Author contributors: Group Engineering Manager, Matt Martin

Challenge

The client, a leading biopharmaceutical company’s existing manual data collection process from Metler S230 Conductivity meters was inefficient and prone to errors. Relying on manual transcription of paper records hindered data accessibility, slowed down operations, and increased the risk of inaccuracies.

Key challenges included:

• Redundancy & Reliability: A redundant solution was required to ensure continuity in operations and minimize system downtime.
• Time Sensitivity: A rapid turnaround was critical to meet the client’s operational needs.
• Data Integration Complexity: Seamless integration of real-time data from the specialized lab equipment to their Aveva PI Historian system.

Solution

E Tech Group developed and implemented a tailored solution to address these challenges:

• Custom Driver Development: Developed a custom driver in Kepware to parse and integrate data directly from the Metler Toledo equipment. This solution was developed for an older Metler product but is adaptable to more recent releases.
• Technological Expertise:
  • Leveraged PI, Kepware, and custom JavaScript to enable smooth and efficient data handling.
  • A serial to ethernet converter module was added to the RS-232 port of the meter, which allowed Kepware to listen to data being broadcast from that device via TCP. The Kepware driver had code to keep its session alive when a PI interface was actively requesting data from it and it was the current “active” OPC Server from PI interface perspective. Operational redundancy was implemented using two Kepware servers and PI Interfaces.
  • Real-Time Visualization:  PI AF was used to create event frames for each calibration and read event. PI Vision displays were developed to provide the user with real time event data.
• Seamless Execution: Delivered a robust solution that ensured accurate and real-time data availability, overcoming the limitations of paper-based systems. The solution was delivered on an expedited schedule in a validated environment.

Results

The project was successfully delivered within the client’s tight timeline, yielding immediate and impactful benefits:

• Enhanced Data Accessibility: The client transitioned from paper to digital data storage, significantly improving operational efficiency.
• Improved Accuracy: Digital integration reduced errors associated with manual data handling.
• Scalable Solution: We delivered a customized solution tailored to the project’s specific needs. This solution is designed to be scalable, enabling implementation across the client’s entire facility as their needs evolve.
• Client Satisfaction: The project reinforced the client’s confidence in E Tech Group’s expertise, strengthening their partnership.

This case study demonstrates E Tech Group’s ability to provide innovative, time-sensitive and scalable solutions that address complex client challenges, showcasing our value as a trusted automation partner.