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Temperature Monitoring Software

Making critical plant temperatures visible in real time

Casestudy

A temperature monitoring system built to improve quality control, support operator safety, and bring real-time visibility to rotating plant equipment.

30-Second Readings
Wireless Temperature Monitoring System
SCADA Visibility

Wireless Temperature Monitoring System for a Chemical Manufacturing Plant

Overview

The Client

Experion developed a wireless temperature monitoring system for a chemical manufacturer operating rotary digesters where wired sensors were not practical. The solution measured temperature every 30 seconds, transmitted data wirelessly through Zigbee, and integrated with the plant’s PLC and SCADA systems. This gave operators real-time control room visibility, helping improve product quality and strengthen plant safety.

A diversified chemical manufacturer producing basic chemicals and chlorine-based products. In a high-temperature plant environment, they needed a safer and more reliable way to monitor rotary digesters without interfering with their continuous movement.

Challenges and Solutions

Challenges

Solutions

Challenges

No real-time visibility inside rotary digesters The plant did not have a real-time mechanism to monitor temperature buildup inside rotary digesters. This affected product quality and created safety risks for plant operations.

Solutions

Real-time temperature monitoring system Experion designed a temperature monitoring system that could continuously track temperature inside the digesters and help operators control variations before they affected quality or safety.

Challenges

Wired systems could not work on rotating equipment Conventional temperature monitoring systems were not suitable because the digesters were constantly rotating. A wired setup would not support the operating conditions.

Solutions

Wireless temperature monitoring system We built a wireless monitoring approach that could be placed inside the rotary digester without depending on wired connectivity. This made temperature tracking practical in a moving industrial environment.

Challenges

Plant operators needed control room visibility Temperature data had to be available where operators could act on it quickly. Without integration into existing plant systems, monitoring would remain fragmented.

Solutions

PLC and SCADA integration Experion integrated the system with the client’s existing PLC over Modbus protocol. Temperature readings were sent to the SCADA system, allowing operators to monitor critical parameters directly from the control room.

Challenges

Temperature data had to be captured frequently and reliably In a manufacturing process where heat variation affects quality and safety, delayed readings could reduce operational control.

Solutions

30-second temperature measurement cycle The system was designed to measure temperature every 30 seconds and transmit the readings wirelessly using Zigbee connectivity. This helped the plant maintain a closer watch on temperature changes during operations.

Challenges

Hardware and firmware had to fit a harsh industrial setup The solution needed to work inside a demanding plant environment and support reliable communication between field equipment and plant systems.

Solutions

End-to-end embedded system design Experion handled the design and architecture of the hardware and firmware, using industrial-grade components and wireless communication to support continuous monitoring inside the digester environment.

Technologies Used

Microcontroller

Microchip PIC18F87J11

Wireless Communication

Microchip MRF24J40MA-I/RM Zigbee module

Temperature Measurement

Analog MAX31865ATP+ RTD to digital converter
R-501 RTD PT100 temperature sensor

Industrial Communication

Analog MAX488CSA+ RS485 Transceiver

Outcomes

The temperature monitoring software helped the client bring better visibility and control to a critical manufacturing process.

Enabled real-time temperature monitoring inside rotary digesters
Measured temperature every 30 seconds
Integrated with the client’s existing PLC over Modbus protocol
Sent critical temperature data to the SCADA system
Improved product quality by helping control temperature variation
Enhanced plant operator safety through better temperature control
Made it possible to monitor critical parameters from the control room
Replaced impractical wired monitoring with a wireless system suited for rotating equipment

By combining embedded engineering, wireless communication, and plant system integration, Experion helped the client monitor what was previously difficult to see — turning temperature visibility into better quality control and safer operations.

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Temperature Monitoring Software

Wireless Temperature Monitoring System for a Chemical Manufacturing Plant