realizacje

Control - ServiceWdrożeniaMedia visualization system and auxiliary installations operation
Media visualization system and auxiliary installations operation
Chemical industry

Modern utility visualization and auxiliary installation management systems play a key role in monitoring and optimizing production processes. By integrating advanced control technologies, it is possible not only to track real-time device parameters but also to respond quickly to failures and analyze historical data.

The implementation of a system covering five production plants in Poland and Ukraine aimed to create a unified, remotely accessible environment for managing utilities and auxiliary installations. Key challenges, such as unifying communication protocols and integrating various control systems, were addressed through the use of the Aveva platform and Microsoft SQL Server database.

The project we implemented covered five production plants across Poland and abroad.

GOALS:

  • Providing data on device operating statuses and failures
  • Enabling remote access to multiple production plants from a single interface
  • Scheduling the operation of individual devices and installations

CHALLENGES:

  • Unification of communication protocols
  • Integration of diverse installations
  • Collection and reporting of large volumes of data

SOLUTIONS:

  • Aveva System Platform, Historian, InTouch
  • Siemens S7 PLCs and various other controllers
  • Microsoft SQL Server Reporting Services
  • Custom solutions based on Microsoft SQL Server database

BENEFITS:

  • Reduced response time to failures
  • Precise and fast fault localization
  • Data availability in the form of reports and device operation logs
  • Optimization of control systems based on collected data
  • Energy consumption optimization through system parameter adjustments (scheduling)
  • Unified media consumption reporting interface
  • SMS notifications for critical failures
  • Email alerts for significant irregularities

Preparation

Before modernization, each installation was locally controlled, with no possibility of remote monitoring and management. The project implementation started simultaneously with the construction of one of the plants, allowing for a gradual integration of installations into the new system. A key assumption was to connect PLCs and other devices with various communication interfaces to the Ethernet network, followed by visualization and remote control of installations.

Execution

The first phase focused on developing the system at the plant under construction, where the main system servers were located. Access to visualization was provided through an RDS service. In subsequent phases, additional plants were gradually integrated. The system was implemented on the Aveva System Platform and consists of:

  • Several Application Servers,
  • Historian Server for data collection,
  • RDS Client Station Server,
  • Reporting Server,

In addition to RDS access for authorized users, visualizations are also available in control rooms and reception areas of each plant.


Scope of Visualization

The system provides visualization for the following installations:

  • Ventilation units
  • Emergency lighting system
  • Heating units
  •  Primary lighting system
  • Emergency ventilation
  • Outdoor lighting system
  • Heat and gas meters
  • Compressor stations
  • Electricity meters
  • Rainwater pumping stations
  • UPS monitoring
  • Wastewater pumping stations
  • Vapor detection system

 

Visualization of media and supporting systems:

 

 

Final Summary

The implemented system enabled full control over the operation of auxiliary installations and utility consumption from a single visualization application. Response time to failures has been significantly reduced, and the media consumption reporting process has become more efficient. Additionally, the system provides valuable data for internal analytics teams, supporting the optimization of processes and operational costs.

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