Optimize next-level automation installations, 2024 and beyond, Part 3: How automation solves bottleneck challenges

Automation insights

• In a January 11, 2024, webcast, “Automation: Optimize next-level automation installations, 2024 and beyond,” Michael DeBoer, director of automation at Interstates, Eric Smith, President at APCO, and Scott Richards, senior project manager at Polytron discussed automation needs and opportunities, as well as providing best practice for implementation.
• In Part 3, Smith discusses the role of automation in addressing common bottlenecks.

In the pursuit of enhanced operational efficiency and productivity within industrial facilities, the push towards greater automation is increasingly evident. The question then arises: where does one commence this complex journey? The identification of bottlenecks presents a fundamental starting point, suggesting that the integration of advanced sensors, logic devices, actuators and analytics, coupled with enhanced visibility, could significantly aid in making more informed decisions. The dilemma extends to whether the focus should be on upgrading existing systems or the procurement of entirely new ones. Furthermore, it is crucial to remain cognizant of the latest standards and regulatory requirements that govern such technological advancements.

In a January 11 Control Engineering webcast, “Automation: Optimize next-level automation installations, 2024 and beyond,” award-winning system integration shared their advice on advancing to the next level of automation applications. The featured webcast instructors were:

• Michael DeBoer, direction of automation at Interstates

• Eric Smith, President at APCO

• Scott Richards, senior product manager at Polytron.

The transcript of their presentation has been provided with minor edits and adaptations.

The role of automation in bottleneck analysis and decision-making

Eric Smith: Automation plays a critical role in both identifying bottlenecks and informing decisions on upgrades and problem resolution. Continuous access to historical production data and batch data is invaluable, enabling detailed analysis and comparison against process flow diagrams (PFDs). This analysis is facilitated by automation technologies that can compile and report data, track valve positions to identify saturation points, and monitor run speeds, among other metrics.

Advanced tools such as simulations, digital twins, and predictive models offer additional insights into production outcomes and market forecasts. The accuracy of these models is crucial, as poor-quality models can lead to misguided decisions. However, the growing availability of high-quality modeling tools, coupled with advancements in processing capabilities and data assimilation, is paving the way for significant improvements in process optimization.

The potential for growth in the utilization of artificial intelligence (AI) and machine learning (ML) technologies is particularly noteworthy. These tools are becoming increasingly accessible, offering the promise of enhanced operational efficiency and competitive advantage. While it’s important for organizations to avoid adopting these technologies prematurely, due to potential readiness or knowledge gaps, forward-looking companies that effectively leverage AI and ML can achieve substantial operational improvements. This strategic approach to technology adoption can position organizations to operate more efficiently and adapt more rapidly to market demands and operational challenges.

Leveraging digital twins for operational efficiency

In the realm of continuous facility optimization, digital twins are proving to be invaluable tools. By analyzing data and optimizing set points within a facility, significant cost savings can be realized in areas such as chemical usage and water consumption. This approach underscores the potential benefits of employing advanced digital technologies to enhance operational efficiencies. However, it’s often the case that substantial gains can be achieved by addressing more fundamental issues first. Simple measures, such as ensuring accurate instrumentation for effective PID (Proportional, Integral, Derivative) loop control and guaranteeing that valves function smoothly across their entire range, represent low-hanging fruit that can yield significant improvements even before more sophisticated solutions are considered.

Conclusion: The path to overcoming bottlenecks

Our discussion has framed bottlenecks not as obstacles but as opportunities for substantial value addition to operations and organizations, often requiring minimal initial investment. Engaging with frontline operators, engineers, and management has been emphasized as a crucial step in identifying and understanding these bottlenecks. Furthermore, the role of automation in both detecting and resolving these bottlenecks has been highlighted, with a particular focus on its capacity to facilitate more efficient operations and enhance control systems, thereby reducing process volatility.

The advent of AI and big data technologies represents a pivotal moment in the field of operational control. The rapid evolution of these technologies offers new possibilities for optimizing processes through the sophisticated analysis of data collected from numerous sensors across facilities. This technological evolution presents an exciting opportunity for professionals in the control field to play a key role in integrating these innovations into client systems, thereby driving forward operational improvements and efficiencies.

In closing, the significance of embracing and adapting to these technological advancements cannot be overstated. As we navigate through this era of rapid technological change, the potential to transform operations and achieve unprecedented levels of efficiency is immense.

Do you have experience and expertise with the topics mentioned in this content? You should consider contributing to our WTWH Media editorial team and getting the recognition you and your company deserve. Click here to start this process.