What are the best practices for plant automation?

1. Inquire about the existing machinery/control system in the plant and learn from customer/operator what they find good about existing system and what may need improvements. 2. When designing automation control system, always take operator safety and machine component safety in consideration, such as heaters, rollers, servo motors. 3. When designing operator interface, never make them complicated and heavy just to look high-tech, all the control components for manual and automatic processing must be separated in such way that when you're in auto mode, u can access only auto process related screens. 4. Interfacing compatibility with existing systems must be considered beforehand.

1- You must check all safety on the line to make sure everything is ok 2- You have to check each stage separately 3- when you startup the line, you will notice some issues and you must take some notes and work on it

- Avaliar a instala??o dos instrumentos e sua forma de comunica??o e sinal. - planejar de forma crítica a parte estrutural e montagem correta dos instrumentos para uma medi??o correta.

It is starts from how you plan to do maintenance. Problem solving is the key to understand automation. Also you will get plant operation knowledge. Keep it increase and try to understand different type of plant.

To get the initial database, hardware information, Third party interface data, etc to get the basic idea and scope of the project.

Selecting the right automation solution is one of the most critical tasks which will be a key factor for the success of your project. In my experience where I worked in a projects where the automation solution was very limited and not capable to cover the process functions which will lead to additional cost to change this solution later on. Or the solution will be more sophisticated and bigger than the process requirement and of course this will come with a high cost.

Select appropriate Technology: Choose automation technologies that best fit your plant's specific needs, considering factors like reliability, scalability, and ease of integration.

In my experience I choose the system and components according to the following: 1-Know the stages of operation 2- Selection of sensors and cables based on the surrounding environment 3- Cost and getting more than one supply offer

Check for install base and performance of the system Getting just new upgraded one may not be best for you Something which is proven and engineered well thinking maintenance in mind will go long way

Choosing the right automation technolgy is very important because each technology have advantages and disadvantages like PLC or microcontroller ,they are effective in large or big plant of manufacturing. Otherwise soc or sip is functionnal in small applications or applications with small number of input/output.

Some of the requirements that I have found useful when it comes to PLC programming: -It controls the process/machine "more or less" (there is a lot to say about this) as specified. -It doesn't fail silently (if the program gets stuck, it shows it on the HMI), it tells the operator the signals/conditions it is waiting for. -It is boring, and reliable. It is much better to have a simple program that never fails, to a sophisticated program that is prone to fail. -It is flexible to accept modifications from a person other than the original writer, without a six year training on the program 'style'. -It doesn't over-alarm. One of the fastest ways to train operators to ignore the alarms is having 200 alarms while still is able to run.

Para una buena práctica en la industria, el PLC debe tener interfaces versátiles, compatibilidad con protocolos estándar, capacidades de red eficientes, soporte para OPC, seguridad cibernética, integración con SCADA, diagnóstico remoto, flexibilidad de programación, escalabilidad, cumplimiento de estándares y sólido soporte técnico. Estas características aseguran una integración efectiva y una comunicación robusta en entornos industriales automatizados.

Always automation systems should be designed and engineered in a way that process data should be easily accessed by other systems they may be required in later stages when the plant is running and you cannot access the information to other systems

Standards Adherence: Program PLCs consistent with industry requirements for seamless interoperability. Clear Naming Conventions: Use regular and clear naming conventions for smooth understanding and collaboration. Structured Coding: Adopt a based coding technique for readability and maintainability. Comprehensive Documentation: Thoroughly record PLC programs to aid training, troubleshooting, and future enhancements. Testing Methods: Conduct rigorous testing to discover and rectify errors earlier than implementation. Communication Protocols: Select well matched conversation protocols for dependable records trade. Integration with HMI, SCADA, and ERP: Ensure seamless integration with HMIs, SCADA, and ERP systems for improved performance

To program a PLC effectively for communication and integration in a plant, it's crucial to first thoroughly understand the specific requirements of the plant, including the processes and machinery it needs to control. Selecting the right PLC is essential, ensuring it supports necessary communication protocols like Ethernet/IP or Modbus and has adequate input/output capabilities for the plant's needs. Finally, standardizing communication protocols is key for seamless integration with other equipment and systems, guaranteeing compatibility and efficient data exchange across your plant's network.

When you design systems think about network architecture keeping extra care on security is always important don’t be to open or over protect Times you want to get some information passed to other systems on running plant and you cannot access it So be mindful of future changes they are inevitable.

Precision in Installation: Execute installation with precision, adhering to manufacturer guidelines for optimal device and system setup. Fine-tuned Configuration and Calibration: Accurately configure and calibrate automation devices, ensuring they operate at peak efficiency within your plant's unique environment. Rigorous Testing Protocols: Rigorously test systems pre-deployment, identifying and addressing potential glitches or inefficiencies for a seamless integration. Compatibility Checks: Verify compatibility and interoperability with existing equipment and infrastructure to prevent disruptions and ensure a cohesive technological ecosystem.

La implementación exitosa de automatización requiere una planificación detallada, evaluación de riesgos y pruebas piloto controladas. Un equipo competente, capacitación del personal y comunicación clara son esenciales. La gestión efectiva del cambio, la integración de sistemas y la documentación son clave. Monitoreo continuo, flexibilidad y adaptabilidad garantizan eficiencia a largo plazo. Cumplir normativas, evaluaciones post-implementación y aprendizaje constante contribuyen al éxito. Una implementación cuidadosa asegura una transición efectiva.

Data Management: Develop effective strategies for collecting, analyzing, and utilizing data generated by automation systems to enhance decision-making and optimize processes.

Effective monitoring and evaluation of automation performance involve the establishment of Key Performance Indicators (KPIs) and the use of real-time monitoring tools. Regularly tracking these KPIs provides insights into the system's efficiency, identifying areas for improvement or optimization. Continuous analysis of performance data enables proactive decision-making, ensuring that the automation system aligns with evolving business goals. Periodic reviews and feedback loops contribute to a dynamic and responsive approach to maintaining and enhancing automation performance.

Key methods include system diagnostics, data logging, and real-time performance analysis. System diagnostics involve regularly checking the PLC for errors or anomalies in its operation, ensuring it functions as intended. Data logging is crucial for tracking the PLC's operation over time, providing valuable insights into patterns and potential issues. Real-time performance analysis, through observing the PLC’s immediate responses and outputs, helps in quickly identifying and rectifying operational inefficiencies or deviations from expected performance.

La supervisión constante y la evaluación sistemática permiten mantener sistemas de automatización eficientes, adaptados a las necesidades cambiantes y en línea con los objetivos organizacionales de las plantas.

Para realizar un correcto sistema automatizado, se debe considerar como buena práctica, tener los planos actualizados (eléctrico, mecánico, control, P&ID). Esto ahorra mucho tiempo en el comisionamiento de los sistemas de control, caso contrario se gastará mucho tiempo en hacer levantamiento de información del cableado que irá al final al PLC, lo que implicará demoras en la puesta en marcha del proceso/sistema.

KISS. All too often our designs and controls can become much more complex, complicated, than they need be. What does it need to do? What is the simplest, reliable way to do it?

Beyond the core best practices, attention should be given to cybersecurity measures to safeguard against potential threats. Comprehensive employee training programs are crucial to ensure the workforce is adept at operating and troubleshooting automated systems. Additionally, a forward-looking approach involves considering the scalability of automation solutions to accommodate future growth and technological advancements. Staying informed about emerging technologies and industry trends is key to adapting and optimizing plant automation strategies in a rapidly evolving landscape.

It's important to implement automation systems with functional safety in mind. The automated process must include conditions that bring the process to a fail-safe situation in the event of faults or equipment failure.

Safety,redundancy, simplifying code as much as possible and designing HMI's in gray scale. Only having important things catch your eye