Efficient Plant April 2022 - 27

feature | solution focus
various upgrades to improve automation
and control.
THE SOLUTION
Th e solution for the plant involved using a
fl exible, reliable, modern DCS that could be
quickly integrated with existing production.
To control reactor processes, the plant now
uses NovaTech's D/3 DCS. NovaTech also
provided new applications programming,
HMI graphics, S88 batch-management
soſt ware, and an updated real-time data historian
application, along with migrating the
I/O from an older version to a new, modern
platform. Th ey also provided startup and
ongoing onsite support.
According to Gepfert, the key was implementing
the full set of processes in a robust,
reliable, fl exible system. It also needed to be
highly automated so the plant can eff ectively
run on its own with minimal operator
interaction.
Th e NovaTech D/3 operator interface
displays real-time process information and
allows the operator to control the process,
enter information, and interact with
sequence programs. Th e operator can
modify recipe parameters, recipe procedures,
production schedule, batch start
rules, equipment utilization, or scale batch
amount at any point during recipe development
and execution. Recipe values are
automatically entered into the system. Th e
operator selects all the equipment to be used
before starting the procedure.
Th e transition to the new DCS was quick
C
M
Y
CM
MY
CY
CMY
K
Remote monitoring technology has been
embraced by bulk material handlers in a
wide range of industries and applications.
Even better news? Martin offers
the equipment,
monitoring service,
maintenance fees, and batteries free
of charge for users of Martin belt
cleaner blades.
and successful. Th e plant's technicians can
change and program the new DCS using
Windows-based servers. Th e plant has
expanded its overall throughput by as
much as 50% and production effi ciency has
increased by 20% to 30%.
" Th e previous system's tolerances were
broader and less accurate. Th e new DCS
provides signifi cantly tighter tolerances and
better-quality control. Th is helps to ensure
APRIL 2022
For factory-direct service, training and sales call 1-309-852-2384
or to access our education and professional development options
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Alerts when an
abnormal condition
is present
Measures
temperature
changes
Warns when
battery life
is ending
Without shutting down the belt, remote monitoring
can assess real-time conditions-ensuring safety,
efficiency and cost effectiveness-making best use of
time and resources, which ultimately maximizes
both production and profitability.
With approximately 2000 operating systems
in service around the globe, the N2 Position
Indicator remotely monitors the position of
the belt cleaner blade, providing estimated
service life, notification when re-tensioning
or replacement is required, and warnings in
the event of abnormal conditions.
Tracks blade
position at
the belt
Senses when
to re-tension
the blade
Knows when
blade change
is required
that all product specifi cations are consistently
met and essentially prevents the waste of
producing off -spec product, " said Gepfert.
Another consideration was the need to
integrate the plant's new DCS system with
the existing enterprise systems. Plant management
sought improved data capture and
conversion of that data into useful knowledge
presented in desktop key performance
indicator (KPI) dashboards that can be used
at the manufacturing execution level and/or
the enterprise ERP level.
" With data never previously available,
plant operators can not only manage but
also optimize production, " said Gepfert. EP
EffiPlant3-22insertV1.pdf 1 3/10/22 9:06 AM
For more information, visit novatechautomation.com.
EFFICIENTPLANTMAG.COM
| 27
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Efficient Plant April 2022

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