Client's Challenge
The client faced significant issues due to the lack of visibility into the plant’s water usage, both per area and per equipment. Without this critical data, they couldn’t implement effective water-saving measures or fully understand their water supply network. They needed a solution to monitor and manage water usage accurately to optimise operations and achieve cost savings.
Our Solution: Enhanced Control and Efficiency
I2R Group addressed these challenges by installing Endress + Hauser EthernetIP and IFM IO Link flow meters throughout the plant. These smart flow meters were integrated into the site’s PLC architecture and connected to a newly developed Ignition SCADA system. This setup provided real-time and historical data visualization, custom daily reports, and the ability to compare water usage with other sites, enabling the client to implement targeted water-saving strategies.
Project Overview
Planning & Design Phase:
- Onsite visit, project. planning and management.
- Created a customised site design and implementation plan.
- Scheduled weekly project status updates to keep client informed.
- Automation architecture design.
- Electrical installation design.
- Mechanical installation design.
Automation Development Phase:
- Development of new Ignition SCADA screens, trends and reports that gave the client easy access to visually see all the water data usage instantaneously and historically, by area and device.
- Integration an EthernetIP and IO Link architecture into the existing automation architecture.
- PLC code development of the new flow meters data feedbacks.
Technologies and Strategies:
- Implementation of the new developed Ignition SCADA screens, to visualize, record data and provide comprehensive reports.
- Worked outside production hours to install flow meters without disrupting processes.
- Supply and installation of new Endress + Hauser EthernetIP flow meters on all the major water supplies and areas throughout the plant.
- Supply and installation of new IFM IO Link flow meters on all the major water supplies throughout the production area.
- Integrated each flow meter into the relevant areas PLC architecture.
Implementation Process:
- Completed comprehensive design for mechanical, electrical, and automation aspects.
- Procured flow meters and developed an installation schedule.
- Developed Ignition SCADA screens, reports, and trends.
- Installed electrical cabling and flow meters according to the schedule.
- Performed electrical terminations and calibrated each flow meter.
- We not only delivered the electrical and automation, we also delivered the project as a turnkey solution meaning we managed the entire project scope including the mechanical installation of flow meters in the existing pipework.
Ongoing Support:
- Conduct site inspections and commence with warranty period.
Measurable Improvements:
- Standardised flow meter types across the site.
- Improved visibility of water supply and usage per area and device.
- Enabled data trending for any device or area.
- Generated custom daily water usage reports.
- Compared water usage per area to other JBS northern operation sites.
Client Outcome:
The solution provided actionable data to analyse and implement cost-saving solutions, addressing key operational challenges and providing critical information for identifying issues.
