North Plant in Meyerton is a world leader in the production of high-value manganese alloys used in the steel industry worldwide. With the majority of its 700 t daily output scheduled for export, work stoppages through plant malfunctions or operator errors can prove extremely costly.
One way to get more control over the complex manufacturing processes was to integrate Wonderware's SCADAlarm solution with the existing InTouch scada system.
SCADAlarm is Wonderware's round-the-clock network and process monitoring solution that works in conjunction with InTouch to turn PCs into communication centres. SCADAlarm broadcasts alarms over telephones, cellphones, pagers, PA systems, PC speakers, radios, e-mail systems and handheld devices such as PDAs.
Metalloys' North Plant InTouch system monitors more than 10 700 tags through eleven networked DCS' (distributed control systems). "The addition and integration of SCADAlarm to our InTouch system has given us a new and highly-effective level of control", says Pierre Briel, Instrument Engineer, North Plant. "Although InTouch monitors every aspect of our production processes, the chances that the relevant personnel will be looking at a screen to spot problems when needed are remote. SCADAlarm overcomes that by communicating with the relevant personnel as and when required and according to rules of our choosing."
"Previously, an operator would contact his foreman about a problem who would then take it up with his superior etc, all the way up the chain of command. But malfunctions do not follow that logic. If there is an electrical problem on a particular fan, for example, the electrician best suited for repairs on that model must be called. If the same fan has a vibration problem, then its vendor may have to be contacted. So, SCADAlarm gives us context-sensitive, intelligent alarming that always involves the right people long before any traditional approach could." Not only are the correct people called, but, should they not acknowledge the communication, they will also be called repeatedly within predetermined periods that will vary according to the seriousness of the situation. Should they not be available repeatedly, then the seriousness is escalated and will involve other personnel who may be able to help.
"When combined with InTouch's remote control facility," says Briel, "SCADAlarm will allow the best available person to directly take over a particular operator's station and to either fix the problem directly or to talk the operator through the procedure. And this can happen from anywhere in the world." Intelligent alarming is helping Metalloys to spot potential problems before they occur and to determine the course of corrective action by alerting the right people to do something about them. This not only reduces plant stoppages and helps maintain production quotas but also improves the plant's maintenance bill. Wonderware's SCADAlarm is helping the people that matter to contribute the right knowledge at the right time by becoming a more functional part of the processes under their control. Prevention has always been better than cure.
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