The future potential of process control systems

THE RESTRICTIONS on travel and face-to-face working imposed due to the Coronavirus pandemic highlighted the benefits of remote commissioning to companies, many of whom are now looking to extract the most benefit from this technology. HRS now offers remote telemetry and control options for all applicable products and systems, using class-leading technology from both Siemens and Allen-Bradley Products.

Process controls can incorporate a range of functions, such as visualisation and Human Machine Interface (HMI) solutions, as well as programming tools and advanced software applications. We utilise a combination of PLCs and graphic terminals to provide easy to use, reliable controls for human-machine interface operation.

HRS also utilises a standard suite of bespoke software which has been developed in-house to monitor and control key parameters such as material levels, flow rates and density, as well as aspects such as valve position, temperature and the flows of inputs and outputs. This standard data can easily be transferred to remote systems – either those belonging to the client or HRS itself, using either hardwired (ethernet) or wireless (4G/5G) communication technology. Security is a key consideration for both the hardware manufacturers and our software engineers, meaning that clients can be confident that their data and equipment will remain safe.

Remote operation and monitoring provides a number of benefits, including the ability for clients to view and control equipment from a central point, something which is particularly beneficial for complex installations, or those which are spread across numerous buildings or sites. It also allows HRS staff to assist with operations such as commissioning, upgrading or running-in, and to provide ongoing technical support should this be required.

The pandemic has introduced many new businesses to virtual or remote commissioning, demonstrating benefits that go beyond avoiding the need to fly personnel around the globe. For example, clients have discovered that they can use remote commission to test automation functions in advance, discovering and rectify faults well before the factory acceptance test (FAT) stage.

Looking to the future

If we consider where such technology was 15 years ago, it is possible to see that in the next five to 10 years we will see a real shift in process control – facilitated by technical developments such as open architecture, data exchange protocols, 5G and HTML5 – which will make it even easier for systems to talk directly to each other – the need to download of swap CSV files and spreadsheets of data will become obsolete.

As clients and suppliers increase their engagement with this technology, the improved communication will begin to fulfil its potential to provide long terms process and efficiency improvements. Control software can be constantly kept up to date, helping to keep systems operating at peak efficiency, but it is perhaps in the area of simulation that the greatest benefits could eventually be realised.

Engineers and commentators increasingly refer to the concept of a ‘digital twin’ – a virtual version of a physical system or piece of equipment which can be used to simulate any change to operation, from differences in product specification to adjusting physical settings such as valve diameter or tube length. Such systems are already widespread in the design phase of heat exchange equipment, but the difference in the future is that they will be used for the day-to-day management and operation of equipment. When coupled with artificial intelligence (AI), such virtual systems can determine the optimum hygiene regimes, best energy efficiency and even the most productive time of day to run certain operations.

Matt Hale is international sales & marketing director, HRS Heat Exchangers

www.hrs-heatexchangers.com