Case Study: Coca-Cola Bottler, Ireland

State-of-the-art Coca-Cola plant uses DataHub scripts to integrate alarm data and reports.

One of the largest soft drink manufacturing plants in the world, Coca-Cola’s Ballina Beverages facility, recently installed DataHub® software from Cogent Real-Time Systems (Skkynet’s subsidiary), to log alarm data and create end-of-shift reports. The 62,000 square meter plant, located in Ballina, Ireland, uses the most up-to-date manufacturing automation systems available, and management is constantly looking for ways to improve them.

Some of the equipment used at Ballina Beverages is designed and manufactured by Odenberg Engineering. Odenberg, in turn, relies on their subsidiary, Tricon Automation to handle the process control of the machinery.

In a recent upgrade to the system, the Odenberg/Tricon team chose DataHub software to construct custom log files to track and archive their alarms. They wanted to combine the live data from each triggered alarm with a text description of the alarm, and then log the results to a file. The alarms were being generated by an Allen-Bradley system from Rockwell Automation Inc., and the 1500 alarm descriptions were stored in an Excel spreadsheet. Each row of the final log would have to combine the time, date, and code of a triggered alarm with the corresponding description of that alarm.

After considering several different scenarios, the most effective approach was to connect their DataHub instance to Rockwell Automation’s RSLinx using its OPC server, and then to read in the alarm condition strings from a text file (instead of from the spreadsheet), using a DataHub script. The same script writes the data to the log file. This works so well that they decided to use another script to create end-of-shift reports.

“We got the basic system up and running in a few hours,” said Gus Phipps, team member from Odenberg, “which was good, because we were working under a tight deadline. The Cogent support team helped us out with the DataHub scripting, but we were able to do most of the work ourselves. It went surprisingly quickly.”

“Using the DataHub scripting language let us customize it to exactly meet our needs,” said George Black, Tricon’s project manager. “It is very flexible, and yet completely robust. It is months now since the project was completed, and the DataHub software continues working away merrily every day, just doing its job. We plan to use it again in other projects very soon.”

Case Study: Kimberly-Clark, Switzerland

Networking control and video systems for quality control using DataHub software

The Kimberly-Clark production facility in Niederbipp, Switzerland, is the leading tissue paper producer for Switzerland and Austria, supplying Hakle, Tela, Scott, Kleenex, and other popular brands of tissues for consumers throughout Europe.

In a recent upgrade to their video-based quality control system, Kimberly-Clark needed to connect their existing ABB QCS (Quality Control System) to a new, state-of-the-art Viconsys Process and Quality Vision System, to ensure the highest quality product. For implementation, they contacted Logic Park, an engineering and system integration company located in Thun, Switzerland.

“This project was a little unusual,” said Bruno Maurer, Head of Solutions at Logic Park. “The two systems had to be connected across a network. But each system was protected by a firewall, and each offered only an OPC server interface for data connections. We had to bridge these two OPC servers, passing the data across the network. Using DCOM for networking was out of the question, because it would open too many ports in the firewalls, and it is difficult to configure. What we needed was a way to tunnel the data across the network, and bridge the OPC servers at either end of the tunnel.”

To achieve these goals, Bruno turned to DataHub® software, which offers both OPC tunneling and bridging in a single, integrated product. He installed one DataHub instance on the same machine as the ABB QCS system, and connected it to that OPC server.

He then installed a second DataHub instance on the Viconsys computer, and connected it to the Viconsys OPC server. Then he configured the OPC tunnel, and was able to see both sets of data mirrored between the two DataHub instances. From there, it was a straightforward task to configure the necessary bridges to write data from one OPC server to the other OPC server. He had a test connection running in a several hours, and within a few days the new system was completely functional.

“DataHub software worked very well for this project,” said Bruno. “Taken by itself, the OPC tunnel is robust and secure. Combined with OPC bridging, this product has given us a complete and reliable way to network real-time data.”

Case Study: Wind Turbine Farm, USA

DataHub Scripting solution calms the conflict of bats vs. blades

Required by law to protect a rare species of bat, a major wind power generation company finds a solution using the Cogent DataHub®.

A rapid expansion of wind farms across the Eastern and Central United States has been checked in the past couple of years due to growing concerns for wildlife. An endangered bat species lives in that area, and is protected by law. Fears that the whirring blades of wind turbines could be harmful to this species of bat were sufficient to halt construction of a wind farm in West Virginia in 2009, and the discovery of a dead bat near a wind turbine in Pennsylvania in 2011 caused the power company to shut down the whole 35-turbine system for several weeks.

Although wind turbines are known to cause a few fatalities among common tree-dwelling bats, the endangered bat was thought to be largely safe, as it lives in caves, hibernates for more than half the year, and is seldom found in the vicinity of wind turbines. However, in the fall these bats migrate from their feeding grounds to their home caves for the winter. During this time, the chances of them passing through a wind farm are greatly increased.

In March a few years ago a major power company in the USA was informed by the US Fish & Wildlife Service that a number of turbines on the bat migration routes would need to be shut down while the bats are migrating. This caused quite a stir. The migration period for the bats is two months long―from mid-August to mid-October. Shutting down the whole system for that length of time would be very costly, not to mention the loss of clean energy which would need to be replaced by fossil fuels.

To maximize uptime, the company gained permission to let the turbines run during the times that the bats were not flying – all daylight hours, and in the night time when air temperatures drop below a specific temperature setpoint, or when the wind is fairly strong. The challenge was to implement a complete solution. A single bat fatality could mean full shut-down, legal penalties, and even lawsuits.

Top management at the company immediately took action, contacting the wind turbine manufacturer, who also provides the control systems. After several months of emails and meetings, it became apparent that the manufacturer would not have anything ready in time for the mid-August deadline.

“With three weeks to go, they told us there was no solution in sight,” said the SCADA engineer responsible for the project, “and we would need to go to manual operation, and reconfigure the cut-in speed on every turbine, twice a day.”

Most wind turbines are designed to “cut in”, or start turning to produce energy, when the wind is blowing at a certain speed. For these turbines, the normal cut-in speed is 3.5 meters per second. As the bats are active in low to moderate wind speeds, the company would need to raise that to 7 meters per second each night, and then drop it back down to 3.5 the following morning. This would mean manually reconfiguring the PLCs for 100 turbines, twice a day.

A better way

“I thought there must be a better way,” the project manager continued. “We’d been using the DataHub for years, and knew the potential was there to leverage this asset further. I gave Skkynet a call, and told them what we were up against. They delivered by helping us to develop a very efficient program using the native scripting language of the DataHub. The code ran right on the SCADA interface of the OEM system – so it’s as reliable as you can get.”

“Working together with Skkynet, we came up with a DataHub script that doesn’t change the cut-in speed of the turbines at all. We just blocked them from starting. The script tells each turbine to stay off, and keeps measuring wind speed. When it picks up to 7 meters per second, the script releases the turbine to start, and it ramps right up to the operating state. At the end of the day, we have a complete audit trail of every turbine controlled, including a history of critical parameters, such as rotational and wind speeds, and energy curtailed.”

“The script also has a temperature component. On cool nights in September and October, when the temperature drops below the dew point, it uses the same algorithm for starting and stopping the wind turbines.”

By the first week of August a test script was written, and after a few days of testing and last-minute tweaks, it was ready. The system went live on August 15th, and is meeting all expectations. Every night, whenever the air temperature is above the setpoint and the wind speed falls below 7 meters per second, the wind turbines stop, allowing the endangered bats to return safely to their caves for a long winter hibernation.

“I call the DataHub the Canadian Swiss Army Knife,” said the project manager. “We are able to accomplish a host of required functions with a single product solution. The ability to provide sophisticated logic and control algorithms with the built-in functionality of this product is the game changer. Being able to securely deliver real-time data between a site and the control center system allows the dispatch team to monitor the control process and maximize the production of clean, renewable, energy sources. Talk about a smart grid – who would have thought we’d be doing this type of thing in real time?”

Case Study: ABB Energy Automation, Italy

Secure OPC tunnel/mirror between power plants and company offices

In two recent projects, Italy’s ABB Energy Automation has developed a control solution that feeds data from power plant facilities directly to corporate offices – in real time – using DataHub® software. A key requirement was to provide a highly secure means of data transmission, with minimal risk of break-ins. For each project they implemented a DataHub tunnel/mirror solution to establish a secure, reliable connection between the power plant and corporate networks.

ABB Energy Automation provides software and control systems for power plants to ensure that equipment operates at optimum speed and efficiency. For these projects, it became clear that several Italian power companies would benefit substantially by monitoring the performance of the plant directly from the company offices. Mr. Michele Mannucci, ABB Project Engineer, began looking for a way to make the connection, using the most reliable and secure means available.

“Customers are very sensitive about security these days since they need to exchange information on the web,” he said. “We had OPC DA servers on our equipment, but found that using DCOM for networking was too risky. It required us to open too many ports in our firewalls. We had to find a way to avoid using DCOM.”

A search on the web brought Mr. Mannucci to DataHub software. For the first test, he connected a DataHub instance to the plant’s DigiVis Freelance 2000 OPC server, and then configured it to tunnel out through the plant firewall. With that working, he installed another DataHub instance on the corporate network, and then created a tunnel/mirror connection between the two DataHub instances.

For the production system, the company decided to use ABB’s own proprietary OPC server on the secure LAN in the plant, and connect that to the DataHub instance. From there the data flows out through the plant firewall via SSL-encrypted TCP to a DataHub instance in the corporate offices, which is connected to the corporate LAN. The two DataHub instances mirror the data, so that every data change on the plant LAN is immediately received on the corporate LAN.

“This DataHub tunnel with data mirroring is very good for our OPC networking, because we only need to open one port, and we are secure from DCOM break-ins,” said Mannucci. “We are considering installing this same solution in our top plants.”

It took only a few days for Mannucci to go from initial testing to a working system in the first power plant. The second system was up and running in a similar time frame. Both systems have been running 24/7 since installation, with no breaches in security.

Case Study: Gazprom, Russia

Gazprom integrates SCADA, HMI modules, RTUs, data processing and historical archiving

Gazprom, the largest gas producing company in the world and responsible for 8% of Russia’s GDP, is using DataHub® software to monitor and control pumps, valves, consumption control units, cranes, and other equipment along 23,000 kilometers of pipeline spanning much of western Russia. The control system was developed by the Federal State Unitary Enterprise and is called the Unified Remote-Control Complex, or UNK TM. Software sales and support were provided by SWD Software Ltd., a QNX and Cogent distributor in St. Petersburg, Russia.

“DataHub software was the perfect tool for the job,” said Mr. Leonid Agafonov, Managing Director of SWD. “It is easy to use and provides robust connectivity for the whole control system. Our customer is very pleased with the project, particularly the reliability of the software.”

The system is an open, distributed-information control system with modular hardware architecture running on the QNX 4 operating system. A DataHub instance operates in each Control Room, and is connected to a number of Remote Terminal Units (RTUs), which in turn are connected to valves, pumps, and other hardware. The DataHub instance is also connected to a SCADA system, various HMI modules, and the Cascade Historian, which stores data to disk.

The system provides real-time operation, a multi-window graphical user interface, data processing components, and archival disk storage of data. Workstation devices and services, such as electro-chemical protection and operational service can be added or removed at any time. There is also teletext communication between the Control Room and the RTUs, through the DataHub software.

The Unified Remote-Control Complex has successfully passed tests administered by the Interdepartmental State Testing Commission and has been recommended for use at OAO “Gazprom” units and facilities. The system was developed by the Federal State Unitary Enterprise “FNPZ Y.E.Sedakov NIIIS”. It has a Measurement Instrumentation Approval Certification #6398 and is listed as #18430-99 in the State Measurement Instrumentation Register.

Case Study: TEVA API Pharmaceuticals, Hungary

TEVA combines tunnelling and aggregation to network OPC data through a firewall

Laszlo Simon is the Engineering Manager for the TEVA API plant in Debrecen, Hungary. He had a project that sounded simple enough. Connect new control applications through several OPC stations to an existing SCADA network. The plant was already running large YOKOGAWA DCS and GE PLC control systems, connected to a number of distributed SCADA workstations. However, Mr. Simon did face a couple of interesting challenges in this project:

  • The OPC servers and SCADA systems were on different computers, separated by a company firewall. This makes it extremely difficult to connect OPC over a network, because of the complexities of configuring DCOM and Windows security permissions.
  • Each SCADA system needed to access data from all of the new OPC server stations. This meant Mr. Simon needed a way to aggregate data from all the OPC stations into a single common data set.

After searching the web, Mr. Simon downloaded and installed DataHub® software. Very quickly he was able to connect a DataHub instance to each of his OPC servers, and determine that he was reading live process data from TEVA’s new control systems. He was also able to easily set up OPC tunnelling links between the OPC server stations and the SCADA workstations, by simply installing another DataHub instance on each SCADA computer and configuring it to connect to the OPC server stations. This unique combination allows him to view data from both OPC servers on either SCADA system

“I wanted to reduce and simplify the communication over the network because of our firewall. It was very easy with DataHub software.” said Mr. Simon after the system was up and running. Currently about 7,000 points are being transferred across the network, in real-time. “In the future, the additional integration of the existing or new OPC servers will be with DataHub technology.”