Reliable Biogas Plant Automation with iFIX and Proficy Historian

The use of iFIX as a SCADA system enables quick and efficient adjustments. A structured engineering approach is characterized by the well-thought-out modular use of subroutines and objects. This inevitably improves the clarity and maintainability of the application. ORmatiC GmbH leveraged these advantages both during commissioning and for subsequent modifications and system expansions.

Operating personnel can easily enter new messages, control commands, setpoints, limit values, and fault thresholds into the installed system at a later date. However, this requires the appropriate access permissions.

The software’s intuitive interface allows the operator to make necessary adjustments right from the start. The project configuration effort is reduced compared to similar projects.

Remote diagnostics runs as a standalone task in the background. The system services are complemented by the capability for wireless remote diagnostics. In the event of a malfunction, the system or equipment status can be analyzed remotely. This enables uninterrupted real-time support for the system.

From the main screen of the process visualization, two types of sub-screens can be accessed. First, there are function screens, which are selected via buttons at the top of the screen and provide additional functions for the process. Second, the sub-screens are supplemented by control screens, which are accessed directly from the user interface and display the respective plant section in greater detail. The picture-in-picture technique was used here to allow easy access to important detailed information. The dynamically animated control screens immediately show the plant operator the operating status of individual plant components.

Process signals are displayed in the form of graphical tags in process screens. A sample application for a biogas plant using iFIX includes over 1,500 external input and output data points. Virtually any application strategy can be covered with various animation links. Objects and object groups, including their process links, can be saved in a library, instantiated, and reused to save time.

iFIX’s extensive symbol libraries also include real-time and historical trend charts as ready-made modules. Historical data can be displayed, saved, and printed. Using pre-built modules, all or individual alarm messages can also be displayed as a summary or history.

System security is a key feature of iFIX. ORmatiC utilizes iFIX’s configurable password protection with various access levels. To this end, the application prompts for a username and password upon startup, and activity monitoring can also be enabled. After the system’s startup cycle, the operator can intervene in the automatic process by changing the setpoints and adjust it according to the desired technological parameters.

In operator mode, all operator screens and the actuators they contain must be switched, and the power of the frequency converters must be adjusted. Function screens, alarms, and trends can also be accessed. However, system parameterization is not possible. Only in expert mode can you switch to the parameterization levels and make process-related settings. General parameters for feeding the fermentation process, as well as setpoints, operating hour counters, temperature limits, and technological parameters such as control parameters or fill quantities, can be adapted to changing requirements.

Interlocks are built into process pumps and valves for both automatic and manual operation. This prevents a process pump from being activated in manual mode unless the associated media flow is unobstructed through open valves. Valves, on the other hand, cannot be switched if a pump in the associated process circuit is switched on. If an open valve moves out of its end position, the associated process pump is immediately switched off automatically.

Each hydraulic control valve can be set to manual or automatic operation. The on/off switch is visible only in manual mode and can therefore be operated. The process pumps and agitators have three interlocked operating states. In automatic mode, the devices are controlled as an automatic program in the PLC. Manual mode switches the devices off via the process visualization. For maintenance mode, there is a local switch on the switch housing for local operation.

In biogas plants in particular, it is important for operators to be able to quickly and easily get an overview of the plant’s status. The operational reporting system is designed to ensure that employees receive the right information at the right time and in the desired format. Both managers and staff members need regular, event-driven information about the operation of the entire biogas plant. The team receives data that helps identify trends, perform checks, or initiate planning.

ORmatiC uses Proficy Historian for the centralized long-term archiving and analysis of process values, messages and alarms, operator interventions, and batch records. Proficy Historian receives all relevant information for storage directly from the process control system. Retrospective analyses of malfunctions and downtime over a period of several months or years help identify weaknesses in the system. This enables precise cost calculations and the optimization of plant operations.

Extensive analysis and reporting functions developed by ORmatiC are available for evaluating the values stored in the database. All data from the Proficy Historian Server is easily accessible and can be freely combined for flexible views. Custom reports and analyses can be easily generated from predefined forms. The individual reports are also tailored to different audiences—from management to operational staff.

In addition to basic query functions, the flexible report generator offers additional options for customizing the content and visual presentation of results. Based on Microsoft Reporting Services, it features informative, pre-built standard reports and flexible analyses. The range of report types is diverse. Predefined reports include daily, weekly, monthly, quarterly, and annual reports, as well as batch reports.