Case Study | Boiler Manufacturer

This case study describes an interesting industrial automation project where Mesa's System Integration team implemented a boiler test station solution for a Tennessee manufacturing facility. Here are the key highlights:

Project Challenge

The boiler manufacturer needed a new test station system that could:

• Retrieve test parameters from a remote SAP PI system in Ohio
• Query the SAP database using unit serial numbers
• Maintain network security by separating production test stands from the SAP interface
• Monitor high-accuracy flow measurements (3-5 million BTU range with 1% accuracy)
• Communicate with PLCs via Modbus TCP/IP
• Be easy to install and expand with minimal recovery files

Solution Approach

Mesa evaluated several SCADA packages but found most solutions would exceed the budget due to requiring expensive server systems with thin manager or ERP integration for web services access.

They ultimately selected FactoryStudio from Tatsoft because it offered:

• Full Visual Studio compliant features
• Cost-effective pricing for low I/O point counts
• Built-in web services capabilities without requiring expensive additional infrastructure

Technical Implementation

The solution architecture included:

• A main web server with dedicated internet access (isolated from plant floor)
• Web Services interface to the SAP PI system
• Recipe queries triggered through directory change events
• Secure data exchange using structured text format
• Separation between web server and test stands for security

This design allowed multiple access points to web services while maintaining plant network security - a clever approach to meeting both connectivity and security requirements.

The case demonstrates how choosing the right SCADA platform can significantly impact project costs while still delivering the required functionality and security.

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