Innovative Automation and Data Acquisition Solutions for Manufacturers, Laboratories, OEM's and Commercial Customers.
Remote Control and Monitoring System
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Innovative Automation and Data Acquisition Solutions for Manufacturers, Laboratories, OEM's and Commercial Customers. |
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Remote Control and Monitoring System |
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THE PROBLEM: Failure of any piece of equipment in a refrigeration system can quickly result in rising ice temperature and substantial revenue loss for the owner. Eight hours later, some frozen products may not be usable. Within 24 hours, the entire inventory may be lost. Restoration requires thousands of dollars, and several days of lost revenue. |  |
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The distance,
between the client’s offices and the location of its refrigeration
facilities complicates troubleshooting equipment. In a typical
troubleshooting situation, the client’s engineers would spend several
hours on the telephone trying to assess the problem.
If that was not successful, the client would contract an HVAC maintenance company, in close proximity to the refrigeration unit, to investigate and repair the problem. However, success is dependent upon the HVAC technician who may not be familiar with the inherent differences between the client’s refrigeration systems and a typical HVAC system. If all else fails, the client’s engineer or service technician travels to the customer’s site and completes the repairs. As a result, the client incurred significant amounts of time and cost with troubleshooting and equipment repair problems. The company needed a better, faster and less expensive method to diagnose and repair equipment problems. THE SOLUTION: REAL Controls designed a control system to solve the problem. First, we provided the client with the ability to communicate over standard telephone lines, with process control equipment, with any customer that incorporated the client’s new refrigeration control system. Using this system, the client’s engineering staff can monitor the process control equipment, evaluate data, change the operating set points of the controller, and take complete control of REAL Controls worked with the client’s engineers to identify critical operating parameters for troubleshooting equipment problems. Sensors were selected and installed into the refrigeration system for each of these critical parameters. Data is automatically collected from these sensors and stored in the operator interface computer. Should an equipment problem occur, the engineer can:
Once the analysis is complete, the engineer has sufficient information to effect repairs and get the equipment back on line. THE RESULTS: A number of temperature and pressure sensors were required, in the refrigeration system, to gather critical operating data enabling the clinet’s engineers to diagnose problems. This increased both the manufacturing and installation cost of the refrigeration system. However, substantial cost savings have been realized due to the client’s new ability to remotely monitor, diagnose and take control of the refrigeration equipment. Troubleshooting time has been reduced because the engineers have a better understanding of both the current equipment condition and the conditions that occurred prior to the failure. Owners and operators have a higher confidence that the client’s equipment will be repaired quickly and efficiently, keeping them in business.
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