Precision Motion Control Phils. Inc. Email: sheila_balayanto@pmcp.com.ph Singapore Wonderware of Singapore Pte Ltd. www.wonderware.com.sg Servo Dynamics Pte Ltd. www.servo.com.sg Taiwan Utitech Technology Co. Ltd. www.utitech.com.tw Thailand Sagitate (Thailand) Co. Ltd. www.sagitate.com Viêt Nam Q Systems Ltd. www.qsystemsco.com MIDDLE EAST Israel Instrumetrics Engineering Ltd. www.instrumetrics.com United Arab Emirates Precast FZCO www.wonderwareme.com U.S. & CANADA Akamai Controls www.akamaicontrols.com Alaska Instrument Co. wwwalaskainsrument.com Wonderware Central www.wonderwarecentral.com Wonderware Cincinnati www.atrdist.com Wonderware Great Plains www.wonderwaregp.com Wonderware Midwest www.wonderwaremidwest.com Wonderware NorCal www.norcal.wonderware.com Wonderware NorthEast www.wonderwareNE.com Wonderware PacWest www.pacwest.wonderware.com Wonderware Southeast www.wonderwarese.com Wonderware West www.west.wonderware.com Wonderware Canada East www.wonderwarecaneast.ca LATIN AMERICA & THE CARIBBEAN Argentina Wonderware Argentina http://latino.wonderware.com Brasil Wonderware do Brasil Email: info.brasil@wonderware.com Chile ARTARON S.A. www.artaron.cl Colombia Colsein Automatizacion y Neumatica www.colsein.com.co Costa Rica GNE Automatización Industrial de Centroamérica S.A. Email: ventas@gnecorp.com México Wonderware de México http://latino.wonderware.com Puerto Rico iMiS (Integrated Manufacturing Information Systems) www.imispr.com Venezuela Wonderware Venezuela http://latino.wonderware.com WONDERWARE REPRESENTATIVES
  • 161. Invensys Operations Management 5601 Granite Parkway Suite 1000 Plano,TX 75024 U.S.A. Tel 1-469-365-6400 www.invensys.com ©2009 Invensys Systems, Inc.All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing from Invensys Systems, Inc. Invensys,Wonderware, InTouch, ActiveFactory, InBatch, SCADA, SCADAlarm and ArchestrA are trademarks of Invensys plc, its subsidiaries and affiliate companies. Microsoft,Windows,Vista,Visual Studio, BizTalk, SharePoint, Microsoft Office and Internet Explorer are registered trademarks of Microsoft Corporation.All other brands and product names are the trademarks or service marks of their respective owners.