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Industrial Video & Control

IV&C Longwatch Video Solutions for the Industrial Environment

We’re all working with less resources and the ability to have “eyes” on our operations is getting harder and harder. To that end, more and more customers are extending video recording capability to their processes and plants to be able to watch and review exactly what happened during the course of operations. Additionally, some manufacturing processes are very difficult to observe without the use of video. These needs are requiring industrial organizations to implement plant floor video solutions so that they have the data to drive better compliance, mitigate safety issues and improve product quality and production efficiency issues. IV&C Longwatch specializes in bringing video data capture to process environments and allowing users to link live and recorded video to their MES and SCADA applications to gain a complete picture of manufacturing operations.

Longwatch and Tires:

When a leading multinational tire manufacturer of tires needed a solution to monitor their manufacturing operations in a greenfield manufacturing facility they turned to Longwatch. When producing tires that cost in excess of $10,000 it is critical to view all aspects of the operation at all times. This required the installation of over 100 cameras mounted with custom mounting brackets. Some of the brackets are attached with magnets to metal structures to allow the cameras to be relocated as needed. The entire solution; cameras, brackets, software and engineering design were provided by Longwatch.

Longwatch and Aluminum:

When a customer of an aluminum company requested videos of a particular operation they selected Longwatch as the solution to provide these video clips. With the ability to trigger the storage of video clips based on an external signal each process video clip can be stored as individual files and easily selected and sent to the appropriate customer. With the addition of a boroscope the Longwatch system is also used to monitor operations within melt furnaces. At the time of the product selection the facility was also updating their security system, so they decided to standardize on one system for all their video needs; process historian and security.

Longwatch and Specialty Metals:

Pouring molten metal to form turbine blades is a critical operation. Due to heat and vacuum conditions it is difficult to view this without the use of cameras. Adding Longwatch to the camera system allowed this manufacturer to store video clips and associate the process data with the pour.

Longwatch and Steel:

A premier steel company in the process of expanding their operations needed a solution that could look into their furnaces to provide operators with a view of what was happening during the melt process so that they could integrate this data into their new Wonderware System Platform SCADA/MES platform that runs their plant operations. The new System is meant to provide operators with all of the data (visual and digital) required to run a state of the art specialty metals operation. Longwatch was selected for their industrial camera offerings and ability to seamlessly integrate video data to their SCADA/MES environment.

Longwatch and Food and Beverage:

One of the world’s largest food companies was having issues stemming from unforced operator errors on their plant floor HMI terminals – so they purchased the Longwatch Console recorder to gain instant visibility into the situation. With no extra hardware needed, Console Recorder allows users to record everything that is happening on a computer, DCS, or thin client screen as if that screen was an IP Camera. Users simply point the Longwatch Console Recording engine to the terminal and record exactly what is happening on the screen to troubleshoot problems, ensure operational compliance and to address additional training needs of plant floor operators.

Stratus

Stratus Fault Tolerant Servers

Aberdeen Research found that downtime cost, on average, $98,000 per hour. In 2012, that number rose to $138,000—a 19% year-over-year increase. Per Aberdeen, when looking at availability percentages, a system that provides only 99% availability would incur $12,088,800 per year.

With more and more companies moving to virtualized environments, this means that a server failure takes out every virtualized application running on that server. One fault and all systems stop running. This kind of scenario is unacceptable in most manufacturing environments but the solutions offered by virtualization software providers are lacking. High Availability and Fault Tolerance offerings from companies like VMWare require multiple computers, a SANS, extra software licensing and significant IT investment in setting up and managing the system long term. HA solutions then still have measureable downtime associated with them and FT solutions can only leverage a single core per VM – something not typically acceptable for applications that need real performance.

Stratus takes the opposite approach of trying to minimize system downtime and works to GUARANTEE UPTIME for users of their servers. Their fault tolerant computing platforms are used in many of the world’s most critical computing systems and they have a published global availability status of 99.99939% across thousands of servers – and this uptime percentage is published live on their web site at any given time. And they act like a single server. No complicated hardware architectures, no duplicate licensing and zero downtime.

Stratus and Metals Manufacturing:

A large metals manufacturer was rolling out a global MES system and needed to set up their Corporate Data Center to protect this critical software asset. The initial thought was to set up a clustered environment leveraging virtualization fault tolerance but when they did the comparison, they determined Stratus Servers offered far more capability in a more cost effective package. The clustered environment required far more complex engineering and long term, would require additional IT resources to manage and maintain the system. By moving to Stratus, they could eliminate an added burden on their IT staff, reduce the need for extra software licenses required in a clustered environment and they would gain far higher levels of availability long term. Additionally, users of Stratus servers typically keep their servers for over 12 years – reducing the need to update hardware during the lifetime of the system.

Stratus and Natural Gas Distribution:

A large provider of natural gas needed a solid platform for the SCADA stations at each of their remote compressor stations. Each station generates significant money for the organization and downtime of critical systems instantly costs big money. Additionally, since these compressor stations are remote, if a problem occurs with a server, it can easily go unnoticed until a failure occurs. Stratus was leveraged to mitigate the problem. Simple setup and zero downtime for critical virtualized applications.

Stratus and Food Processing:

A food processor was updating their infrastructure on critical manufacturing lines and moving to a virtualized environment to host their core manufacturing systems. For cost and compliance reasons, they cannot absorb any downtime in the event that a server fails during production, and having multiple systems running in a virtualized environment means that server downtime takes out all virtualized systems. The Solution was to leverage a Stratus server. Stratus will help insure that the new processing line never goes down and the IT burden on the organization is reduced to almost zero for that system.


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