Media visualization system and auxiliary installations operation
Modern utilities and auxiliary systems visualization solutions support monitoring, analysis, and optimization of production processes. By integrating advanced control technologies, we enable real-time tracking of equipment performance, rapid response to failures, and analysis of historical data.
The implemented system covered 5 production plants in Poland and abroad. The goal of the project was to create a unified, remotely accessible environment for managing utilities and auxiliary installations. Key challenges, such as standardizing communication protocols and integrating heterogeneous control systems, were addressed using the AVEVA platform and a Microsoft SQL Server database.
Goals
- Providing data on equipment operating states and failures
- Enabling monitoring of multiple plants from a single location
- Scheduling operation of individual machines and installations
Challenges
- Standardization of communication protocols
- Integration of heterogeneous installations
- Collection and reporting of large volumes of data
Solutions
- AVEVA System Platform, Historian, InTouch
- Siemens S7 controllers and PLCs from multiple vendors
- Microsoft SQL Server Reporting Services
- Custom solutions based on Microsoft SQL Server databases
Benefits
- Reduced response time to failures
- Fast and accurate fault localization
- Access to equipment logs and operational reports
- Optimization of control systems based on collected data
- Energy consumption optimization through scheduling of installations
- Unified reporting interface for utility consumption
- SMS notifications for critical failures
- Email alerts for significant abnormalities
Preparation
Before the modernization, each installation was controlled locally, without the ability for remote monitoring or management. The project started in parallel with the construction of one of the plants, which enabled gradual integration of the installations into a unified system.
The key objective was to integrate PLC controllers and devices with various communication interfaces into an Ethernet network, followed by the deployment of visualization and remote control of the installations.
Implementation
The first phase of the project was carried out at a plant that was still under construction. This is where we located the servers responsible for the entire system. Access to the visualization is provided via the RDS service. In subsequent phases, we progressively integrated the remaining plants.
The system was implemented on the AVEVA System Platform. It consists of:
- several Application Server instances
- a Historian Server for data collection
- an RDS client station server
- a reporting server
In addition to RDS access for authorized users, visualizations are also available in control rooms and gatehouses across the individual plants.
Visualization scope
The visualization system covers the following installations and areas:
- air handling units
- emergency lighting system
- heating units
- basic lighting system
- emergency ventilation systems
- outdoor lighting system
- heat and gas meters
- compressor stations
- electricity meters
- stormwater pumping stations
- UPS monitoring system
- wastewater pumping stations
- vapor detection system
Visualization of utilities and auxiliary systems
Summary
The implemented system enabled full control over auxiliary installations and utility consumption from a single visualization application. We significantly reduced response time to failures, and utility consumption reporting became more efficient and consistent across all plants.
The system also provides valuable data for the internal analytics department, supporting optimization of production processes, energy consumption, and operational costs.
