Rockwell Process Analytics for Cement Manufacturing Facility
Project Drive
A cement manufacturing facility worked with Corso Systems to implement a process historian and data visualization tools for its R&D plant. We completed the work on-site, working directly with the facility personnel to specify the data to be stored in the process historian
Solution
We met with the client to discuss their existing system and how both the PLC and operator interface were failing due to age and general wear and tear. The mixer had been installed when the plant was first opened in the early 90s. No software was available for the Cutler Hammer PLC or operator interface HMI 20 years after installation.
We worked with the plant operators to understand and develop a control philosophy for the mixer and make upgrades to the operator interface. One major issue with the existing hardware was that some of the inputs to the PLC from safety devices had failed. These issues were resolved with the upgraded PLC.
The operators also requested recipe management functionality, allowing them to easily configure various mixing steps depending on the product being produced. We implemented a screen in the HMI for them to configure a handful of steps with various mixing speeds and times. This allowed the operators to reduce a large amount of over and under-mixing from manually timing steps using the old system.
The new system was commissioned, operators were trained, and the process was back up and running by lunchtime. The client now has updated copies of all documentation, putting them in a better position for the future.
Benefits
Process data stored in a centralized database
Data accessible from outside of the HMI application, including access to corporate staff upgrade
Automated reporting capability
Reduced overhead to collect data required for periodic reporting
Decreased overhead for managing test data
Increased productivity of R&D process
Increased knowledge and awareness of R&D projects
Project Details
Industry: Aggregates
Location: Gilroy, CA
Services: Process Historian, Process Analytics, Data Visualization
Technology
FactoryTalk Historian
FactoryTalk VantagePoint
Allen Bradley ControlLogix PLC
SQL Server
Focus
To improve usefulness of R&D testing processes
To collect process data in a centralized location
Make process data easily accessible to plant personnel
Configure hardware and software
Establish expectations for data collection and analysis
Train staff on optimal use of the systems