Control System Optimization

Customer Success: Pharmaceutical Cleanroom Standardization

What if you could dramatically reduce manufacturing costs, accelerate production cycles, and enhance the reliability of your control systems?

75% reduction in component costs
80% decrease in programming time
30% smaller control panel footprint

Curious how they optimized their control systems?

“I’ve worked with a lot of companies that provide solutions around Automation and Controls across Texas and the Gulf Coast over my 30 years in this line of work, including time with one o the biggest oil majors, and AWC tops them all.”

Optimizing older control system designs or developing new systems requires a structured approach that utilizes the latest technology and expert resources.

What does AWC, Inc. suggest for PLC system needs analysis?

Since 1965, AWC, Inc. has helped engineering managers recognize automation efficiency by following our structured approach. It begins with a thorough needs analysis process that includes evaluating the current system, defining customer resource plans, identifying problems and goals, outlining restrictions, defining solution attributes, and assessing change risks.

Let’s see if we can help.

Chat with Our Team Today

AWC’s Control System Optimization Process

1 Needs Analysis
2 Identify Options
3 Review Alternatives
4 Design Solution
5 Customer Review & Feedback
6 Sourcing & Division of Labor
7 Proof of Concept
8 Prototype
9 Production

Chat with one of our Specialists to schedule a Control System Optimization Review.

View Needs Analysis Checklist

Step 1

Needs Analysis

We will schedule a 45-minute discussion of your current control system and general functional requirements. Along with your improvement goals, time, resource and budget restrictions.

Current Situation (PLC Based Automation)

NDA Requirements
Timing
Number of systems
Budget/System

As is

System Overview – What does the system do?
System Topology/Architecture (Drawing)
Customer resource plan: User requirements definition, Design, Build, Program, Commission, Support
Anticipated Scope of Work (AWC/ACE/A3IM)

Problems / Goals

Reliability
Cost
Size
Communications/Remote Monitoring
Control Functionality
Scalability
Flexibility/Reusability
Diagnostics
Support
Spare parts availability/cost
Safety
Security
Operator Experience (ease of use)
Other

Implications?

What is the urgency, impacts of no change?

Restrictions?

List technology or resource constraints

Need Definition?

Summarize the solution attributes (not the solution) needed to meet their goals/requirements

Change Risk? (Escalate for approval to proceed)

Health, Safety, Environmental (PSM)
Loss of Production
Material Loss
Legal

Step 2

Identify Options

If it sounds like we can help you achieve your goals, our Automation Engineering team will conduct a review of your current control system or system specifications.

The review will include an order of magnitude estimate to determine if the desired functionality can be met within your schedule and budget goals.

Documentation

P&IDs
Schematics
Sequence of Operations, C&E
Existing programs, etc.
Tag List

I/O Count & Type

Local
Remote Drops

Panel Considerations

Heat load calculation
Minimum spacing
Heating/Cooling – HVAC, Fan, Heaters

System Architecture

PLCs, RTUs, Single Board Controller,
HMIs
Network hardware
DCS, SCADA
On premises/Cloud Gateways
Data export/Analysis
VFDs
DC Power/UPSs
CBs, Fuses, Disconnects
Motor starters,
VFDs

I/O Count & Type

Local
Remote Drops

Power Requirements

Incoming Power Feed: 480V, 230V, 120V
Transformer, Generator, UPS/Battery, Solar
Grounding/Bonding/Surge Suppression
Field Power

Environmental

NEMA rating
Corrosion Protection: Stainless Steel, Carbon Steel, Aluminum, Plastic
Hazardous Area Ratings/Intrinsic Safety
Unique Certifications/Approvals

Step 3

Review Alternatives

If our analysis proves we can help, we will provide a Preliminary System Design and Budget for your consideration at no charge. If you decide to proceed, we will work with your team to complete the process and deliver an optimized system that meets your goals. See how our team can help streamline your operations. Get started with a personalized evaluation.

Legacy automation holding you back? Discover how AWC approaches the challenge.

An Original Equipment Manufacturer of chemical injection skids needed to remotely monitor their equipment health to ensure ZERO down time for their customers. Their legacy automation platform supplier “nickeled and dimed” them to the point of making the equipment too expensive.

In addition to the excessive costs for remote monitoring, the legacy system also required two controllers with two different software platforms making control system updates painful.

To provide the OEM with the remote monitoring capabilities and cost reductions they needed, AWC followed a clear and effective process. Together we were able to help them realize some amazing results, including:

Material Cost savings of $30,000/skid (over $570,000/year)
Reduced number of components (Integrated Ethernet switch, gateway)
Reduce project engineering and support time by over 40 hours/skid

This involved these key stages:

1 Needs Analyzed & Communicated

Reduce downtime with more accurate and frequent data collection
- Injection skid pressure, flow, temperature, and tank levels
Increase injection measurement and control
Reduce time required for design improvements
Simplify field support

2 Project Scope Defined

PLC Panel
Power Distribution Panel
MOV (Motor Operated Valve)
Pressure, Temperature, and flow Transmitters
NEMA Motors
C1D2 LED lighting

3 Solution Presented

Analysis of existing system
Engineering design and software development support
Project management
Initial proof of concept and prototype build
Testing and Commissioning
Local Inventory and kitting services (Multiple system builds)

Talk with our chat team about scheduling a Control System Optimization Review.

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