Automation

Industry 4.0 at BIAZZI

Industry 4.0 is becoming the standard for fully digitalized production.

The objective of ‘Industry 4.0’ is to link information and communication technologies to industrial solutions for production processes. BIAZZI has developed an ‘Industry 4.0’ solution while addressing industrial security concerns regarding globally connected solutions.

BIAZZI, as a technology developer and plant manufacturer for the production of energetic materials and intermediates for the chemical industry, now offers an ‘Industry 4.0’ integrated solution incorporating. The BIAZZI solution achieves the following vital elements and objectives:

  • Reduction of unplanned production downtime through preventive alarm detection by the maintenance system.
  • Increase of plant performance and productivity by monitoring and acting on key parameters.
  • Visualization of operating status of the plant in real time through secure remote connections and available on mobile devices.
  • Configure networked instruments via Ethernet.
  • Detection and advanced warning of potential plant degradation situations.
  • Diagnostics applied to each networked element.
  • Maintenance time minimized and optimized resulting from detailed reports and diagnostics generated by the preventive system.
  • Reduced human error during on-site maintenance.
  • Generated reports and statistics enabling analysis of an evolving situation.
  • Local QR code system enables equipment scanning and direct link to the BIAZZI technical documentation, resulting in maintenance team effectiveness and efficiency.
  • Real-time energy consumption tracking and data capture.

The BIAZZI solution can be fully autonomous and independent of Internet connection.

Dashboard

YOUR PLANT, OUR SUPPORT

1 control system, 4 options – click on the information below to learn more about what BIAZZI is offering (click for further information)

SMART PLANT IoT 4.0 DIAGNOSE

1 SMART plant system - diagnosis and maintenance

An industrial computer composed of:

  • Intel processor, large RAM.
  • Large type 1 RAID mirror disk.
  • HD screen with high resolution.
  • Keyboard mouse.
  • RFID access reader with programmable cards depending on the level of access to the control system.
  • The power supply comes from the UPS uninterruptible power supply.
  • The SMART plant system is accessible, by BIAZZI only, via the secure VPN module of the process control system.

2. Software used

  • WEB interface developed by BIAZZI, accessible from PC and tablet
  • SQL database
  • Communication from PLC (s) by OPC UA

3. Overview:

The main page of the Dashboard indicates in graphical form and in real time, the states:

  • Plant bus PLC network.
  • Motors.
  • Pumps, agitators, reducers, bearings, belts, etc.
  • Pneumatic valve islands, control valves and TOR valves.
  • Instruments.
  • Indication of network synchronization status.
  • The last 5 system alarms and the 5 most recurring.
  • Synthesized energy measurement.

4. System alarm

  • Trend of system alarms, indication of the number of alarms as a function of time.
  • Sorting by alarm frequency, sorting by alarm duration.
  • List of the most recurring alarms.

5. Plant Bus PLC network

  • Complete monitoring from the PLC to the input / output card.
  • Alarms in the event of a station or channel failure.
  • Access to the PLC webserver and fault diagnosis.

6. Motor

  • Counting of the number of motor starts.
  • Number of hours of use, switched on and off.
  • Average power measurement and storage of the min and max value.
  • Current measurement, average measurement and storage of the min and max value.
  • Average voltage measurement and storage of the min and max value.
  • Average torque measurement and storage of the min and max value.
  • Measurement of the average PT100 motor temperature and storage of the min and max value.
  • Measurement of the average rotation speed and memorization of the min and max value.
  • Measurement of energy consumed.
  • Warning, error and alarm list diagnostics.
  • Request for motor inspection.
  • Access to the drive's web server.
  • Maintenance of engine-related parts: inspection message for pumps, agitators, change of bearings, change of belts, gear oil level, etc.

7. Pneumatic valve

  • Opening and closing counting of each valve.
  • Number of hours of use, output on and off.
  • Warning and error diagnosis.
  • Module inspection request.
  • Access to the module's web server.

8. Regulating valve

  • Deviation alarms for PIDs for continuous processes.
  • Measurement of the valve position by feedback, deviation alarm.
  • Warning and error diagnosis.
  • Number of hours of valve operation.
  • Inspection request, calibration request.

9. ON-OFF valve

  • Calculation of valve travel time and deviation alarm.
  • Number of hours of operation of the valve, energized and activated.
  • Request for inspection.

10. Instrumentation

  • Number of hours of operation, instrument powered on.
  • Measurement of physical quantities with average and memorization of the min and max value.
  • Warning and error diagnosis.
  • Inspection request, calibration request.

11. Diagnostic report

  • Basic summary report for the production manager.
  • Detailed report for maintenance personnel indicating the status of each element, network, valve, motor and instrument, and indication of the most critical.

12. Webserver

  • Dashboard page regrouping the call buttons of the various webservers of the installation.


SUPPORT
PACK 1

Two models are offered by BIAZZI

1. Standard remote support

Included:

  • Remote system connection via secure VPN.
  • 10 hours of connection included per year, and 5 connections.
  • Remote system diagnosis and analysis.
  • Remote troubleshooting.
  • Writing of the diagnostic and troubleshooting report.
  • Update of the program and the diagnostic system.
  • Spare parts proposal.

2. Advanced remote support

Included:

  • Remote system connection via secure VPN.
  • 20 hours of connection included per year, and 10 connections.
  • Remote system diagnosis and analysis.
  • Remote troubleshooting.
  • Writing of the diagnostic and troubleshooting report.
  • Update of the program and the diagnostic system.
  • Analysis of data and alarms.
  • Analysis of warnings and errors.
  • Process improvement by precise adjustments of production parameters.
  • New product recipe, set of parameters and alarms.
  • Spare part at cost price.

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SAFETY
PACK 2

If there is a need for increased security and availability, we can deliver and commission the following equipment:

1. DCS Digital Control System

  • A server to host the database, this configuration requires a client PC.
    The server is RAID1
  • Redundant server, one master and one slave, with synchronization and recovery module
  • A programming computer separate from the operator computers.
  • System access by fingerprint (biometric) reading instead of RFID

2. Redundant PLC and fieldbus

  • Redundant PLC, a primary master and a backup slave with synchronization module, for example the H series from Siemens
  • HF series safety and redundant PLC (SIL IEC 61508 and IEC 61511)
  • Plant bus field network in MRP (Media Redundancy Protocol) ring
  • LAN A and LAN B redundant field network (PRP (Parallel Redundancy Protocol)
  • Redundant decentralized IO module
  • Redundant IO card

3. Hardwiring

  • Additional wired security system, independent of PLC and safety PLC

4. Redundant Power supply

  • Redundant 24VDC power supply in the cabinets
  • Redundant UPS


VISU
PACK 3

We can deliver and put into service the following equipment:

1. Specific HMI

  • Additional HMI
  • HMI in hazardous area
  • Process simulation SCADA
  • Full spare SCADA

2. QR code

BIAZZI equipment has a QR code that can be read via tablet, a scan of the QR code allows direct access to BIAZZI technical documentation, the latter will be updated remotely in the event of changes.

Delivered material:

  • Technical documentation located on a SMART plant computer
  • Zone coverage by Wifi transmitter in protected and ATEX zones
  • Operator's tablet for hazardous area.

3. OPTION PACK 3 VISU
PLUS VIDEOSURVEILLANCE:

We can deliver and put into service the following equipment:

CCTV System

  • Control joystick for controlling the cameras.
  • HD ATEX IP camera: fixed, remote zoom, PTZ dome.
  • ATEX thermal IP camera.
  • Motion detection and intrusion alarm.
  • Smoke detection.


ENERGY
PACK 4

Complete energy measurement of the BIAZZI installation, we can deliver and commission the following equipment:

Energy measurement

  • Energy measurement at the power input of the entire BIAZZI installation, three-phase current
  • Energy measurement of each motor starter and consumer, three-phase and single-phase current
  • Energy measurement of the control system
  • Measurement of air consumption on each air treatment
  • Air network leak detection sequence

Detailed report and analysis to manage your energy efficiency and ecological impact.

Your automation system is developed by BIAZZI specialists in Switzerland.
It will be maintained by the same design team, which allows you to maintain flawless reliability of your installation, and guarantee increased productivity. Who better to maintain your installation than the builder?

With BIAZZI, your productions are therefore sustainable in terms of quality and quantity.