Forge Furnace Automation and SCADA Monitoring

A client in the metals industry reached out to PTS with a vision for an automated system to monitor their many forge furnaces. They had been reliant on paper processes for scheduling, part serialization tracking, and quality monitoring. We provided the project management experience to help them through the planning phase by guiding them through the many PLC and SCADA plant monitoring options. Once the client chose Honeywell PLC’s and Automation Induction’s Ignition SCADA platform, PTS worked with the client to develop a scope of work that would achieve all their project goals including monitoring furnace temperatures, soak times, allow remote setpoint of temperatures, trending data, alarms, scheduling, and much more. We estimated the PLC work ourselves and created and submitted specifications to SCADA integrators and installers, which led to budgetary estimates for a full project budget and schedule.

Once the project was approved, PTS managed the execution phase of the project to completion. Our controls team designed and developed the new PLC controls and HMI software for each of the furnaces for communication to the SCADA system. A SCADA integrator was selected, and PTS worked closely with them to manage features, scope, budget, and schedule. The client purchased materials and contracted and completed installation of the new networking based on drawings provided by PTS. Once everything was ready, PTS came on-site to startup the controls and make sure communications were in place. We also went on-site for final testing of the SCADA system with the integrator. As with all large projects, there were challenges along the way, but PTS guided the client over the hurdles until the project was complete. PTS provided the project management experience and resources to allow the client to complete a project that was too large for them to manage internally.