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A Managing System for Manufacturing Execution Systems was assimilated in Solbar Industries Plant by Contel I. T. S., a subsidiary of the Contel Group. A new software system for the production management within Solbar plants in Israel and in the USA was uploaded, and is expected to be distributed to additional sites of the company, both in Israel and World–Wide. The Contel I. T. S. solutions were chosen after the completion of a prolonged deepened process of exploration.

The Contel I. T. S. Ltd Company of the Contel Group, a software solutions supplier for production management, assimilates a manufacturing execution system (MES) for the purpose of managing the production floor in Solbar Industries plants – one of the world leading companies dealing with the production of special soybean protein. The project will be gradually implemented in the company plants in Israel as well as in other various sites world–wide.

In the framework of this project, a managing system for the production floor is being assimilated these days within plants of Solbar Industries by Contel I. T. S., using an innovative technology of the company.

The system is an essential operational tool for the Solbar activity – It provides the company management with a direct access to information related to production output, stock supplies, downtime periods and so on, improving the control of the various managing functionaries over the different aspects of the manufacture and chain of supply. The system also delivers abilities to the quality assurance improvement and Audit Trail.

Shai Gershon, CEO of Contel I. T. S. states “I. T. S. is continuously leading and developing the MES market in Israel. Based on the Solbar controlled policy introduced by the management, which raises the banner of investment for the purpose of organizational increasing efficiency, we expect that Solbar will continue on growing.” He adds, “Just like other projects implemented throughout the industrial fields by us, this system which has been assimilated in Solbar, is going to deliver excellent operational tools designed to improve the control held by the various management functionaries, and to grant Solbar with the flexibility and transparency in the production floor.”

Yaffa Barzinov, the manager of information systems in Solbar says, “The assimilation of the new system for the production management will enable the company to continue its growth momentum. The new system is essential to the efficient operation of the production in the Solbar Industries plant, and the decision about the system assimilation earned all the support from the company senior functionaries. The implementation of the system and the identification of the operation processes, the reporting of the production and the quality required in Solbar industries plants, both in Israel and world–wide, are going to widely improve the control and the information accumulation from all the company plants”.

About Solbar

Headquartered in Israel, Solbar is a global company with production plants in Israel, in China and in the USA. The company deals with the development, manufacturing and marketing of soybean protein to the food industry various fields, such as beverage, snacks, meat and meat substitutions. In addition, Solbar markets animal food products and isoflavones.

Contel participated in the veteran RAX Exhibition again this year. RAX is the professional exhibition for the electrical, electrical engineering, lighting, control, and instrumentation and automation sectors. The exhibition is held every two years at the Israel Trade Fairs Center in Tel Aviv.  Professional gatherings are held at the same time for engineers, consultants, maintenance, instrumentation and control personnel, and lighting engineers. The RAX Exhibition is the only exhibition that is a meeting place for manufacturers, importers and marketers and a specific, professional customer audience.

At the exhibition, Contel presented solutions in the area of industrial control, HVAC&R control, and process control.

Dates:
Tuesday, Wednesday, Thursday 8-10 June, 2010

Hours:
Tuesday June 8, 2010   12:00-20:00
Wednesday June 9, 2010         12:00-20:00
Thursday June 10, 2010           11:00-19:00

Exhibition location:
The exhibition was held in Building 1, Israel Trade Fairs Center, Tel Aviv

Target audience:
Engineering and lighting engineers, consulting and planning firms, electricians, electrical and industrial technicians, electrical contractors, electronics engineers, maintenance engineers and managers at plants, enterprises and in large buildings, tool operators, control personnel, purchasing and logistics managers in industry and in the institutional sector, energy authorities, as well as architects, designers, security officers and general technicians. 

Gas turbines, GG and Compressors systems

Instrumentation, ESD, Process Control and Automation systems

Contel proposes a turnkey project for Electrical, Instrumentation, ESD (Emergency Shut Down), Process Control and Automation systems for Gas turbines, GG and Compressors systems. The Company has specific expertise in this area, and a proven track record in the complex upgrading of systems with minimum production downtime.

Position Control Block – Gas Turbine

Contel proposes a comprehensive upgrade for all the components of the gas turbine control systems including detailed design, manufacture of the Control and Instrumentation Panels, Field wiring work, on-site installation of the Panels and field instrumentation, the PLCs, Control Valves, and protection systems for the rotating equipment. In its projects, Contel uses leading-edge technologies from Rockwell Automation and several series of controllers from Allen-Bradley. Contel has extensive experience in carrying out upgrades in a volatile environment using the most advanced protective measures in the world. Combining vibration monitoring solutions with advanced control systems is the key to the success of the upgrade projects that Contel offers its customers. Upgrades of control systems are based on PLCs from the ControlLogix flagship series, enabling implementation of full redundancy for all the system’s components. The protection systems supplied by Contel include use of the Entek product series acquired by Allen Bradley, and use of existing sensors from Bently Nevada or installation of new sensors. The protection systems for rotating equipment enable not only emergency stopping, but also prediction of turbine performance, hence reducing down time resulting from maintenance actions that are not necessarily immediate, and increasing production output. The software systems and the HMI supplied by Contel come from the Rockwell Automation Factory Talk View series.

Contel’s scope of works consists primarily of products and services that fit Contel’s core business and expertise.

Contel’s proposal includes:

a. Some or all of the following activities:

i. Automation and Control system, including process control / PLC’s. A-B ControlLogix and PlantPax products,

ii. TMR Triple Modular Redundant, Emergency Shut Down System

iii. Allen-Bradley  ( ENTEK XM family) Vibration ESD system

iv. Operator interface, HMI, and Historian solutions.

v. Plant Floor Communication systems.

vi. Instrumentation such as temperature, pressure, flow sensors/transmitters.

vii. Gas Analyzers and BTU gas Metering system

viii. The range of activities includes some or all of the following electrical systems:

1. Switch Gear

2. Motor Control Panels (MCC)

3. Distribution panels

4. Field cables contracting works

ix. Integration services, control room, field-side electrical system and remote control.

x. CCTV, excesses control and security system.

b. Some or all of the following engineering services:

i. Detailed design and engineering works.

ii. Software implementation works

iii. Validation and documentation.

iv. Commissioning activities.

c. Maintenance and repair services, including predictive maintenance facilities, scheduled services and breakdown services.

d. Contel reference list includes wide range of activities, including complete turnkey project for upgrading Gas Turbine, Gas generator Turbine compress system, including all the above mentioned activities and products.

e. Contel is the sole distributor and authorized Rockwell Automation, Allen Bradley in the territory of Israel, since 1966 as well as Dresser Masoneilan, for Control Valve for Oil and Gas Industry. Dresser is global leader company in the Oil and Gas Industries

f. Contel is Panel manufacturer and works under the ISO 2001/9000 standard, our manufacturing plant manufacturing during 2009 about 1,000 control PLC small panels for Thermo-Solar power station and running the turnkey for this project including Fiber-Optic cables connection works, servers and complete control room.

HMI Screen- Compressor System at Gas Turbine

HMI Screen- Compressor Overview at Gas Turbine – Vibrations Monitoring Overview

Success Story – Luginetsk Gas Compressing Station for Tomskneft

Contel upgraded the control systems for main compressors and control and instrumentation equipment at Luginetsk Gas Compression Station, OAO “Tomskneft” as a subcontractor to OOO “Intek”. Contel did the works in very short time and with minimum downtime. The challenge was to upgrade the systems with minimum interference to the station works. Contel upgrade the first system while on the same time the second station remain running. The first system shut down was for 3 weeks. After a successful commissioning – the second system was shut down for its upgrading for the same time.

In this project – Contel scoop of works includes the following:

1. Detail design of the control system including the design of new control panels and design of cabling connection works

2. Panel manufacturing including supply of Allen Bradley ControlLogix control system

3. Automation software implementation works

4. Local operator panel software implementation works

5. HMI software implementation works including dynamic operator viewers , Trends, Reports and alarming system.

6. Simulation works including running of control panels with operators panels, HMI and Automation software with Tomskneft station engineers on Contel premises

7. Onsite installation and cable connection works

8. Loop Test and commissioning

9. Final tuning and balancing works

Contel integrated an MRB module at the Shefa plant in Arad, as part of MES (Manufacturing Execution System) software installed at the plant. Material pending an MRB (Material Review Board) is material suspected of being defective, and hence initially kept back from production until tested.

Contel ITS integrated an MRB module at the Shefa plant,  a member of the Unilever Group, in Arad.

Contel ITS integrated an MRB Forms module at the Shefa plant in Arad, as part of MES (Manufacturing Execution System) software installed at the plant. Material pending an MRB (Material Review Board) is material suspected of being defective, and hence initially kept back from production until tested. Initially, tests are performed by the line operators and line managers who give their opinion. The material is then transferred to the lab for more thorough testing. After the testing, the lab issues its report on the material and its disposition, ranging anywhere from return to production to physical destruction. The decision, approved by the plant managers, is reported back to the production personnel, who implement the disposition.

According to Daniel Baron, Manager, Logistics and Information Resources at the plant: “This software module is expected to improve the production and control processes at the plant. We expect ever-greater efficiencies in the production processes to continue thanks to the MRB module.

The module is designed to handle, control and track material that is pending an MRB, from the identification of suspect material by plant employees, to the disposition decision by the lab personnel and plant managers, and finally, to implementation of the decision. In addition, the documentation is stored, enabling an analysis after the fact and drawing of conclusions for the future. The module contains documentation and the details of employees who handled the material, decisions made about the action to be taken and the reasons for the decisions, and links to forms and to external documents in order to document the material.

According to Itai Gittler, project manager at Contel ITS, combining use of this module with MES data will increase efficiency and improve the handling of material suspected of being defective in the production process. The module is directly linked to the production data accumulated in the MES system: work orders, stoppages, faults, shutdowns, etc. This constitutes a major advantage when analyzing the data and drawing conclusions, an advantage not feasible in a system that is not closely linked to production in the way the MES system is.

About the Shefa plant

The Shefa plant, which makes morning cereals in Arad, is part of Unilever. MES software installed at the Shefa plant three years ago has brought about major improvements in the production processes at the plant.

Contel supplied the Paz Ashdod Refinery with a sophisticated analyzer room. The room is equipped with four advanced analyzers for monitoring gases and liquids.

Contel supplied the Paz Ashdod Refinery with a sophisticated analyzer room. The 5mx3m, stainless steel room is equipped with four analyzers for monitoring gases and liquids. Designed and built by Contel, the room was fitted with advanced analyzers systems equipped to operate in an explosive environment. Two EX air-conditioners were installed to keep the room at a constant temperature, with 100% availability provided by a hot backup. The analyzer room includes a gas leak detection system and a system that delivers clean air to the room. The room was designed and built at Contel’s panel plant, which recently supplied similar rooms to Makhteshim and Dead Sea Works plants. Contel also supplied the same project at the Paz Ashdod Refinery with a chromatograph to measure parameters in the fuel and a two‑flow sampling system.

About Paz Ashdod 

Paz acquired the Ashdod Refinery on August 1, 2006 in a deal worth NIS 3.25 billion, which subsequently became the Paz Ashdod Refinery Ltd. The Paz Ashdod Refinery extends over 100 hectares (250 acres) of land, and has a refining capacity of four million tons of crude oil a year. Pipelines link the Refinery to the national fuel pipeline, to the Eilat Ashkelon pipeline, and to two Israel Electric Corporation sea links in Ashdod. The Ashdod Refinery is connected to the national natural gas grid, and uses gas to heat the furnaces. The use of natural gas significantly reduces the emission of pollutants into the environment, and is economical.

Klil integrated a new software system for managing conveyance on the production floor at its plant in Karmiel. The company chose the solutions from Contel ITS after a lengthy investigation. The scope of the project: NIS 650,000.

Contel ITS, a member of the Contel Group and a provider of MES solutions, successfully implemented a system for managing conveyance on the production floor at the Klil plant in Karmiel. Klil is the leader in the development, production and marketing of aluminum systems for the building construction and industrial sectors in Israel and abroad. The scope of the project: NIS 650,000.

According to Klil CEO Arie (Richie) Richtman: “Integration of the new system upgraded production at Klil, improving deliveries to customers in Israel and abroad, as the conveyance of thousands of profiles was significantly upgraded”.

In the project, Contel ITS integrated a conveyance management system on the production floor to replace the existing one. The system is a critical tool for Klil operations, constituting a link between the inventory management system and the production floor controllers.  Its main function involves receiving an aluminum profile conveyance instruction from the inventory management system, processing the incoming instruction, and sending instructions to the plant’s controllers that control the array of conveyor belts and cranes.

According to Shai Gershon, CEO Contel ITS: ” ITS, the leader in the MES market in Israel, has a proven track record in the implementation of such systems in a wide array of industries, including the plastics, food, drugs and pharmaceuticals industries.  Our experience and expertise is reflected in our many projects in Israel and Europe, which is why we were chosen by Klil to execute the biggest project of its kind ever in Israel”.

In the event of a fault in the inventory management system, the system enables conveyance instructions to be issued directly to the plant’s controllers. In addition, the system provides a user interface to information on the system status, work reports, stocks, communications faults, and faults reported by the production floor controllers.

During the development phase, Contel set up another communications channel in addition to the existing one, enabling the existing system to continue working while the new installation underwent testing and commissioning. This resulted in a short system commissioning time, without any disruptions to routine production at the plant.The user interface was upgraded to the latest technology and assigned a Hebrew web interface. The new interface allows system users with different levels of permissions to log on from any workstation at the plant and to perform operations, view data, monitor events and generate reports.

About Klil

Klil Industries Ltd. is the largest Israeli firm developing, designing, manufacturing and marketing aluminum systems for the building construction and industrial sectors, for both local and export markets. The company was founded in 1950 and employs a workforce of 250 at its new complex near Karmiel. The company’s shares have been traded on the Tel Aviv Stock Exchange since 1981, with most of the shares held by the Daboosh Investments Group.

Upgrading of a production line for cutting and packaging flat glass in Spain

Written on December 1, 2009. Belongs to the categories:   Industrial Automation and Control, and Success Stories. 

The project made use of the ControlLogix family of programmable controllers from Rockwell Automation.

Contel ITS is currently implementing a computerized control and recording system for a shot peening machine in the Civil Aircraft Division of the Israel Aircraft Industries. 

The IAI supplies products to the aviation industry around the world, and is subjected to stringent quality testing by leading international institutes.  Shot peening is required in the manufacturing process in order to harden the items being produced. The shot peening process must comply with stringent SAE aviation standard AMS-2432 in order not to damage the item being manufactured, and in order to create an even spread over the shot peened part.  Technological parameters tailored to the item being shot peened need to be strictly adhered to. The control system that exists today is composed of a PLC5 controller and Rsview HMI software from Rockwell Automation.

To comply with the standard and to improve the efficiency of the manufacturing process, the IAI decided to computerized the process, which would provide the following benefits:

• Storing of technological parameters tailored to the item, the type of shot peening and the work stage.
• Automatic downloading of the technological parameters from the bank of parameters to the control system.
• Immediate stopping of the machine in real time in the event that the process deviates from the definitions contained in the standard.
• Receipt of reports on and computerized recording of the actual shot peening process and of the inspection process.
• Creation of interfaces for receipt of work orders and transfer of actual shot peening data to the central computer system.

Contel has extensive experience in the area of control and software and in the integration between them. We provide technological solutions to Israeli and overseas manufacturers who need to comply with international aviation standards. Our aviation customers include the IAI, Techjet (an Iscar subsidiary), Cyclone, a member of the Elbit Systems Group, and the Russian aviation industry.

For this project, ITS has brought together its unique skills to combine implementation of control systems with software – and is implementing the software to save the required recipes and the reports. Close integration and coordination with the existing control system at the facility is required. The software is being written using Vb.net and an SQL Server 2008 database.  The software interfaces with the central database from Oracle.  The software uses OPC (OLE for Process Control) in order to download the technological parameters to the controller.

Contel, a provider of automation and control solutions, successfully implemented the upgrading of a control system for a glass cutting and packaging line in Spain.

The challenge:

• Integration of third-party products such as robots and image processing systems.
• Control of position/ motion with high-power AC servo motors.
• Speed, motion and accuracy.
• Short production line downtime during the conversion.

The Solution:

The project made use of the ControlLogix family of programmable controllers from Rockwell Automation.

For motion control, PowerFlex 700 variable speed drives from Rockwell automation were selected. This series of drives is tailored to work with AC motors as well as to provide control of servo motors, and is capable of implementing applications that require position control and generation of motion profiles. These features were employed in the project. The drives controlled servo motors and were responsible for conveyance of the glass and its position on the line.

The PowerFlex 700 series of variable speed drives are effectively also servo controllers. The drive enables definition of many parameters, so that it operates with closed-loop position feedback control.

The line operator interface was subjected to development and integration with the existing application at the plant using RSView from Rockwell Software.

Ethernet TCP/IP was selected as the communications protocol for the system. The communications network connects up to the controller, variable speed drives, HMI, the Vision system, main line controller (which sends glass to the cutting and packaging line), as well as to robots used to pick up and package the glass.

System Description:

Glass from the main line is sent to the packaging line. The line is capable of receiving two plates of glass at a time. Information about the glass plates sent is received from the main line controller. The information includes the size of the plates that must be produced from the sent glass as well as other details about it. The controller and the drives position the plates of glass one after the other above the breaking point, and break the sent glass into smaller plates that are then sent for packaging.  The plates, after the breaking, pass under a Vision system which inspects for defects in the glass and/or incorrect breaks. The inspection is performed on the fly while the plates are moving. The controller routes remnants of the original glass and plate rejects to the plant’s recycling system. Plates that pass the Vision system’s inspection continue on towards the end of the line for pickup and packaging.  The glass is picked up on the fly by two robots, one on each side of the line, and placed in special holders. In addition, development of the system took into account future upgrades to the use of four robots.

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