Weber Metals Case Study

Challenge: As the largest aerospace forging press in the Western Hemisphere, Weber Metal’s 60K Press has numerous moving parts that require tedious coordination and closed-loop feedback. For this reason, operations are complex and require exact precision. One of the challenges faced by our client included no central viewpoint of the work cell to collect data and control operations. […]

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Well Field SCADA with Ignition 8.0 and Perspective

Challenge: Our client operated thousands of assets like pumps, tanks, generators, and other equipment spread out over a large geographic area. Over the years, new equipment had been installed from a variety of vendors using a wide range of automation technologies. Data collection was a challenge due to varying PLCs, HMIs, and communication protocols, as […]

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Upgrading an Aging Rockwell-Based Control System with Minimal Downtime

Challenge: NXP Semiconductor, a leader in developing innovative high-performance mixed-signal solutions, was facing several issues with an aging control system for its ultra-pure water (UPW) plant in Chandler, AZ. The aging Allen-Bradley PLC-5 control systems were state of the art when installed in the late 1990s, but most of the components are now discontinued or […]

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Water District Upgrades Aging Radio Telemetry Network

Challenge: The rapidly growing Phoenix, Arizona suburb of Town of Queen Creek was struggling with a telemetry system using aging GE/MDS iNET 900 and iNET II radio technology. SCADA response times were so bad, operators would often drive to a site after starting or stopping pumps to make sure the command had actually taken effect. […]

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Creating the Ultimate SCADA System for Solar Energy

Challenge: Solar energy is a growing industry, but utility-scale solar power plants can present many challenges for a traditional SCADA system. A typical solar power plant contains thousands of connected devices from a variety of vendors dispersed across a large geographical area. A robust, scalable SCADA architecture which can be quickly rolled out as new […]

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Water Utility Distributed SCADA System and Automated Demand Response

Challenge: The Adelanto Public Utility Authority needed to implement an automated demand response system for water utility assets. The utility operates three reservoirs and 22 pumps. The Authority is enrolled in a clean power plan (CPP) that incentivizes the reduction of energy usage during periods of high grid demand. Unfortunately, the authority did not have […]

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Precision 2D Measurement

Challenge: The client was looking for a way to increase their product’s quality and reduce waste by analyzing their materials at the beginning of their manufacturing process. Using a Siemen’s ET 200SP PLC they developed a machine that could measure the thickness and density of their products, but they couldn’t read, store and analyze their […]

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Waste Water Treatment Facilities

Challenge: The client had two active waste water treatment facilities running on aging Allen-Bradley SLC-500 PLCs and Wonderware InTouch. Operational requirements made it impossible to shut these plants down so upgrades had to be performed without interrupting plant operation. Documentation did not exist for many of the existing control panels, and the client had no […]

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Craft Brewery Whitebox

Challenge: Production facilities run at a lightning fast pace and every minute of downtime and each incidence of waste translates to a big cost. Our primary challenge was to automate the gathering of production rates, waste, and downtime on a running line without interrupting production in any way; on dozens of customer line and network […]

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Georgia Power

Challenge: To build an power plant scale solar field, the client required integration of the full spectrum of utility grade photovoltaic power generation equipment including inverters, trackers, soiling monitoring stations, meteorological stations, substation power meters, and relays into a single SCADA system. The client required technology that their maintenance and operations groups were familiar with […]

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Process Control System for Santa Elena Silver Mine

Challenge: This gold and silver mine in Northern Mexico was located in a remote location with extremely limited local resources. The client needed to fully automate the on-site processing of gold and silver ore under tight schedule requirements. Because of the remote location, the client required a modular process control design along with pre-wiring and […]

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Amarillo International Airport

Challenge: The City of Amarillo needed to upgrade their airport baggage handling system to meet modern security standards. Much of the conveyor needed to be replaced, and new automated baggage security scanners needed to be integrated into the system both for security and passenger convenience. Conveyor programming needed to meet strict TSA security requirements, and […]

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