JBA Consulting Ltd

Key Features:

> Scaleable from 1-100’s of units

> Planned expansion achieved without obsolescence

> Systems can be divided into zones to match the requirements of the support team

> High availability with minimum investment using our unique Watchdog technology

> Full maintenance and system upgrades using automatic program upgrades that propagate through the network

The system is based on a general industrial controller, which also combines data acquisition with alarm handling and a unique level of diagnostic support; this unit is known as the Controlstar®. A Controlstar® handles all the functions at an individual pumping station. The Controlstar® provides more functionality than pure telemetry, for instance the controls capability of each device is both flexible and powerful, it is programmed with a drawing tool which means it can easily be modified to meet new requirements.

Over the next year the total size of the system will exceed 100 stations, out side of the main utilities this represents one of the UK’s largest remote asset management systems.

The dual hot standby master station in Doncaster.

Roaming access to stations.

The Controlstar® was designed from the outset to be fully scalable offering commercially viable solutions to applications ranging from a single Controlstar® to large systems needing many hundreds of units. A major achievement over the years has been the continuous growth in both the size and use of the system without the need for major expenditure on new equipment or the obsolescence of any element of the system. In fact continuous upgrades have been provided to every unit under the standard maintenance cover, this has ensured that all users have access to the latest facilities. New facilities continue to be developed and provided within the flat rate maintenance cover.

Initially the system was provided for Scunthorp Anclom and Messinghame, the master station for the Telemetry was at JBA’s offices in Doncaster with a slave station at the Consortiums Depot at Cadney. As further IDB’s were added to the system the same arrangement was followed with Doncaster continuing to be the hub of the network. Each new operational centre however was given it’s own unique zone, thus the operational staff are only aware of the stations and alarms for which they have responsibility. Doncaster has a full view of all zones. To prepare for further expansion the system has been upgraded so that the Depot or zone master now act as their own communication centre, with the data being automatically forwarded to Doncaster which continues to act as the engineering centre for the whole network. Both Doncaster and the local Depot masters can access the individual stations directly at any time.

A diagrammatic representation of the system structure
The functionality provided by each Controlstar® has changed over the period; the most significant change being the introduction of a ‘fail safe’ watchdog module which is deigned so that existing control equipment can be fully integrated and monitored by the local Controlstar®, creating a minimum cost redundant automatic changeover solution. This watchdog technology is now in use throughout the system.

The Micro Controlstar was introduced in 2004, this is a battery operated device giving remote level measurement and trending and SMS alarms triggered from user configurable high levels. The micro Controlstar has been fully integrated within the existing network.

The system has also been developed to reduce the cost of implementing system changes and to provide cost effective maintenance coverage for the whole network. By design, the Controlstar® provides a user with first class diagnostic facilities, this allows the cause of many problems to be identified prior to visiting a site. As part of the maintenance support Controlstar Systems operate a dedicated master for the support of all clients, using this telephone assistance can be given using live information received directly from any station. All the Controlstar’s®, the zones, and Doncaster master stations can be accessed and updated from the support system in Controlstars offices. The programs and the configuration data can be directly downloaded to the stations; in addition the system has been designed so that when any master station has been upgrade it will automatically upgrade any unit to which it communicates. This arrangement reduces system maintenance costs by allowing enhancements to be provided with a minimum of installation costs. These facilities are aimed at maximising the effectiveness of support and it has allowed the whole network to be continually enhanced, without major costs and mostly within the existing maintenance support contracts.