The latest entry into our Digitalization Digest consists of a project for a Pennsylvania Borough of an existing Grit Well control system that was based on a DCS system. The system was proving to be very costly and now effectively obsolete and could not be readily expanded. The system’s age made replacement of parts difficult, with long lead times and limited sources for the required parts.
For the new system, it was decided that the remote DCS I/O would best be a new Modicon hardware, to include a new PLC and panel to replace the existing remote panel. Modicon provided compatibility with the WWTP – supplier Activar VFDs as well as accessibility for product spares and replacements. The software selected for the control system was Ignition, an affordable product providing unlimited clients, unlimited data points, unlimited screens and remote alarming via email/SMS. A further advantage to the Ignition platform is that scalability is very cost-effective relative to the leading competitors. Additionally, the Ignition software was selected by PDA for the SCADA aspect as well as for the overall visualization of the project.
The new system is a standalone control system operated via Ignition. For estimation purposes, data collection was assumed to occur on up to 25 points and initially, the data points were collected and stored within the existing SQL database for the DCS system. As the changeover progressed the existing database became the Ignition database and provided historical long-term storage for both data sets. This action was predicated upon PDA having full access to the SQL database.
PDA provided the labor for engineering and data services, as well as for the system I/O requirements. PDA also provided hardware, including the main control panel that housed the controller, all M340 rack-based I/Os and an M340 rack for future expansion. This panel was also fitted with a door-mounted HMI touch screen for local control of the system. All control equipment was pre-installed in the cabinet, together with E-stop equipment, power requirements, and miscellaneous panel components.
At the completion of the project an internal assessment led to the following observations:
PDA is a full-service, CSIA Certified industrial control systems integration firm. Our Controls Engineering group specializes in physical automation system design, programming, and commissioning. We also feature a dedicated Digitalization Group (DSG) that connects automated equipment and systems to the business system environment including protected recipe systems, data collection and reporting, and data historian implementation. DSG can provide the systems you need to set your systems up for proper operation and then provide the tools you need to make sure you execute as planned.
Our Digitalization Digest includes articles and thoughts regarding manufacturing plant digitalization.
Process and Data Automation’s (PDA) Digitalization Group (DSG) is not your average software integration group. PDA places a lot of emphasis on training for the benefit of our customers and as such, makes sure that members of the DSG group are certified as ISA/IEC 62443 Cybersecurity Fundamentals Specialists and have obtained Cisco Routing and Switching Certification among other industry certifications.
ISA has developed the ISA/IEC 62443 Cybersecurity Certificate program to increase knowledge and awareness of the ISA/IEC 62442 standards. The first certificate in the program is the ISA/IEC 62443 Cybersecurity Fundamentals Specialist. The specialist certificate program is designed for professionals involved in IT and control system security roles that need to develop a command of industrial cybersecurity terminology and understanding of the material embedded in the ISA/IEC 62443 standards. The ISA/IEC 62443 Cybersecurity certificates are awarded to those who successfully complete a designated training course and pass the exam.
“As Cybersecurity becomes a focus in the industry, we wanted to add more credibility to our networking team. Having the ISA perspective allows our customers to see that we have dedicated and direct experience with industrial networking and industrial cybersecurity”, PDA Data Services Manager, Scott McCausland shared.
Earning a Cisco CCNA Routing and Switching certification is one of the best ways for PDA employees to provide our clients with expert networking. Cisco pioneered routing and switching technologies—and continues to lead the way, with the greatest market share and largest installed base across many industries. The overwhelming majority of today’s Internet traffic travels over network pathways built with Cisco infrastructure products. Equally important is the fact that certification keeps our DSG group current with all of today’s technology.
PDA is proud to have a world-class DSG group that is always on the forefront of the latest technologies. Our customers can be assured that our team is one of the most skilled and knowledgeable in the field.
PDA is a full-service, CSIA Certified industrial control systems integration firm. Our Controls Engineering group specializes in physical automation system design, programming, and commissioning. We also feature a dedicated Data Services Group (DSG) that connects automated equipment and systems to the business system environment including protected recipe systems, data collection and reporting, and data historian implementation. DSG can provide the systems you need to set your systems up for proper operation and then provide the tools you need to make sure you execute as planned.
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