No question – automation is the future of the industrial sector. From OEM machine builders and metals production to pharmaceutical entities and alternative protein startups, automation and system integration will soon become a necessity to succeed in any given sector.

However, savvy businesses know that manufacturing automation solutions are already integral to success in the present. Automating previously manual processes and integrating control systems across facilities reaps real returns – it can completely transform a business from one that’s struggling to keep up to one that’s always a leg up on the competition.

But engineering quality automation systems for industrial facilities requires anything but an off-the-shelf, one-size-fits-all approach. CSIA control system integrators offer manufacturers a fast-track through automation present and into the future with performance-driven automation and integration tailored to each client’s unique needs. 

Why Tailored Process Automation Solutions Matter in Industry

During the first wave of automation, standard industrial automation solutions made sense. It was a new field of engineering and technology – there were scarce product options and strategic system design was in its infancy. The manufacturing and automation sectors needed time to gain their footing.

Fast-forward a couple decades, and many manufacturers are weighed down with piecemeal automation systems that carry stark limitations on capability, adaptability and scale. And with the rapid development of new process automation technology and engineers who have now had decades to gain expertise in the area, these aging systems are simply not a viable option anymore.

In today’s market, adaptability and scalability is key. Standard automation solutions aren’t going to get you there.

Benefits of Custom Machine Automation Solutions for Businesses

Certified control system integrators like E Tech Group design, implement and support custom process automation systems that significantly impact a business’ success in any sector:

Precision & Efficiency

• Increased productivity: Custom automation is fine-tuned to your specific production processes, materials, and workflow, minimizing bottlenecks and optimizing output.
• Enhanced product quality: Exact control over parameters and processes leads to consistent, high-quality products with fewer defects.
• Reduced waste and rework: Accurate automation minimizes material waste and the need for rework due to errors, saving time and money.

Flexibility & Scalability

• Adaptability to changing needs: Custom process automation solutions can be easily modified and upgraded to accommodate new products, processes, or production volume shifts.
• Integration with existing equipment: A precisely designed system can seamlessly integrate with your existing infrastructure, avoiding compatibility issues and costly retrofits.
• Future-proofed for technological advancements: Tailored control systems can incorporate cutting-edge automation technologies like AI and IIoT, keeping your facility competitive.

Cost-Effectiveness

• Long-term ROI: While the initial investment might be higher, custom automation often delivers significant cost savings over time through increased efficiency, reduced waste, and lower maintenance needs.
• Improved resource utilization: Precise process automation optimizes energy consumption and minimizes material usage, leading to cost reductions.
• Competitive advantage: Increased efficiency, agility and product quality can enhance your competitiveness in the market, increasing profitability.

Logistical Benefits

• Improved data collection and analysis: Custom systems often provide valuable data on production processes, enabling data-driven decision-making and continuous improvement.
• Enhanced employee satisfaction: Automation can free up workers for more skilled and creative tasks, leading to better job satisfaction and morale.
• Improved worker safety: Performance-driven systems can automate risky tasks, reducing the risk of workplace injuries and improving overall safety.

These benefits culminate in the two overarching advantages of a custom-built manufacturing automation solution: the ability to compete, and the ability to grow.

E Tech Group: Advanced Industrial Automation Services Across Sectors

As a leader in industrial automation and engineering, E Tech Group partners with clients across North America to create an automation system and integrated controls that fits their unique specifications and preferences. Open communication, the best in automation products, and a growth-focused approach define our brand of process automation solutions.

The benefits of an automation system that fits your businesses needs cannot be understated – streamlined operations, improved quality, less errors and downtime. Implementing an advanced, integrated control system now can ensure you stay competitive, adaptable and scalable in even in fast-paced markets.

In 2020, AVEVA, a global leader in engineering and industrial software, announced its intent to acquire OSIsoft, a forerunner in industrial data management. This strategic move served to merge two giants in the field of industrial intelligence, combining each company’s complementary abilities.

Completed in 2021, this new partnership between AVEVA and OSIsoft would have an almost immediate impact on the automation industry at-large. Control system integrators partnered with AVEVA had an opportunity to expand their expertise to support OSIsoft PI as well, adding yet another tool to our control system design belt, if you will.

Who are AVEVA and OSIsoft? And how does this acquisition affect manufacturers looking for bleeding-edge process automation solutions? Let’s take a look:

About AVEVA

AVEVA launched in 1967 under the name CADcentre. They quickly became the game-changers on the frontier of CAD applications in industrial processes. They were the first engineering firm to create a 3D computer plant model in 1976.

AVEVA has led the charge in collaborative automation system design and cloud-based applications. Today, as a global leader in industrial intelligence, AVEVA strives to innovate sustainable automation solutions. They’re renowned for:

• Basic engineering design: Conceptualizing and designing industrial facilities.
• Detailed engineering: Creating detailed plans for construction and equipment installation.
• Operations and asset management: Monitoring and optimizing production processes, ensuring asset performance and safety.

About OSIsoft

OSIsoft was founded in 1980 as Oil Systems Inc. where they initially focused on real-time data acquisition and analysis for the oil and gas industry. They developed PI System, which revolutionized the management and utilization of industrial process data.

By the early aughts, OSIsoft had expanded their PI System capabilities for other sectors like chemical and power, and launched PI Server, an internet-based platform for accessing data. A pioneer in real-time industrial data management, OSIsoft’s PI System is a powerful automation system platform that collects, contextualizes, and analyzes data from industrial assets, providing crucial insights for:

• Process optimization: Identifying inefficiencies and improving production performance.
• Predictive maintenance: Anticipating equipment failures and scheduling preventive maintenance.
• Compliance and safety: Ensuring adherence to regulations and maintaining safe operating conditions.

Acquired by AVEVA in 2021, OSIsoft operates as a distinct brand within the company.

Impact of the AVEVA’s Acquisition of OSIsoft

The recent acquisition of OSIsoft was a genius strategic move on the part of AVEVA, and according to both industrial trailblazers, was driven by 3 main factors:

• Complementary strengths: AVEVA’s engineering expertise combined with OSIsoft’s data management prowess created a comprehensive solution for managing the entire industrial lifecycle, from design to implementation.
• Market opportunity: The demand for industrial intelligence was rapidly growing, driven by factors like digital transformation initiatives and the increasing adoption of IIoT.
• Synergy potential: The combined entity aimed to achieve significant cost savings, cross-selling opportunities and accelerated innovation in the automation and control system software market.

And they were right. Adding OSIsoft PI to AVEVA’s portfolio of automation software has had a significant impact on the landscape of industrial automation applications:

• Creation of AVEVA PI System: This combined offering leverages OSIsoft’s real-time data with AVEVA’s engineering and operational software, enabling enhanced process visibility, improved decision-making, and optimized performance across the industrial value chain.
• Strengthened market position: AVEVA has emerged as a major player in the industrial intelligence market, competing with established players in automation software, like Siemens and GE Digital.
• New innovations: The merger has spurred the development of new automation solutions and services that capitalize on the combined expertise of both companies.

Automation happens in two contexts. In the industrial sector, the integration of AVEVA and OSIsoft has driven innovation in automation applications and industrial intelligence. And in the engineering sector, this merger has driven automation companies to integrate their expertise in both to offer a new brand of OSIsoft support.

E Tech Group Supports OSIsoft PI as an Endorsed AVEVA System Integrator

As an endorsed system integrator with AVEVA and a leader in North American industrial automation, E Tech Group engineers leverage these companies’ complementary technology to support OSIsoft and AVEVA-based automation systems. And because we are dedicated to providing high-value automation and IT services, we will continue to expand our expertise as these products evolve.

Even the best automation systems don’t add up to much if the HMI is inadequate. Whether it’s difficult to access industrial data analytics, equipment aren’t communicating with sensors, or the control system panel is unable to present data saliently, a poorly-conceived control system panel can render otherwise well-designed building automation system a risk to operations and reputation.

Designing and fabricating custom control panels isn’t something every automation system integrator is experienced with, and this can contribute to subpar design. E Tech Group provides clients with this often-missing piece in automation implementation: control panels tailored to your facility’s needs.

What Should a Proficient Control System Panel Do?

There are several factors to consider when drafting a new control system panel, because there are several things a well-designed system panel should be able to do:

Monitoring & Data Acquisition

Control system panels gather data from sensors and other devices to provide real-time insights into the status of industrial processes. This data is often displayed on screens or gauges, allowing operators to monitor critical parameters such as temperature, pressure, flow, and speed.

Process Control & Regulation

Control panels incorporate PLCs, which are the “brains” of the control system. PLCs receive data from sensors and interpret it based on pre-programmed instructions. They then send commands to actuators, such as valves, motors, and pumps, to regulate the behavior of industrial equipment and maintain desired process conditions.

Human-Machine Interface (HMI)

Control system panels often feature HMIs, which provide operators with a user-friendly interface for interacting with the control system. HMIs allow operators to view process data, modify parameters, and troubleshoot issues, enabling them to effectively manage industrial processes.

Safety & Alarm Systems

Control panels often incorporate safety interlocks and alarm systems to prevent hazardous situations. These systems can detect abnormal conditions, such as excessive temperatures or pressure spikes, and trigger alarms or activate safety measures to protect equipment and personnel.

Communication & Networking

Control system panels can communicate with other devices and systems through various communication protocols, such as Ethernet, Modbus, and Profibus. This networking capability allows for centralized control and data exchange, enabling integration with supervisory control and data acquisition (SCADA) systems and other enterprise-level management software.

Regulatory Framework to Apply in Panel Design

Panel design must adhere to or exceed NEC, NFPA 70, and UL 508 and the newer UL 60947-4-1 industry standards for control system panel architecture. This requires an automation integrator with a breadth of expertise in system panel frameworks across industries.

NEC (NFPA 70)

The National Electrical Code (NEC), also known as NFPA 70, is the primary electrical safety standard in the United States. It covers the design, installation and maintenance of electrical systems in all types of buildings and structures. While the NEC is not a law in itself, it is widely adopted by state and local governments as mandatory code.

The NEC includes several provisions that specifically regulate facets of the design of control system panels in Article 409:

• Panel enclosure and protection
• Component selection, rating and installation
• Wiring and cabling
• Grounding and bonding
• Overcurrent protection
• Labelling and identification
• Access and maintenance
• Hazardous location considerations
• Compliance with manufacturer’s instructions
• Compliance with state codes and regulations

The NEC/NFPA 70 offers the broadest coverage of safety regulations applicable to industrial control system panels.

NFPA 79

Also known as the “Electrical Standard for Industrial Machinery,” NFPA 79 provides comprehensive guidelines for the design, installation and maintenance of electrical equipment and systems used in industrial machinery. While NFPA 70 addresses general electrical safety requirements, NFPA 79 specifically focuses on the safety of electrical systems in industrial machinery applications.

Key regulations set forth by NFPA 79 for control system panel design draws on NFPA 70 as a foundation, and sets further requirements that apply specifically to architecture and installation of control system panels. NFPA mainly delves into the electrical work, offering guidelines on wiring gauge and installation, wire trays, conduits, and also requires all control system panels be designed to operate at 600V or less.

UL 508 & UL 60947-4-1

UL 508 was the industry standard for designing and installing a control system panel for decades, but has slowly been phased out and replaced by UL 60947 in the last few years. The UL 60947 standards are a revision meant to harmonize industry standards between the US, Canada and Europe in order to streamline global manufacturing and commerce.

However, if a control system panel was fabricated before the code switch (27 Jan, 2017) and complies only with UL 508, it is grandfathered in.

Some areas of control system equipment covered by these standards include:

• Product testing and qualification
• Industrial voltage regulation
• Control circuit design
• Guidelines for power circuit wiring
• Branch protection
• Group motor design

Environmental Aspects to Consider in Panel Design

A facility’s automation system doesn’t happen in a vacuum; there are physical parameters that need to be addressed, especially when it comes to workplace safety. Physical design aspects to factor into schematics for a new control system panel are:

Spatial Requirements for Enclosures

Where is the control system panel going to go? What kind of enclosure will be used? There needs to be enough room and outlets inside the panel enclosure so that it can be wired and worked on. Is it a cabinet enclosure? Factor in swing distance for the doors. Is it a high-temperature location? Ensure there’s proper cooling and ventilation measures taken.

Human-Machine Interaction

Operator devices might be anything from an indicator light to an intricate touchscreen display. While a more intricate HMI might allow for more complex interactions, keeping things as simple as possible is important. An HMI must be user-friendly, without blind spots, and allow full access to the control system’s operations.

A control system panel must also include a physical emergency stop device that is not a button on the HMI, per OSHA regulations.

Supply Conductors & Overcurrent Protection

The supply conductor needs to be designed so that if every single apparatus in the system were running, it could still handle the load. This requires an understanding of the sum of all those connected apparatus’ is, so a buffer can be added.

Overcurrent protection is for what happens if the system panel receives more power than it’s rated for. This device protects the electrical components of the panel from overload. The control panel can be designed to include overcurrent protection, or it can instead be a discreet device, which may make it more convenient to access.

Front Panel Construction

There must also be physical parts that protect the control system panel itself from everyday operations. Face plates should resist water, high temperatures, chemicals, cleaners, and, if applicable, extreme weather. Because front panels/plates include user guidelines, they must also be designed to remain readable for the foreseeable lifespan of the panel.

Best Practices for Implementing a Control System Panel

Just like anything in industrial automation, when it comes to designing a control panel, the devil is in the details. A thorough approach to project strategy, schematics, fabrication, and installation is absolutely vital to implementing a cutting-edge control system panel. Key practices E Tech Group automation engineers apply to these projects include:

Component Placement

Placement and organization of the interior components of the control system panel are crucial to everything from daily operations to troubleshooting to reconfigures and upgrades. Organizing circuits and components like PLCs correctly is a balance of

• ensuring temperature grade inside the panel is coolest at the bottom so heat can escape through the top, and
• making sure the way everything is laid out is clear and intuitive to the user.

Panel Size

Component spacing is important. In theory, it might seem logical to minimize the size of the panel and enclosure to use the least space possible, but in practice that is not true. A larger panel is almost always better.

Panel size will depend on the number of components, wiring, location, and what layout is ideal for safe, accessible usage of the panel. There should be a generous amount of space for the current setup; this makes troubleshooting, reconfiguring, expanding or upgrading the current control system much simpler.

Wiring Layout

Wiring should be organized and wireways should be set up so that, should every I/O terminal be in use in the future, the layout would still work. This streamlines the process of adding new pieces of equipment.

Labelling

There is no such thing as too much labelling when it comes to building a control system panel. Each item should be clearly and concisely labelled with a syntactical system that corresponds with each part’s PLC. Labelling is important for daily use, but especially for troubleshooting.

E Tech Group: Intuitive Control System Panel Fabrication & Implementation

As a North American leader in automation engineering services, one of our unique capabilities is designing and fabricating custom control panels tailored to the goals and obstacles of a specific facility.

Even within the same industry, different buildings have different parameters that affect what makes the best automation system and, in turn, the best control system panel. E Tech Group’s team works closely with yours to model and build the ideal system panel for your enterprise.

As a CSIA-certified integrator, our automation services adhere to the highest industry standards, and our deep domain expertise in regulatory compliance means you can rest assured your operations exceed compliance benchmarks. Ensure you get the most of your newly-integrated control system with a panel designed to help your company reach its goals.