Category

Case Studies

Conveyor Speed Sync for an Energy Bar Packaging Facility

By Case Studies, Food and Beverage, HMI, PLC, Process Control

An energy bar manufacturing facility’s processing line used eight standalone pieces of equipment with conveyor belts and the speed of the conveyors needed to be synced across all of the machines for optimal operation. The speeds were previously synced by adjusting potentiometers on each piece of equipment leading to unequal speed variations throughout the line. We worked with the staff to implement a PLC-based system with an operator interface HMI to set the speeds for the line, as well as select which speed should be used at any given time.

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Production Data Management System for Diatomaceous Earth Processing

By Case Studies, Database Management, Mining, Process Analysis

A leading diatomaceous earth processing facility was storing its production data in Excel spreadsheets. The long-term effects of this method lead to large amounts of spreadsheets on their servers, and made it difficult to access necessary information efficiently. The best remedy for this problem was to move to a web-based solution. This approach provided a centralized database to store the data and an interface for authorized users to enter, edit, and view the data.

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Custom Data Monitoring Website for Solar Facility Commissioning

By Case Studies, Database Management, Process Analysis, Process Historian, Remote Support, Standardization, Web-based Solutions

Our staff worked with a solar power provider to develop and implement a web-based monitoring system for use at 3 of their new solar power plants. The website was configured to allow internal users to monitor real-time data from each facility, with data access to the general public on a 30 day delay. The system provided operational staff with automatic email and text notifications of equipment alarms. The site included functionality for customer invoicing and utility reporting to comply with regulatory requirements.

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SCADA System for Multiple Remote Solar Sites

By Case Studies, Database Management, HMI, Process Analysis, Process Control, Process Historian, Remote Support, SCADA, Solar, Standardization

Corso met with the SCADA operations team for a large solar power provider to discuss a standardized system built using Wonderware System Platform. The goal was to build objects for the various pieces of equipment at a solar plant, inverters, breakers, power meters, etc., to enable rapid deployment of SCADA systems for new facilities. As part of developing the system, we developed a standardized naming convention for the facilities and all of the data points to allow a script to populate a centralized OSI PI Historian with data from each facility.

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System Migration: Wonderware to FactoryTalk Historian

By Case Studies, Database Management, Mining, Process Analysis, Process Historian

A diatomaceous earth processing company had two facilities with Wonderware Historian installations on older server hardware. After years of exposure to an extremely harsh environment, the server at one of the facilities catastrophically failed. We were able to recover historical data from the machine and exported it to FactoryTalk Historian. The Wonderware Historian configuration was migrated to FactoryTalk Historian and the data was imported with no loss of data.

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Process Change Management System For A Mining Company

By Case Studies, Database Management, Manufacturing Execution Systems (MES), Mining, Process Analysis, Technology Migration, Web-based Solutions

A diatomaceous earth processing facility worked with us to develop a centralized process change management system. We developed requirements based on their existing system, which was based on Excel spreadsheets. Many of the requirements were designed to provide a robust and automatic approvals process for proposed changes.

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