Client Challenge
A tobacco processing facility in Tennessee required a robust monitoring system for 211 tanks. The system needed to record and report temperature and humidity data for each tank on an hourly basis. Additionally, our client requested the capability to associate batch numbers with each tank when filled, ensuring detailed real-time product tracking and traceability.
The reporting system needed to generate automated overnight reports summarizing hourly temperature and humidity data for each tank. Remote monitoring for wireless telemetry devices, including signal strength and battery level, was also critical for system reliability.
Our Solution
Our team designed and installed a comprehensive remote tank monitoring system that met the client’s requirements. Key deliverables included:
- Wireless Telemetry and Instrumentation:
- We implemented wireless telemetry devices and instrumentation for each tank, ensuring reliable data acquisition and transmission.
- We configured addressing for temperature and humidity probes and conducted thorough bench testing to validate performance.
- SCADA and Historian Integration:
- Communications were configured between the wireless devices and the Ignition SCADA and Historian systems for centralized monitoring and data storage.
- We developed an intuitive operator interface that allowed users to enter batch information for tracking and reporting purposes.
- Automated Reporting:
- We created a reporting system that automatically generated daily reports summarizing each tank’s hourly temperature and humidity data, streamlining the client’s reporting process.
- Remote Monitoring and Alarming:
- Remote monitoring was enabled of wireless telemetry devices, providing real-time visibility into signal strength and battery levels.
- We configured alarms to alert operators of any communication or power issues, ensuring system uptime and data reliability.
- On-Site Support:
- We provided the on-site installation of the system to ensure proper deployment.
- Our field service team provided commissioning support to validate system performance and functionality.
The Results
The remote tank monitoring system delivered exceptional outcomes for the client:
- Improved Data Accuracy and Reporting: Hourly temperature and humidity data for 211 tanks were reliably captured and stored, with automated overnight reports reducing manual effort and improving operational transparency.
- Enhanced Product Traceability: Batch numbers could be tied to individual tanks, ensuring detailed tracking and compliance with regulatory requirements.
- Real-Time Monitoring: Remote monitoring and alarming capabilities enabled proactive management of telemetry devices, reducing the risk of data loss or downtime.
- Operator Efficiency: The intuitive interface and streamlined workflows allowed operators to manage batch information and monitor tank conditions effectively.
- On-Time Delivery: The system was successfully delivered and commissioned within the project timeline and budget.
This project demonstrated DSI Innovations’ expertise in designing and deploying advanced remote monitoring systems tailored to client-specific needs, providing reliable, scalable, and user-friendly solutions.
