PcVue as a SCADA and Integrator
USV Limited, a prominent pharmaceutical company based in Daman in India, 4 hours away from Mumbai, is recognized for its high-quality pharmaceutical products, initiated a project to improve the monitoring and control of two 1200L Rapid Mixer Granulators (RMG04 and RMG06). At first, USV used another SCADA to monitor their granulation processes. However, frequent software crashes and issues with date and time stamps led to significant operational inefficiencies, prompting the company to seek a more reliable solution. In 2021, after testing PcVue SCADA for a couple of months, USV was impressed with its reliability and decided to proceed with the migration.
CHALLENGES AND THE NEED FOR A NEW PROJECT
The transition from the old SCADA system to PcVue came with several challenges.
• USV had to navigate the complexities of dealing with a machine manufacturer that had gone inoperational;
• They faced a lack of support from their existing supplier and associated automation product companies;
These challenges underscored the necessity of transitioning to PcVue software.
A SMOOTH INTEGRATION
The integration of PcVue system into USV Limited’s operations was executed smoothly, thanks to a collaborative effort. PcVue India partnered with USV Daman team for PLC programming, while our team independently handled the software implementation, ensuring a seamless transition from the old system.
PROJECT ARCHITECTURE
The system was built on PcVue 15 comprising of USFDA 21CFR part11 compliance, featuring two HMI panels and the configuration of 500 tags for monitoring and control. The communication interface with PcVue is using Mitsubishi MELSEC protocol and Dream Report for report generation.
IN THE FUTURE
Currently, the project is fully operational and delivering the expected results. Discussions are already underway to expand the project by adding more machines, leveraging on the robustness and scalability nature of PcVue software. This successful integration underscores PcVue India team and their system integrators to support and implement complex customer requirements thanks to a holistic approach and understanding of the complete PcVue solution range of product.
TECHNICAL POINTS
- Reporting Tool: Dream Report
- SCADA Version: PcVue 15
- HMI: 2 HMI panels were integrated into the system on Advantech Panel PCs
- Tags: The project involved the configuration of 500 tags for monitoring and control
- System Architecture: Standalone project with OPC UA enabled for third-party communication
- Protocol: Modbus TCP/IP as well as Mitsubishi MELSEC Protocol
RESULTS
- A successful migration: PcVue’s dual role as both the SCADA provider and integrator ensured a smooth and efficient migration
- A seamless integration: With PcVue Handling the entire integration process, USV Limited experienced a streamlined implementation, resulting in minimal disruption to their operations
- Reliability and stability: The project achieved enhanced system reliability, maximum uptime, with PcVue SCADA eliminating the previous Issues of software crashes and incorrect time stamps, ensuring consistent and stable performance
Created on: 16 Oct 2024 Last update: 17 Oct 2024
