How do you distinguish between plant automation systems?

Plant Automation Systems consists of "linear loads"(motors and resistive type light bulbs), which typically affect the performance creating reactive power (power factor). Non-linear loads (variable speed drives, power supplies, and LED lamps), all create harmonics, which effect performance of other controllers, sensors, and devices that have power supplies. Harmonics and Power Factor effect facility performance and utility transformers. Utilities will charge accordingly.

The automation world has taken a big change. Automation products were always available and cost was very competitive over the different platforms. Covid changed all of that, now you have to decide what platform to use by deciding where you can get all the components. I have been in the business for over 40 years and I never saw it so hard to get components. Sad to say I have resorted to buying overseas.

Plant automation systems consist of essential components: Sensors: Collect data like temperature, pressure, and more PLCs: Control processes based on sensor data. HMI: Interface for monitoring and system control. Actuators: Execute commands from PLCs, e.g., motors or valves Control Software: Defines process logic and safety interlocks Communication Systems: Enable data exchange between components SCADA: Centralized monitoring and data storage. Networking: Connects components using Ethernet or fieldbuses Safety Systems: Ensure personnel and asset safety. Redundancy: Minimizes downtime by duplicating critical elements Data Analysis: Tools for historical data-based optimization Power Systems: Reliable power supply with UPS and generators

1. Functionality: Different automation systems offer varying levels of functionality. 2. Scalability: Consider the scalability of the automation system. Will it be able to accommodate the anticipated growth and expansion of your plant 3. Integration capabilities: Check the compatibility and integration capabilities 4. User interface and ease of use: 5. Reliability and support: Look for a reputable vendor or supplier that offers reliable automation systems. Consider their track record, customer reviews, and support services. A robust support system, including technical assistance. 6. Cost-effectiveness: Assess the overall cost-efficiency of the automation system, considering not just the initial investment but also long-term maintenance,

Level of automation: This refers to the degree of control that the system has over the plant. Manual systems have low automation, Fully automatic systems have the highest level of automation, Mode of communication: This refers to the way in which the different components of the system communicate with each other. Local control systems only communicate within a small area, while distributed control systems can communicate over a wider area. Supervisory control and data acquisition (SCADA) systems can communicate over a wide area network (WAN). Architecture of the system: This refers to the way in which the different components of the system are arranged. Centralized systems, decentralized systems

From my experience, this proposed concept is not accurate. A system can be manual and yet have high communication and integration. What really defines if a system is manual, semi-auto or automatic is the programming and mode selection by the operator. e.g.: You can have a sensor connected to a controller using a network protocol, with embedded diagnostics, but still need an operator to give a “manual” open/close command from an HMI or push-button panel.

Partly true Manual system can also have a high level of automation. It can be so that dangerous jobs in the plant have been automated with integrated sensors and a high level of communication. But to control and make decision based on the situation the operator is still needed. Semi automation can also be performed with low level communication such as hardwired sensors and actuators, depending of the surroundings. For e.g. in an nuclear power plant where there is high radiation which will destroy modern electronics rapidly.

Discussion on Types of automation systems is incomplete without mentioning : 1. Continuous process control 2. Discrete process control These factor significantly changes the entire solution structure of automation system.

In my experience the best automations (that are most appreciated and most likely to be multiplied) are the ones with best ROI (return on investment)not the ones that offer 100% automation or the latest or the fastest. Those who went in for automation with out respecting the ROI are unlikely to be sustained.

Each?of?the?systems?types?has? advantages?and?disadvantages,?and? the decision?about?the?level?of? automation?is?influenced?by?a?number?of?variables, including?the?complexity of the processes,?the?cost,?and?the requirement?for?flexiblity. It's?critical?to? strike?the correct?balance?between? automation?and human?interaction?if you?want?to?maximize factory?output? and?efficiency.

Plant automation SCADA systems enables operators to monitor and control all the plant through PC in the control room The operator can detect any alarm and it's reason , also have history report about plant alarming or history reports about conusming materials like in Batching systems

Redundancy in operating systems have become critical to me during some intensive manufacturing processes such as petroleum refining, metal forging, steel making, and chemical manufacturing processes.

another important category that has emerged in recent years is sustainability of systems, how many spare parts are required, life cycle of the equipment given changes in climatic conditions around the world, it may be a sub caregory of reliability but sustainability determines the manufacturing of devices

From a personal viewpoint, plant automation systems are a captivating blend of technology and precision engineering. Feedback, whether comparing actual and desired outputs or proactively anticipating changes, reflects their adaptability. Choosing between open-loop and closed-loop control methods is akin to conducting an orchestra, one following predefined rules and the other dynamically adjusting for harmony. The idea of redundancy underscores the importance of reliability, acting as a safety net in case of component failure. In essence, automation systems are intricate ecosystems, finely balancing precision and adaptability, shaping the efficiency and dependability of industrial processes.

- One more perspective to it ?? More automation will increase the efficiency but I will surely require more capex while less automation will result in more opex. So, it's a trade off.

While in general it is true (Capex Opex trade off), there is more to that. It depends on what is the cost of your resources like power, manpower, water, compressed air etc. We need to constantly strive to locate those opportunities where the ROIs are so high that it pays back within the financial year. I worked on projects where the ROI is better than 6 months.

In my experience automation in critical tasks like welding gives very good value proposition wrt efficiency and productivity. In few cases Material handling in assemblies also improves productivity. There is nothing called fully automated in manufacturing industries. Instead we always find the most efficient and effective ways of manufacturing products, which most of the time results in automating process in bits and pieces. Whereas strategic tasks are always performed by operators.

Automation is extremely helpful to smaller operations. While larger facilities can employ a diversely talented staff, plants in rural areas rarely have more than 2-3 operators and must still perform all of the same requirements. However, this advanced tech is a double edged sword, because operators at highly automated operations can lose touch with the basis of design and forget how to do things in an emergency situation. We keep hearing about the old guard retiring, but one can only hope that the younger generation is learning as much possible from them to avoid this knowledge loss.

this really depends on what kind of task is being automated. if there is a challenging task which requires a high level of automation,there is a chance that monitoring the automation may require more manpower than manual operation

From experience, another thing to consider is future maintenance of the system. Not only parts availability for future repairs (yes, nothing lasts forever, no matter what the salesman says), but some other factors that play into future costs and the sustainability of your system. Here are some other factors to consider. Here are some other considerations: Types of devices needed, The extent of automation necessary The device locations

Huge investments in automation in one go is strict no no. We need resources to continuously and dynamically optimize the resources based on demand. This is a more sustainable situation.

As every manufacturer strives to get a one piece flow where every order or product can be customized to a specific order at a cost comparable to a high volume production line there will be a merger between manual systems and automated systems where the preprocessing is performed on automated machinery and the final processing is performed manually. Even the manual processing can be automated . For example one our factories took a product with over 300 different variations and used automated light cannons and PC screens to take a human and meet production quotas the first day of employment. The manual work station included assembly and testing. Monte Swinford Bosch Rexroth

One thing that I have found to be true every plant will have its own heartbeat. More often than not calibrations can help keep the automation in a system running in peak performance. Keeping calibration logs along with PID change logs in the CCR is another great help in keeping a plant or sub system running as intended.

Plant automation systems offer tremendous potential for improving efficiency, safety, and productivity. Leveraging these systems effectively, fostering collaboration between humans and technology, and prioritizing safety can lead to a successful and prosperous industrial operation.