Innovative Thinking

The manufacturing process for a single product can be modified much easier in order to improve its efficiency and productivity, compared to a plant floor where several different products are being produced. Higher Return on Investment is the prime motivation for automation, and improving the parameter becomes more complex as the production capacity increases in difficulty.

Implementation of a new distributed control system is one of the toughest projects undertaken by any process control engineer, with several complexities and risks. In order to do one successfully, the engineer must be well-versed in all steps involved, from documentation to grounding practices. Even though control engineers prepare themselves for such an implementation right from the start of their career, they often develop tunnel vision and find themselves stuck in a mesh of complexities. A couple of best practices regarding DCS implementation can help them navigate through common problems, ensuring that their project is a success.

Standardization

By using a standard wiring scheme throughout the implementation, it would be easier to carry out maintenance and upgrades. The use of standard, off-the-shelf components would allow future operators to stock and replenish supplies. Another possible addition would be purchasing products from two separate sources of vendors.

The Basics

Ensure that you use proper grounding and termination for electrical signals. The supplier’s grounding requirements must be understood clearly and objectively. All automation engineers, and not just the electrical staff, need to understand the grounding principles. When international standards are followed, a supporting booklet and/or tutorials should be provided to ensure that misinterpretations do not take place in the future. Before powering up any part of the DCS system, be sure that there are no short circuits. This can be done during the Site Acceptance Test.

Communication Paths

Several vendors use different software versions for communication purposes, ensuring that all data is transmitted. Several systems will transmit the basic parameters, robbing the setup of advanced diagnostics. A concept known as “Control in Field” can play a vital role here that transfers the control process from the central control unit for field devices. This gives sensors the autonomy to issue a response to an actuator based on the measured variable.

Structuring I/O

The I/O structures should be shifted away to the field that would cause a reduction in the cost and space requirements. The electronics manufactured today are usually resistive to high temperatures and may have G3 compliant conforming coating. Fiber optics should be utilized for communication links, preferably in a ring configuration to increase the reliability of the system. Extended I/O terminal blocks can be utilized for connecting the field working directly, avoiding additional costs and weak connections.

Dual Purpose

A DCS is designed to serve two purposes, to provide a centralized human control and a focal point for MIS information to the management network. Distributed Control Systems shouldn’t be burdened with tasks such as auto-tuning of control loops. Instead, such functions should be restricted to dedicated controllers.

Factory Acceptance Test

To top it all off, before the shift-over takes place, make sure a detailed Factory Acceptance Test (FAT) is carried out that allows experienced operators to interact with the engineering functions of the DCS. This ensures that all functions operate the way they are expected to operate, and if any ambiguity exists it can be cleared straightaway.

Interested in learning more? Visit our website www.premierautomation.com, or talk to one of our specialists today.

Motors have been the cornerstone of industrialization and automation. About 45% of energy generated is consumed by motor loads globally, enunciating the hardware’s importance in today’s world. Over the past 30 years, motors have greatly evolved. The advent of modern processing tools allows manufacturers to get a clear idea as to how motor performance can be improved and tailored for specific applications. Furthermore, the growth of smart manufacturing techniques allows users to monitor process performance in real-time, giving them clearer insights and information required to boost productivity.

The early 1950's marked the entry of one of the most revolutionary products in the history of industrial automation: the Variable Frequency Drive. Since then, the product design has evolved and refined at an increased pace. Even in the 21^st century, there is no alternative in sight, and thanks to continued improvement, VFDs have solidified their position in the field of automation.

Variable Frequency Drives, or more commonly known as VFDs, are known for their unmatched speed-control within several industries. However, any machine that is subjected to the chopped DC square wave is also prone to a number of harmful effects. By making the right choice with cabling, these harmful components can be alleviated, and the connected machinery’s lifespan can be elongated.

Some people are increasingly under the impression that their cars are consuming more fuel than the manufacturer’s data initially specified. Is this a deliberate issue or is it because laboratory conditions are different from real-world scenarios? One thing is certain: the problem extends to all branches of manufacturing, whether it's automotive, power electronics or other consumer products.

Lean methodology has gained significant traction within modern organizations who want to ensure top operational efficiency to compete with adversaries in a globalized market. The list below presents the do’s and don’ts that can be followed by manufacturers for their lean implementations.

The value of digitization in the industrial sector has been viewed with renewed importance starting at the beginning of this decade, with companies investing more into adopting it. This has given rise to a new industrial culture; one that moves towards proactive maintenance rather than reactive maintenance.

There are numerous efficiency and regulatory standards that design engineers must follow without asking any questions. Efficient and reliable systems are necessary for maximum productivity. In order to guarantee this, engineers must make sure all common motor/VFD specifications issues have been resolved.