Control System Optimization
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Path to Success
Customer Challenge
A global leader in prefabricated pharmaceutical cleanrooms needed to replace outdated automation and controls to deliver enhanced features, lower costs and shorter manufacturing cycles for their customers.
The engineering team worked with AWC to bring their automation and controls design and engineering in house, and standardized on Siemens. Achieving reductions of 75% on component costs, 80% on programming time, and 30% in control panel space, all while improving functionality and reliability for their customers.
Customer Success Brief
Customer Profile: Chemical Injection Skid OEM
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.
The engineering manager reached out to AWC
to see if we could help.
1 Needs
- 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 Scope
- PLC Panel
- Power Distribution Panel
- MOV (Motor Operated Valve)
- Pressure, Temperature, and flow Transmitters
- NEMA Motors
- C1D2 LED lighting
3 Solution
- 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)
4 Results
- 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
Talk with our chat team about scheduling a
Control System Optimization Review.
Customer Success Brief
Customer Profile: Chemical Injection Skid OEM
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.
The engineering manager reached out to AWC to see if we could help.
Talk with our chat team about scheduling a
Control System Optimization Review.
- 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
- PLC Panel
- Power Distribution Panel
- MOV (Motor Operated Valve)
- Pressure, Temperature, and flow Transmitters
- NEMA Motors
- C1D2 LED lighting
- 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)
- 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
1 Needs
- 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 Scope
- PLC Panel
- Power Distribution Panel
- MOV (Motor Operated Valve)
- Pressure, Temperature, and flow Transmitters
- NEMA Motors
- C1D2 LED lighting
3 Solution
- 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)
4 Results
- 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
Let’s see if we can help
Optimizing older control system designs or developing new Systems requires…
- NDA Requirements
- Timing
- Number of systems
- Budget/System
- 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)
- 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
- What is the urgency, impacts of no change?
- List technology or resource constraints
-
Summarize the solution attributes (not the solution)
needed to meet their goals/requirements
- Health, Safety, Environmental (PSM)
- Loss of Production
- Material Loss
- Legal
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.
- P&IDs
- Schematics
- Sequence of Operations, C&E
- Existing programs, etc.
- Tag List
- Local
- Remote Drops
- Heat load calculation
- Minimum spacing
- Heating/Cooling – HVAC, Fan, Heaters
- 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
- Local
- Remote Drops
- Incoming Power Feed: 480V, 230V, 120V
- Transformer, Generator, UPS/Battery, Solar
- Grounding/Bonding/Surge Suppression
- Field Power
- NEMA rating
- Corrosion Protection: Stainless Steel, Carbon Steel, Aluminum, Plastic
- Hazardous Area Ratings/Intrinsic Safety
- Unique Certifications/Approvals
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.