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How can you design control systems that are easy to troubleshoot?

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If you are a plant engineer, you know how important it is to design control systems that are easy to troubleshoot. Control systems are the backbone of any industrial process, and when they malfunction, they can cause costly downtime, safety hazards, and quality issues. Troubleshooting control systems can be challenging, especially if they are complex, poorly documented, or poorly maintained. In this article, we will share some tips on how to design control systems that are easy to troubleshoot, so you can save time, money, and headaches.

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Rob Portmann

Supervisor at Canrig Drilling Technology Ltd.
Keith Koodrin

Lecturer Electrical at TAFESA
"Rick A.

Artifex | Polymath | Polyglot | Veteran

1 Use standard components and protocols

One of the first steps to design control systems that are easy to troubleshoot is to use standard components and protocols. Standard components and protocols are widely available, well documented, and compatible with most tools and software. They also reduce the risk of errors, conflicts, and failures due to incompatible or obsolete parts. For example, you can use PLCs (programmable logic controllers) that follow the IEC 61131-3 standard, which defines common languages, data types, and functions for control systems. You can also use common communication protocols, such as Modbus, Ethernet/IP, or Profibus, that enable easy data exchange and monitoring between devices.

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Rob Portmann

Supervisor at Canrig Drilling Technology Ltd.
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Ease of troubleshooting starts with overall design. Initially, an interface for identifying the issue or failure point quickly and effectively is key. With multiple PLC's or control systems, it is imperative that a complete feedback to central control with accurate alarms is provided. General alarms with too many instances cost valuable time and create confusion. I am a huge believer in real time feedback troubleshooting on a machine interface showing anomalies. Accurate drawings and standard color codes are also helpful.

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Keith Koodrin

Lecturer Electrical at TAFESA
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Keep updated copies of schematics near The Controls or switchboards and Have Clear Labels on Inputs, Outputs and components. Color coded Wiring and or numbers help find things at a glance.

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"Rick A.

Artifex | Polymath | Polyglot | Veteran
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I've walked into plants that have had a mix and match of PLCs installed, I imagine depending on what was cheapest at the time. In other words, Siemens, Omron and ABB were installed on different machines. Not only did this mean that technicians had to know procedure for several different systems just to run/troubleshoot/maintain but also created a disaster in terms of having components to order and inventory. Some systems were no longer being produced so parts needed to be found on ebay. Used components being used on critical systems! Not having standard components or a way to address their replacements creates far more problems than they should have.

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Collins Ogbonna

ELECTRICAL TECHNICIAN/SHIFT HEAD @ PZ CUSSONS.
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One of the first steps of troubleshooting is knowing the principle of operation of both the failed equipment and the existing detective instrument or procedures.

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Valdimiro Samucuanha Pereira

Bacharel em Engenharia Industrial e Sistemas Elétricos || Técnico de Electricidade & Instrumenta??o Industrial
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I totally agree with the use of standard components and protocols to avoid mistakes and to easy troubleshooting. Eg.: It happens a lot of time, when you go to solve a situation and you see that the previous technician didn't follow the wire colour standards, it makes you a little confused because you've to go throw a lot of effort to solve the situation. Follow the standards is very important.

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2 Document your design and configuration

Another key step to design control systems that are easy to troubleshoot is to document your design and configuration. Documentation is essential for understanding how the control system works, what are the inputs and outputs, what are the parameters and settings, and what are the expected behaviors and outcomes. Documentation can include diagrams, schematics, manuals, labels, comments, and code. You should document your design and configuration at every stage of the project, from planning to testing to commissioning. You should also update your documentation whenever you make any changes or modifications to the control system.

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Ir. Sugeng S.T

Project Coordinator
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The Document out Design is finally output and than continue to Constructions process Will be execution By Contractors in this stage We should be making accurate data based on design drawing needed, exactly Selection of Equipment, standard, Reflective Drawing should be included all of fixtures legend, symbols, General Noted, One line diagram, schedule, layout Plan, details, Specbook

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3 Implement modular and hierarchical design

A third step to design control systems that are easy to troubleshoot is to implement modular and hierarchical design. Modular and hierarchical design means dividing the control system into smaller and simpler units that perform specific functions and can be easily isolated, tested, and replaced. Modular and hierarchical design also means organizing the units into logical levels that correspond to different aspects of the process, such as physical, functional, or operational. For example, you can use a modular PLC that consists of a base unit and several expansion modules that can be added or removed as needed. You can also use a hierarchical control system that has a master controller that oversees the overall process and several slave controllers that handle the individual tasks.

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4 Use diagnostic tools and features

A fourth step to design control systems that are easy to troubleshoot is to use diagnostic tools and features. Diagnostic tools and features are software or hardware components that help you monitor, analyze, and correct the performance and status of the control system. They can include indicators, alarms, logs, reports, graphs, trends, simulations, and tests. You should use diagnostic tools and features that are appropriate for your control system and your troubleshooting needs. For example, you can use a HMI (human-machine interface) that displays the current values and states of the sensors, actuators, and controllers. You can also use a software tool that allows you to access, edit, and debug the code of the PLC.

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5 Follow best practices and standards

A fifth step to design control systems that are easy to troubleshoot is to follow best practices and standards. Best practices and standards are guidelines and recommendations that help you design control systems that are reliable, efficient, and consistent. They can cover various aspects of the control system, such as wiring, grounding, shielding, labeling, coding, testing, and maintenance. You should follow best practices and standards that are relevant for your industry, application, and regulation. For example, you can follow the ANSI/ISA-5.1-2009 standard, which defines the symbols, formats, and rules for creating instrumentation and control diagrams.

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QASIM KHALIL

LINE SUPERINTENDENT
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for effective control system troubleshooting, using a systematic and logical approach. 1 Understand the system. ... 2 Isolate the problem. ... 3 Analyze the problem. ... 4 Implement the solution. ... 5 Test the system. ... 6 Learn from the experience. ... 7 Here's what else to consider.

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6 Train and educate your staff

A sixth step to design control systems that are easy to troubleshoot is to train and educate your staff. Training and education are crucial for ensuring that your staff have the skills, knowledge, and confidence to operate, maintain, and troubleshoot the control system. Training and education can include formal courses, workshops, manuals, videos, webinars, and mentoring. You should train and educate your staff on the basics of the control system, such as its components, functions, parameters, and modes. You should also train and educate your staff on the advanced aspects of the control system, such as its logic, code, diagnostics, and troubleshooting methods.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you design control systems that are easy to troubleshoot?

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1 Use standard components and protocols

2 Document your design and configuration

3 Implement modular and hierarchical design

4 Use diagnostic tools and features

5 Follow best practices and standards

6 Train and educate your staff

7 Here’s what else to consider

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