Efficient Plant October 2022 - 16

feature | power systems
in Texas revealed that 75% of its installed
devices were smart. Th ey just needed to
be networked together to get the data
fl owing and the digital transformation
kickstarted.
Once information is moving from
intelligent electrical devices to the
control system, you can make the data
accessible from any operator control
station.
ASSESS YOUR
CONTROL SYSTEM
Integrated power-control systems can capture electrical
data from aging production assets so you can monitor performance
and help minimize unexpected downtime. You can use this data
to better understand electrical distribution and motor-driven asset
performance. It also can be used to schedule repairs or maintenance,
instead of " white-knuckling " the risk of failure and being forced
to react-or overcorrecting by performing unnecessary and costly
maintenance. Th is data can also help you better monitor and optimize
asset energy usage.
To make these types of upgrades easier, tap into packaged off erings-with
all the elements of the electrical-distribution system-
that provide plant personnel with total access to all the information
in the substation. With these kinds of packages, all the devices can
be digitally integrated, regardless of which manufacturer supplied
the device.
Standardizing and consolidating technologies reduces the number
of systems your team must support. Th is lowers operating expenses
by providing for the use of common spare parts and reducing overhead
and overtime for training.
USE THE DATA
Finally, connect Level 1 to Level 2 to focus on making the data easy
to access and use through human-machine-interface (HMI) displays.
Th is makes it easier for your team to monitor what's happening and
when. In real-time, before a process alarm sounds, your personnel
can be alerted to a potential electrical issue and begin the repair
process, averting an unplanned event that will aff ect productivity
and equipment performance.
You also can defi ne and track trends to gain even more operational
insights. For example, set a trend to track the transformer winding
temperature. Th en, if the temperature spikes unnaturally, the operator
will be aware and can proactively address the potential failure.
One refi nery, for example, tapped into unifi ed data to cut downtime
16 | EFFICIENTPLANTMAG.COM
related to equipment failures by 27%. Th ey reduced
costs related to maintenance troubleshooting
by 35%.
Another benefi t of switching to a digital
solution is the ability to support remote
monitoring, which also helps improve the
safety of your personnel and the health of
your equipment. With an intelligent,
integrated electrical system, personnel can
even work from a smart phone or tablet,
giving them distance from potentially
hazardous conditions.
As your company takes step-by-step measures to
digitally transform, more comprehensive and informative
data can be captured, analyzed, and leveraged. For example, even at
a rather basic device level, the technology stores information, providing
an objective source of truth that your team can access and
share, rather than relying on inconsistent manual shiſt notes. It also
helps avoid blame games and fi nger pointing.
Consider the recent scenario in which a breaker in a large chemical
plant kept tripping. Aſt er analyzing the stored performance
data, the engineers determined the breaker performed its job and,
in fact, the failure was due to personnel errors. Once revealed, they
redirected the team and avoided buying an expensive piece of new
equipment.
BUILDING DIGITAL FOUNDATION
Whatever steps you take, you can make signifi cant strides over time,
and that are appropriate to your budgetary constraints, to implement
a digital strategy in your plant. Even with the simplest digital capabilities
in place, you can better monitor and upgrade aging electrical
assets, as needed, and reduce the costs associated with supporting
disparate systems and troubleshooting unplanned events.
From there, you can focus on creating opportunities to improve
operations and processes, boost production, and gain understanding
of energy use to reduce operating costs. Each step brings the organization
closer to unlocking insights at all levels to manage risk and
optimize performance. EP
Ramon Farach is Global Chemical Industry Technical Consultant
for Rockwell Automation, Milwaukee (rockwellautomation.com). He
provides industry and technical insights to help understand and solve
customer challenges, develop product and service messaging, and support
product development. Farach has more than 20 years of chemical
industry experience in areas including process engineering, operations
support, process design, installation and commissioning, and R&D.
OCTOBER 2022
http://www.rockwellautomation.com http://www.EFFICIENTPLANTMAG.COM
Efficient Plant October 2022

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