Continuous monitoring and reporting software.

When World Color Press, Dyersburg, TN, decided to replace its outdated computerized supervisory control system for its large solvent recovery operation, it turned to AMCEC Inc., Lisle, IL. World Color Press wanted a system that would provide uncomplicated screens and flexible graphic importing. It also wanted to avoid long hours of training.

A solution was found in an object-based automation software called Lookout, from National Instruments Corp., Austin, TX. The PC-based human-machine interface (HMI) supervisory control and data acquisition (SCADA) system, saved hours of training time and immediately provided quick and easy report generation and day-to-day monitoring. AMCEC designed, built and installed the solvent recovery system, and uses Lookout to control it. The company is a member of the National Instruments Alliance program, through which it receives consulting and systems integration services.

The large printing facility uses solvent-based inks for high-volume printing. After ink is applied to the paper, the paper passes through ovens for drying before proceeding to the next print station. Depending on the job, the paper may pass through as many as 12 stations.

The air used for drying the paper is collected with a manifold duct system and connected to the solvent recovery system, which recovers solvent vapors - primarily toluene - from the air and vents the clean air to the atmosphere. A recovery rate of between 95 percent and 99 percent is typical.

AMCEC configured the software to perform a wide range of monitoring, control and report generating operations. Through the intuitive screens and panels, World Color Press personnel monitor motor status, valve positions, temperatures, process pressures and exhaust concentrations, as well as bearing and filter maintenance hours. The system allows control of main system operations, auto/manual selections, process control settings and process control timing. In conjunction with third party spreadsheet software, the system allows users to generate extensive daily and monthly operating reports for on-screen display or hardcopy. Automatic averaging, totaling and other features are available.

Jerry Filip, AMCEC Senior Electrical/Instrument Engineer, says the company has used other brands of HMI/SCADA software for its supervisory control systems, but Lookout provides a higher rate of customer satisfaction and requires less debugging. We are very pleased with Lookout and how it has worked for World Color Press, Filip says. We have used Lookout at other facilities for complete solvent recovery, analytical monitoring and speed control systems with equally good results.

SCADA systems are crucial to the operation of solvent recovery operations. The systems not only help companies meet state-mandated continuous monitoring and reporting requirements, but also provide the user with important insights into recovery plant operations. Because AMCEC usually designs such solvent recovery plants for 24-hour operation, excellent functionality and reliability are critical.

World Color Press uses a Siemens/TI 540 programmable logic controller (PLC). Lookout provides a graphical user inter-face with supervisory control. Problem investigation or report generation is conducted in conjunction with control system operations. Recovery operations continue even if Lookout is off-line. In addition, the software allows the import of custom 3-D graphics that provide clear representations of specific units and equipment.

According to Scott Thomson, Manager for Solvent Recovery Operations at World Color Press, the Lookout system offers many advantages and capabilities: We now have the ability to fully monitor the solvent recovery operation on screen. The Lookout system not only warns us of problems, but prompts us when routine maintenance is to be performed, such as filter changes. Thomson adds that the Lookout system has enabled World Color Press to save many hours usually required to compile reports and identify causes of problems.