Are manufacturing plants prepared for the benefits eSCADA systems offer?

Electrical supervisory control and data acquisition insights

• Manufacturing facilities must have the appropriate connectivity to reap the benefits of eSCADA systems.
• Developing a modernization strategy helps manufacturing plants prepare for the future.

Today’s industrial manufacturing operations require modern-day tools and technologies like artificial intelligence (AI), machine learning (ML), augmented reality/virtual reality (AR/VR) and the industrial internet of things (IIoT) to help people effectively run, maintain and sustain equipment and processes. Using these technologies with data-retrieval tools and visualization systems, people can make insightful operational decisions in real time.

Most people who work in automation have heard of a supervisory control and data acquisition (SCADA) system and understand it monitors and controls industrial devices and processes. But what is eSCADA? The “e” stands for electrical, and it is used to monitor and control power distribution systems. With an eSCADA system, operators gain insight into electrical power distribution systems and process control systems to understand the entire manufacturing process better.

Any worker who has witnessed a sudden stop in manufacturing operation due to a circuit breaker trip in their power distribution system knows it typically takes a considerable amount of time to track down the issue. With eSCADA, this information is readily available, saving valuable time in getting to the root cause of the problem quicker than with traditional methods. Retrieving this data at a moment’s notice helps facilities maximize uptime.

The current and future workforce expects more integration and use cases with the rise of technologies like AI and ML. These technologies empower workforces and support sustainable manufacturing.

Manufacturers can integrate fourth-generation IIoT devices into control systems and use eSCADA to manage the data. Additionally, they can set the stage for integrating some of the earth’s renewable resources into power and energy management systems to make operations more sustainable.

eSCADA can enable innovations, but are manufacturers ready?

Before manufacturers can take advantage of new technologies and innovations, they must ask, “Is our facility ready?” Determining the starting point is critical and likely fits into one of three stages: zero connectivity, some connectivity and intelligent infrastructure ready.

Zero connectivity is usually found in legacy facilities that have unintelligent, obsolete networks, non-existent network devices or contain analog devices that desperately need replacing because parts or replacements are no longer available. Many manufacturers are generally comfortable in this status quo stage, because no additional funding is required until something goes wrong. Also, a lack of required workforce skills or bandwidth might prevent them from adding intelligent devices and connectivity.

For manufacturers to benefit from an eSCADA system, they must have modern IIoT devices and connectivity. Without eSCADA, it is much more labor intensive to track down problems, understand the root causes and determine the right action to remediate.

Digitally transforming a facility with modern technology like an eSCADA system can help manufacturers reduce the amount of time it takes to perform tasks, like electrical issue identification. Think about how long it takes, for example, to receive a call on the radio, find the location of the call, discuss what happened with the operators, walk to the electrical room and finally see where a fault or breaker trip occurred.

Performing a root cause analysis is another time-consuming task where an eSCADA system can bring efficiencies. Facilities often collect relevant data in different ways for sustainability actions. For legacy facilities, this data-collection task is a manual process where an individual or team walks through a plant and collects data points from meters –– both electrical and non-electrical devices –– which takes hours. This task can be done instantly with modern technology.

Some connectivity is where manufacturers have aftermarket bolt-on devices added in the form of power quality meters or other devices that have metering capabilities. However, this solution is inelegant, and there are often gaps in data and metering locations. Extra hardware is most likely required as there are no fundamental communication capabilities on the motor controls, circuit breakers or protection relays. In this stage, manufacturers often struggle to get full connectivity and communication throughout the facility.

Developing a modernization strategy helps prioritize key areas for additional bolt-on metering and/or total replacement with intelligent IIoT devices. Once goals are set and well-understood, the projects can be prioritized against capital or expense budgets to take the right steps in getting the advantages that come with an eSCADA system. Most facilities are in the zero connectivity or some connectivity stage.

In the intelligent infrastructure stage, facilities have connected devices on a unified platform. Ideally, this is the best place for manufacturers to be. Within this stage, manufacturers take preventative measures and proactive approaches to their environmental, social and governance (ESG) goals. Actionable data helps them respond faster to prevent or remediate failures. They actively seek out ways to attain their sustainability goals through monitoring and prioritizing projects that have a greater impact on efficiency with utility usage like water and energy and find ways to eliminate excess waste and be more efficient in the overall operations of the facility.

Greenfield facilities or modernizing major brownfield facilities with intelligent devices and eSCADA systems might seem risky and take some effort but building a resilient facility and significantly improving manufacturing processes is worth it for long-term success. Plan early as costs increase when changes are made late in a process and implementing technology like eSCADA is an afterthought.

Setting the stage for success with eSCADA

Take a strategic approach and set the facility up for success based on where it is today. To get to the intelligent infrastructure stage and beyond, expanding possibilities requires trust and the right expertise. The number-one priority for all manufacturing facilities is keeping people safe. When eSCADA systems are in place, the groundwork is set with technology that can improve manufacturing operations and enhance the safety of personnel that maintain and operate the systems.

Imagine the best possible way to enter potentially dangerous spaces, like electrical rooms, where people don’t have to put on bulky arc flash protective gear (see Figure 1). New technologies, such as AR/VR and AI, provide a time-saving and safe alternative to train people in various situations. New personnel can easily train and get acclimated to their new environment and dangerous applications before they complete a procedure in real time. AR/VR can also act as a measure to test different scenarios to fix certain shutdown or malfunctioning situations. An eSCADA puts these technologies within reach.

Figure 1: Electrical supervisory control and data acquisition (eSCADA) systems can help manufacturing plants monitor and control power distribution systems. Courtesy: Rockwell Automation

Now more than ever, companies are targeting lofty ESG goals but take many differing avenues to reach those specific goals. With these targets in mind, the first step is to fully understand the facility and how energy is consumed and then correlate that energy consumption to production. Once again, having an eSCADA makes this step easy.

Green energy is a sustainability pillar that is most certainly part of the overall strategy. Nothing sets a company up better than to put those goals within reach. Implementing an eSCADA system helps set the stage for bigger and better applications. Consider some of the best strategies to fully capitalize on the head start that an eSCADA system can provide.

Many variables affect power quality and energy prices, especially when manufacturers rely on traditional utility providers. One green energy strategy is to take away the variables and have the facilities take charge of the way energy is not only consumed but the way it is received.

Today’s power generation trend is focused on using smaller distributed energy resources (DERs) that can supply a more constant and improved power quality without the giant complex infrastructure of traditional power transmission and distribution. Medium to large manufacturing facilities are well-positioned to take advantage of this trend by installing and operating their own DERs to integrate solar, wind and energy storage, to supplement energy usage and keep the risky utility as a backup or secondary option.

This approach keeps energy costs down by eliminating the potentially costly peak demand charges from the utility. It also creates improved power quality while ensuring there is a verified green energy source. With major pushes and advancements for green hydrogen, it is within the realm of possibility that hydrogen can also be used for energy storage when combined with fuel cells. This provides a clean source that can be used for various applications.

Facilities can also choose to replace the diesel or natural gas backup power generators or supplement peak loads with hydrogen power. These advances become much more attainable when facilities and plants begin with intelligent infrastructures and an eSCADA system that is required to manage and coordinate energy usage with power management systems.

eSCADA as an influence on the future

Manufacturers that stay ahead of the curve are more likely to stay resilient and be vigilant when it comes to successful data management. While it is important to stay ahead of trends, many of these changes can be gradual to help spread the capital expenditure over a reasonable time frame. In addition, companies might want to make sure their new technologies are safe from cyberattacks.

Manufacturers can get to where they want to be with the right automaton solutions provider. Many of these strategies of energy management and integrating fourth-generation IIoT devices can happen as soon as today.

Be the change that our future wants and needs. An eSCADA system is a great place to start.

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