Steam Usage Monitoring for Large Food Production Facility

A client approached Genesys Controls for engineering of a real time steam usage monitoring system for their six boiler steam system. Their goal was to have the steam usage continuously sent to a remote PC for the purpose of viewing and logging of the information automatically.

Genesys Controls engineers created a new Windows-based graphical user interface application that periodically collected real-time steam usage from 3 separate flow meters along with related pressure and temperature data. The data was monitored by an Allen-Bradley MicroLogix 1100 Ethernet PLC, and stored on a PC. The information was saved in a file format suitable for Microsoft Excel reporting, graphing and trending for steam usage analysis by shift, on a weekly or monthly basis. This allowed the customer to chart maximum and minumum intervals of steam usage, resulting in greater boiler efficiency and energy savings.

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