As automation continues to grow in grain storage facilities, it can be challenging — for many reasons — to implement the right automation plan. Many facilities have operated for years with existing infrastructure and disparate control systems from days of the past, such as pushbuttons, switches and lights.
Typically, automation systems grow little by little over time and become a hybrid of antiquated hardwired controls along with programmable logic controllers and human machine interfaces. Without a solid automation road map, the disjointed automation system focuses only on the task at hand, creating several “islands of automation.”
It seems that conventional thinking supports the islands that are spread throughout the facility, leaving facility operators to “run around the facility” rather than “run the facility.” The primary objective should be to unify the facility automation system and create a facility central command, where the automation system gives the operators insight to the entire facility and visibility to what is happening with each supporting system through a common interface. This concept requires a challenge to conventional thinking and the development of a strong automation road map and implementation plan.
What systems are oftentimes standing as islands? This question alone challenges longstanding paradigms and is the root of identifying a plan and the development of your facility central command system. By examining some specific functions, you may identify some islands at your own facility. Think about the following examples and how much benefit it would be to have complete facility visibility from a central command station:
1. Hazard Monitoring:
• Visibility into live bearing and rub-block temps and speed sensors through live temperature readings and trend charts
• Automatic interlocking for controlled shutdowns on alarm sensing
• Automatic emailing to selected roster on alarm conditions
• Complete reporting for setpoint modifications and alarm data (when occurred, when cleared, when acknowledged and by whom)
2. Grain Temperatures
• Visibility into live grain temperatures and alarms when they reach alarm levels or rate of rise notifications
• Complete trend charts for temperatures over time 3. Motor Currents
• Live motor current values on the operational screens along with complete trend charts
• High current alarms activated based on specific commodities being run 4. Dust Collection
• Complete control of all dust systems and visibility into differential pressures across dust filters
These are just a few examples of value that can be realized by tying together your islands of automation. The objective is to decrease the cost of operating your facility by maximizing your investment and power of your automation infrastructure. Challenge paradigms of the past and examine what you can do at your facilities.
