The Challenge

Bluco wanted to increase production by operating one of its automated heat treat processes around the clock. While the furnace itself was capable of continuous operation, the existing system required an operator to be on-site to monitor equipment, respond to alarms, and verify process conditions.

To safely transition to unattended operation during off-shifts, Bluco needed remote access providing real-time visibility into the process, immediate alarm notification, enhanced life safety through ammonia monitoring, and integration of additional equipment required for reliable operation.

The challenge was bringing together multiple technologies including OEM controls, safety systems, and remote monitoring into a single, easy-to-use platform capable of future growth.

The Solution

Leveraging extensive experience in industrial automation and heat treating, Corso Systems designed and implemented an integrated monitoring and control solution using the Ignition SCADA Platform.

The solution combined:

Ignition Perspective for secure, remote access on any device
An OEM Siemens S7-1200 PLC controlling furnace operations
A Corso-programmed Opto 22 groov EPIC PLC to manage ancillary equipment
CTI Gas Detection Specialists ammonia sensor for life safety monitoring
An HD IP camera integrated through Node-RED to provide real-time visual verification of the process

Using the Corso DRIVE Framework, the project was planned, developed, tested, and commissioned with a focus on reliability and long-term scalability.

One of the primary technical challenges involved integrating the OEM-provided Siemens PLC. Because additional programming was required within the OEM controller, Corso worked collaboratively with the furnace manufacturer to define the required data exchange and ensure seamless communication with Ignition. This cooperative approach gave Bluco a unified view of both furnace operation and supporting equipment without sacrificing functionality.

The resulting system provides operators with a single interface for monitoring process conditions, receiving alarms, viewing live video, and responding quickly from virtually any location.

The Results

The completed solution transformed Bluco's ability to operate its heat treat process.

By combining remote monitoring, automated alarm notifications, integrated safety systems, and live video verification, Bluco can now confidently operate the furnace 24 hours a day without requiring an operator to remain on-site overnight.

Key benefits include:

Increased production through continuous 24/7 operation
Improved operator efficiency by reducing unnecessary after-hours site visits
Enhanced life safety with automated ammonia detection and emergency furnace shutdown capabilities
Faster troubleshooting through integrated live video monitoring
A scalable Ignition platform ready to support future equipment and process expansion

Rather than simply adding remote access to their existing system, Bluco gained a connected operational platform that improves safety, increases uptime, and gives operators the information they need to make informed decisions from anywhere.