Moving forward without re-engineering
Computerised automation systems are now commonplace in most businesses. The problem is often how to modernise without the huge cost of replacing older systems, which work perfectly well.
The simplest and best solution is often to keep what works and ‘piggyback’ a new system onto the established system. These solutions allow you to:
- Update or expand systems without the cost of replacing or re-engineering existing control systems;
- Create a more open system making it easier to expand further;
- Allow better integration of information by linking control systems to: Business Databases, Information Web-sites, Messaging Systems (SMS paging, Email), etc
Control Room Displays (SCADA)
Modernisation and increased efficiency often requires control screens to be moved from the shop-floor to a central control facility. Creating a new overview SCADA has many advantages:
· Older control systems can be left in place, saving money and providing a fall back control system when necessary;
· Control displays can be updated and indications and screen colours can be standardised, some systems use red for running plant others may use red to indicate the plant is stopped. This type of confusion can be very dangerous and lead to damage and health & safety issues. (HMI screen design white-paper);
· Critical information can be condensed onto fewer screens;
· Systems can be integrated with modern IT infrastructure, to allow sharing of information in a secure environment.
In a project for Manx Electricity, Hexatec combined information from multiple control systems to create a single centre desk screen in a new central control facility.
“Over the years, a number of different vendors have been used to provide industrial software solutions for turnkey projects. As we grew, it became increasingly clear that all the information being collected from these individual sites needed integrating onto single screens.” Jim Crombie (Manx Electricity)
Centre Desk Case Study
Management Information
Integration of data from installed control systems can also provide valuable up to minute management information. This allows accurate real-time data from metering systems and other measurement systems to be gathered automatically and included with other business critical data in a central database. Using Hexatec’s Audit1000 software with a SQL database, Manx Electricity has been able to create an advanced Electricity Trading system using real-time metering data, which has delivered real cost savings.
MEA Trading Case Study
Techniques
which help you move forward but keep those working legacy systems.
There are many established methods to exchange data between control systems; OPC, DDE, Serial Protocols, File shares, etc.
OPC (OLE for Process Control)
OPC is the modern standard for linking systems over networks. We routinely use OPC to link systems from different manufacturers.
DDE (Dynamic Data Exchange)
DDE was widely used to exchange data between MSWindows applications and continues to be used in many older systems.
Serial Protocols
We have over 20 years experience developing and debugging serial communications with a wide range of control & I/O equipment. Where possible, we prefer to use standard protocols such as Modbus but, where required, non standard protocols can be supported.
Data Sharing
Where other options don't exist, file sharing is the most basic method of exchanging data between applications, but great care is needed to avoid conflicts and timing errors.
To find out more or to order a feasibility study contact the Hexatec team.