Page 176 - CW E-Magazine (30-7-2024)

Special Report

agement. At a basic architectural level, ments, greatly reducing the risk and of modular automation systems also
a modular automation system consists associated costs of unplanned downtime. offers multiple benefi ts for customisation.
of PEAs at the operation, communicat- ABB’s Ability™ System 800xA exem- These systems can be rapidly reconfi g-
ing upward through the MTPs to the plifi es how IoT data can be harnessed ured for different products or grades, with
Process Orchestration Level (POL) with modular automation to deliver IoT data aiding in the precise tuning of
that in turn manages overall process predictive maintenance solutions. The each production run.
control. Bidirectional communication supply chain can also be streamlined
between modules and top-level orches- by IoT devices that track raw material Plug-and-produce automation in action
tration and supervisory functions is via levels and fi nished product stocks. This The benefits that modularisation
the open architecture network OPC real-time information facilitates logistics can deliver is seeing the technology
UA (Open Platform Communications, optimisation and production schedule already being widely applied to plant
United Architecture.) tweaks to meet demand effi ciently, design and fabrication in the chemical and
ensuring a smoothly operating produc- other process industries, reducing time
In this context, the MTP offers tion process from end to end. to market and lowering construction
a standardised solution for achiev- costs. To date, however, a lack of tech-
ing seamless interoperability between The combination of modular auto- nology standards has seen modularisa-
process modules and the orchestration mation and IoT also offers a solution tion of automation systems for process
layer above them. As such, it helps to to helping better manage the inherently control and management lag behind.
ensure that any module should be able high energy consumption of chemical The emergence of open standards that
to plug into any automation system – processes. The sensors identify waste defi ne communications between pre-
delivering on the promise of ‘plug and and conservation opportunities, and automated modular units and high-level
produce’ automation. modular automation systems act on this orchestration/supervisory functions now
data to trim energy use, lessening the provides a gateway to cost-effective
Opening new possibilities for chemical industry’s ecological footprint and cutting modular automation solutions that
production costs. Safety and environmental compli- dramatically simplify plant level engi-
The chemical industry stands on the ance are paramount in the chemical sec- neering, making production more fl exi-
brink of a technological transformation, tor. IoT sensors are instrumental in moni- ble and improving chemical producers’
driven by the convergence of modular toring emissions, effl uent quality, and ability to capitalise on new market op-
automation and the Internet of Things other environmental metrics to guaran- portunities. This standardised approach
(IoT). These innovations are not mere tee operations stay within legal bounda- now allows chemical, biotech, pharma
buzzwords; they are reshaping the ries. Modular automation systems can and life sciences manufacturing plants
industry by offering real-time data and be programmed to take immediate ac- to reap the effi ciency gains of modu-
automation capabilities that were once tion when needed, averting incidents and lar automation. These include greater
the realm of science fi ction. ensuring adherence to regulations. fl exibility to accommodate demand for
new products, the ability to scale capa-
In the vanguard of this change is Remote monitoring and control have city rapidly by numbering production
real-time process monitoring. Chemical been enabled by the fusion of IoT and up and down, greater resilience against
facilities are now outfi tted with IoT sen- modular automation, allowing chemical cybersecurity threats, and simplified
sors that monitor vital parameters such engineers to oversee and adjust processes maintenance with less impact on plant
as temperature, pressure, fl ow rates, from afar. This is especially benefi cial in uptime.
and chemical concentrations. This data hazardous or remote settings, with com-
is channelled into modular automation panies like Honeywell leading the way in Conclusion – a catalyst for transformation
systems, which can swiftly adjust pro- solutions for remote operations. Quality The integration of IoT with modu-
duction conditions to maintain optimal control, the cornerstone of manufactur- lar automation is a pivotal shift for the
levels, resulting in enhanced product ing, is more vital than ever in the chemi- chemical industry, promising enhanced
quality and consistency. cal industry. IoT sensors provide continu- safety, effi ciency, product quality, and
ous product quality monitoring during environmental sustainability. As chemi-
IoT sensors are also revolutionising production, feeding data into modular cal producers navigate the challenges
predictive maintenance. By keeping automation systems that can promptly of today and tomorrow, these techno-
an eye on critical equipment, chemical adjust to keep the fi nal product up to the logies are set to unlock new potentials
fi rms can foresee maintenance require- highest standards. The inherent fl exibility and redefi ne industry standards.

176 Chemical Weekly July 30, 2024

Contents Index to Advertisers Index to Products Advertised