Project Overview

The plant is an ethanol facility producing approximately 41,100 gallons per day (15MM gpy). Dahlen Systems, Inc. primary role included the design and purchase of the instrumentation, controls and SCADA system, the creation of a process narrative, programming the control system, programming the SCADA system, programming the SQL database, creating reports, plant checkout, start-up and operator training

The plant uses Wonderware InTouch and Schneider Automation Quantum controllers to control the process. The system controls the entire plant from grain receiving to ethanol loadout. All plant control is done in the Quantum controllers. Process information (temperature, pressures, flow etc.) is logged using a Wonderware InSQL server. Batch information is stored in a Microsoft SQL database.

Each piece of equipment controlled by our system had an automatic mode and a manual mode for maintenance and testing. All of the systems function in full automatic with minimal operator intervention.

In addition to the normal process control of the system, a Grain Sampling system allowing the operator to do tests on a sample of the grain prior to accepting the product was added. The Grain Sampling system communicates with the different test equipment via serial communications. Keypads on Profibus are setup to allow the truck drivers to enter information into the system without going into the control room. The data entered is checked against a SQL database and verified before a sample is taken. The system allows the operator to accept, reject or accept with a discount the grain received.

Project Costs

Total Project: $19MM
Control Engineering and Materials: $520K
Instrumentation: $430K

Controls

Schneider Automation Quantum PLCs

	3 Quantum Processors
	9 remote I/O enclosures on Profibus
	8 MCCs with Seriplex on Profibus
	115 I/O Modules on Profibus
	220 analog points
	950 discrete points

Wonderware InTouch SCADA system

	5000 tags
	30 main screens showing a graphical representation of the process
	Several pop-up screens for common control of different equipment, i.e. motors.
	Ethernet network via fiber optic cable to controllers
	Grain Sampling System
	Real time and Historical data logging using InSQL logging
	Additional data logging to Microsoft SQL of warehousing summary information
	4 View and control nodes
	Reports created in Seagate Crystal ReportsWonderware HMI

Wonderware InSQL/MS SQL

	5000 Tags
	Data stored at variable rates
	Grain Sampling Data Collection/Reports