A large glass manufacturing plant, required a reliable nitrogen supply for its float glass production line, where nitrogen acts as a protective and shielding gas during high-temperature glass forming. To ensure continuous and efficient nitrogen delivery, the factory implemented a fully automated Nitrogen Station Monitoring System built around ASU (Air Separation Unit) technology and an integrated PLC + SCADA control architecture.
The system utilizes four PLCs to manage three independent nitrogen air-separation units and one vaporization system, connected through SCADA software. Three industrial PCs running SCADA Software operate in a parallel configuration, ensuring redundancy, if one workstation fails, the others continue to operate without interruption. This design greatly enhances system reliability and operational uptime.
The Nitrogen Station Monitoring System was designed to meet the following operational and automation requirements:
Data Acquisition: Collect on-site operational data from ASU equipment via industrial-grade PLCs.
Secure Private Network: Dedicated PC-to-PLC communication network using specialized industrial cabling.
Historical Data Logging: All process data stored in the SCADA database for historical trend analysis and event recovery.
Independent Control Logic: Each nitrogen unit runs independently, avoiding cross-system interference.
Control Architecture: Flexible and scalable design enabling easy system upgrades.
Visualization Interface: Graphical dashboards for intuitive monitoring and control.
Reliable and Stable Operation: Ensures high availability for continuous industrial nitrogen supply.
The entire system is structured into three (3) functional layers:
1. On-Site Control Layer
Uses internationally recognized PLC series controllers to automate key ASU components such as valves, pumps, compressors, and vaporization equipment. Each PLC manages a distinct subsystem to maintain autonomous operation and system modularity.
2. Data Acquisition & Monitoring Layer
This layer handles real-time data collection from all PLCs and nitrogen vaporization systems. Three SCADA stations operate in parallel, providing fault-tolerant system monitoring and control.
Operators can:
View real-time and historical trends
Adjust PID parameters for valve tuning
Print automated daily critical-data reports
Execute remote control commands for on-site valves
Access permissions are role-based: system administrators can configure and modify key parameters, while operators are limited to essential control functions—enhancing system safety and integrity.
3. Application & Data Management Layer
Located at the central control room of the glass factory, this layer hosts a dedicated SCADA + Web-enabled server.
Key functions include:
Unified data storage for real-time, alarm, and historical information
Web-based dashboards for remote viewing across the facility
Dual-NIC configuration for network isolation between data acquisition and corporate IT networks
This architecture enables factory management to access real-time operational insights while maintaining strict cybersecurity and data-integrity boundaries.
Enhanced Automation Efficiency – Reduces manual supervision and operational workload.
Visualized Operations – Real-time SCADA dashboards for easier diagnostics and process optimization.
High Reliability – Parallel workstation design ensures zero downtime during system failures.
Open Integration Framework – Interfaces prepared for future software or hardware expansion.
Secure Data Isolation – Physical network separation between control and office networks enhances safety.
Scalable Infrastructure – Ready for capacity upgrades and additional ASU integration.
ICP DAS USA provides a wide range of industrial data acquisition, PLC, and SCADA solutions compatible with SCADA Software and other industrial automation platforms, including:
Modbus TCP/RTU I/O Modules for nitrogen flow, pressure, and temperature monitoring
ET-7000 Ethernet I/O Series for remote data acquisition
PM-3000 Power Meters for energy usage tracking within ASU systems
WISE-5231 and WP-9000 Controllers for edge computing and logic control
iKAN LED Displays for on-site operational alerts
