Client Challenge
Our team was approached by a pharmaceutical facility to install a fully automated SCADA platform for a new HVAC air handler system. The system had to centralize control, integrate multiple systems, and provide real-time monitoring and alarm management for both HVAC and facility control. This project included coordinating with multiple contractors and ensuring seamless integration of Rockwell FactoryTalk for system control and Exele TopView for alarm management in a virtualized server environment.
Our Solution
Our system integrators implemented a centralized SCADA system integrating Rockwell FactoryTalk and Exele TopView to manage the Building Management System (BMS).
The key components of the solution included:
- Centralized Control: The FactoryTalk system was implemented as the final control layer for managing the entire HVAC system, including controllers, VFDs, and other vendor equipment.
- Virtualized Servers: We configured 11 virtual servers for high availability and redundancy, ensuring robust performance and failover capabilities across FactoryTalk and TopView systems.
- Alarm Management: The TopView alarm system was integrated with both the BMS and plant manufacturing systems to monitor alarms, ensuring critical system failures were promptly addressed. Real-time data from the BMS was sent to the OSI Pi Historian for trend analysis and reporting.
- Chillwater Pump Control: We provided a turnkey solution for controlling the chilled water supply, using a new PLC to eliminate downtime risks associated with modifying the existing system. This solution involved designing control panels and coordinating with the vendor to integrate VFDs with the new PLC.
The Results
- Seamless Integration: The system was installed and configured with zero downtime. DSI successfully transitioned from a temporary Ethernet/IP network to a permanent network without disrupting plant operations.
- High Availability: The system was designed for redundancy, with virtual servers configured for failover capabilities, ensuring continuous operation even in the event of hardware failure.
- Improved System Efficiency: Real-time monitoring and alarm management allowed operators to optimize HVAC performance and address issues in real time without interrupting production.
- Energy Savings: Integration of HVAC and energy systems enabled better control over environmental conditions, reducing energy consumption across the facility.
