Are your processing applications letting you down?
March 2016System Integration & Control Systems Design
By Marthinus Venter, segment manager for process automation, Festo.
Many factory environments have applications involving the measurement, control and regulation of raw materials. These applications would fall under the realm of process automation (PA). Many other applications fall under the umbrella of factory automation (FA).
It is important to distinguish between the two, as each has its own unique requirements. While efficiency is key in both, there are enough differences to necessitate a different approach in automation.
PA systems must generally be robust and simple in order to handle corrosive liquids and hazardous materials. They are slow and continuous and therefore require less sophisticated equipment to control. FA, by contrast, calls for more complex and fast moving handling systems and control. Typical equipment would be actuated valves, tubing and pneumatic connections to solenoid valves.
It’s easy enough to get the distinction right when your plant works primarily with one type of automation. A process-focused plant, such as a water treatment facility, will have greater insight into the types of systems and components necessary to automate its processes. However, a factory with only select PA applications may lack the knowledge to optimise these particular systems.
Dangerous binds
There can be negative consequences associated with failure to automate processing applications. One such drawback is the increased exposure employees may have to hazardous material. A tyre factory that has its workers handle rubber manually is a good example.
Then there are the financial consequences. Inefficient dosing, which results in variations in the final product and wastage of raw material, is one such drawback. And with manual processing of material comes a higher chance of contamination.
Give me some sugar
Our observations have been that factory owners tend to invest heavily in automation technologies in the production environment, while continuing to process raw materials manually. Let’s take a real-life example within the food industry: a beer brewing company that has the latest technology dedicated to applications like packaging, labelling and inspecting, while relying on manual processing of sugar.
This was the case before a brewery recently chose to automate its sugar distribution system. Before, they would load sugar by hand. After installing a fully automated distribution system, the company experienced a quantum leap in efficiency. It is now able to automatically transport dry sugar from trucks to silos to the production environment, making distribution loss almost negligible. It has also reduced the chance of contamination in the final product due to cleaner raw materials.
The automation advantage
When choosing to automate processing applications within a factory environment, it is important to deal with a supplier specialising in PA. We recently dealt with a customer that had bought valve and actuator assemblies for a steam application. Because they had ordered it from a supplier that did not understand the PA environment, the components were not robust enough and started to leak.
By dealing with a company that specialises in PA, factories have access not only to the expertise required to build an optimised system, but also the availability of the specific products required. In the example above, we were able to identify and source the right components for a replacement assembly in a very short space of time.
Luckily, we are seeing more factories identify the weaknesses in their processing applications and addressing them accordingly. For those that haven’t yet made the leap, we recommend they take a close look at their processes and see which of those might be letting them down.
Turning system integrators into trusted technology partners Schneider Electric South Africa
IT in Manufacturing System Integration & Control Systems Design
Schneider Electric’s Alliance Partner Programme is repositioning system integrators from hardware suppliers into lifecycle-value partners. Oriel Soupen explains the competency framework, certification model and real-world results that are already helping African system integrators win higher-value, longer-term engagements.
Read more...When digital twins move from concept to critical tool
IT in Manufacturing System Integration & Control Systems Design Maintenance, Test & Measurement, Calibration
Digital twins are moving out of the lab and onto the mine, the factory floor and the transport network where they predict failures before they happen. Amritesh Anand looks at where they earn their keep, the data and integration work behind them, and the security questions every organisation should ask before switching one on.
Read more...Best practices for managing the MRO supply chain in Africa RS South Africa
System Integration & Control Systems Design
RS South Africa outlines how strong data governance and digital tools can turn maintenance, repair and operations procurement into a strategic advantage across Africa.
Read more...Containerised Solar Solution Accelerates Delivery of Riverside 3 MW Power Plant Proconics
System Integration & Control Systems Design
Proconics was engaged by NewFields to deliver the electrical integration solution for the Riverside 3 MW Solar Power Plant in Zimbabwe. The project required a compact, modular approach that could simplify deployment, minimise site works, and support rapid commissioning in a remote location.
Read more...Modern Energy Metering Solution Enhances Reliability and Reporting for Major Power Utility SAM Systems Automation & Management
System Integration & Control Systems Design
This project involved the implementation of a modern energy metering system for a major power utility operating within the industrial automation and energy management sector. The objective was to improve the reliability, accessibility, and accuracy of energy data while simplifying infrastructure and reducing system complexity.
Read more...Solving common automation challenges with Festo’s servo drive and servo motor solutions Festo South Africa
Motion Control & Drives
Automation projects face challenges that include limited installation space, the need for precise and repeatable linear motion, rising cycle-speed demands, and seamless integration with existing control architectures. Festo’s servo portfolio directly addresses these issues with compact, modular drive and motor solutions designed for specific applications.
Read more...How to size and select a servo motor Festo South Africa
Editor's Choice Motion Control & Drives
Festo highlights some factors to consider in the process of sizing and selecting a servo motor effectively to ensure optimal performance, reliability and energy efficiency.
Read more...PCS Global PCS Global
System Integration & Control Systems Design
PCS Global led a digital infrastructure initiative in a southern African data centre setting, aiming to merge several essential operational systems into one cohesive platform. The objective was to break down silos, enable real-time decisions, and ensure seamless operation in a mission-critical environment.
Read more...Seamless migration from ET 200M to ET 200SP HA for future-ready automation Moore Process Controls
System Integration & Control Systems Design
Moore Process Controls undertook a modernisation initiative spanning the mining, petrochemical, and oil & gas sectors. This project involved upgrading legacy Siemens ET200M I/O systems to the advanced ET200SP HA platform.
While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.
printer friendly version