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Leading Clothing Retailer - Case-Study

Case Study: Energy Saving & Availability Monitoring System

Project Description:  The European distribution centre of clothing manufacturer and retailer is situated in the Midlands. The conveyor systems are controlled by 8 Siemens S7-400 PLC systems. In May 2006 MCS Control Systems were contracted by our client to introduce energy saving into the each conveyor system and also to develop a system of monitoring, displaying and archiving system availability data. This data was required to provide unbiased and meaningful reports on equipment availability, including downtime, common occurring faults and response times which can be used by all parties.

Approach:  Firstly, to ascertain system power usage, MCS installed energy monitoring relays in all conveyor control panels. This then provided base-line power usage figures for each panel. The PLC software for each panel was then closely interrogated and modified to introduce configurable energy saving times for each logical group of conveyors.

To monitor Availability, MCS introduced a Siemens WinCC SCADA station to the system. This connects directly onto the existing established Ethernet network and gives a direct connection onto the 8 Siemens PLC systems. For availability calculations MCS used the sensible and logical rules of FEM 9.222 (“Standards of the acceptance and availability of installations with storage/retrieval machines and other machinery”). Working on site closely with our client’s engineering staff, MCS developed user friendly screens and automatic reports to detail system availability, downtime and response times.

Results:  With the new energy saving features in place, early indications show an overall average energy saving of 52%. With availability data on a per day/per shift basis, Our client now has the ability to identify and address recurring system faults, plan preventative schedules more efficiently and address response time issues to maintain and improve operational targets.

 


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