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Crematoria control: a technical undertaking03 May 2010The combination of an Ethernet router, 3G modem and VPN server is providing secure, Internet based remote control and diagnostics for crematoria operators. As well as enabling remote access, it is providing an early warning of impending component failure and saving unnecessary service engineer call-outsIn recent years, UK-based crematoria have come under pressure from the Government with regard to pollution control. Several years ago, Environment Agency studies found that crematoria were the fastest rising source of mercury emissions in England and Wales. Emissions of mercury from dental amalgams were rising fast and while mercury is not toxic when contained within an amalgam, its release from the amalgam when exposed to high temperatures poses an environmental toxic hazard.
Traditionally, crematory systems use bespoke control systems. However, off-the-shelf, fully integrated PLC systems are now available to monitor and control all aspects and functions of a crematory, to ensure safe, efficient and reliable system operation.
Crawley, West Sussex based systems integrator, Automation Integration designs and installs PLC and SCADA based control and automation equipment for a wide range of customers, including suppliers of crematoria equipment, and these are developed specifically to meet manufacturers' process cycle and abatement requirements.
A simple one-button command by the operator will take the crematory through its programmed cycles in a safe and predetermined manner. The PLC continuously monitors all vital functions and provides LED system status display, along with current operating temperatures and burner status. Control systems such as these provide superior fuel and airflow control capability resulting in a very much more efficient operation. Automation Integration director, Steve Mays takes up the story.
"In a recent project at a UK-based crematorium, the new control system that we supplied comprised Siemens S7 PLCs, HMIs and a SCADA system, which were located in a control cabinet at the crematorium. However, because the cremator was using a new process cycle, we had to keep sending a service engineer to site in order to check and monitor the system."
According to Mr Mays, his customer wanted to know if there was a way in which the system could be controlled and monitored remotely in order to save the costs associated with service engineer visits. "We spoke to the local authority who owned the crematorium, to see if we could install a broadband connection. However, this was declined because the local authority did not wish its IT department to take over responsibility for the connection to the crematorium. We therefore had to look for an alternative solution."
After trawling the UK market for a potential supplier, Automation Integration finally selected MAC Solutions (UK) whose system provided the required level of security as well as a reliable remote monitoring capability. Equipment supplied by MAC Solutions enables the two cremators, the abatement system and the SCADA software to be networked at site.
Three eWON Ethernet routers are connected to 3G modems at three separate sites. Each installation is housed in a wall-mounted control panel close to the cremator, and connected to the Internet via a BT SIM card. The 'eWON' range of industrial routers is compatible with a wide range of serial and Ethernet-based PLCs, including Siemens, Rockwell Automation, Schneider Electric and Omron.
MAC Solutions also supplied one Endian VPN (Virtual Private Network) server box, which is located at Automation Integration's head office in Crawley. This provides a totally secure, 'always-on' VPN connection to multiple crematoria sites, as required. Thus the two Automation Integration service engineers assigned to this project are able to access the PLCs at any time from their own office. Modifications to the PLC can be carried out from this location, including changing process cycles and system parameters. Steve Mays again:
"It's as if the service engineer is physically at the crematorium accessing the control panel and PLC. Previously, if a fault occurred at a crematorium, such as a thermocouple failing or the burner losing efficiency, a service engineer would have to travel to site to rectify the problem. Now, the remote system enables the engineers to monitor constantly both the cremator and abatement systems.
"We've programmed in early warning alarms so that the system can tell us when a thermocouple is starting to deteriorate, rather like a condition monitoring system. We can even give the Environment Agency or the local authority access to the reporting side of the system, providing them with monthly or quarterly emissions reports.
"Since installing the new system, no service engineer has had to visit the site and we've been able to implement the new process cycle without getting in the operator's way. What I also like about MAC Solutions' products is that we can use them for other projects outside of the crematorium sector, as the system can be easily adapted for other industries."
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