News & Knowledge

We’re your source for automation news. Keep up with the latest industry updates and E Tech employee spotlights, as well as tips and guidance from our manufacturing experts.

| July 31, 2023

Mitigating Risks Through Modernization: PLC/HMI and Radio Upgrade Plus Water Well Expansion

Outdated systems have the potential to transform assets into liabilities. It is important to know the signs and risks of using outdated systems, and when it is the right time to invest in a modern solution. This was a challenge faced by a company specializing in environmental management services who was operating eleven water well sites across a five-mile area. These sites were being controlled by legacy PLCs and HMIs and relied on slow serial radios for communication, posing several risks such as high maintenance costs, poor HMI responsiveness, and limited scalability due to the outdated equipment. The customer recognized how their outdated system negatively affected their productivity and efficiency which prompted them to seek engineering support. The company engaged E Tech Group to design and deploy a modern solution, which included upgrading their PLC, HMI, and radio controls as well as install an additional water well to expand their operations.

| June 2, 2023

What are the Current Pain Points with Supporting Utilities?

Supporting utilities such as ammonia refrigeration and steam generation play a critical role in keeping industrial operations running efficiently. Yet these systems operate in the background, only drawing attention when something goes wrong. From stringent safety requirements to specialized maintenance needs, they present unique challenges that can impact uptime, compliance, and operating costs. Understanding these common pain points is the first step toward building a proactive strategy that minimizes risk and keeps production on track. Common Pain Points with Supporting Utilities Aging Systems Many ammonia refrigeration and steam generation systems have been in operation for decades — often 20-30 years or more. In comparison, the average industrial boiler in the U.S. is 30-40 years old. These legacy systems typically rely on low levels of automation, with control panels based on relays and contractors rather than modern PLCs or distributed control systems. As a result, they require frequent human intervention, increasing labor demands and the risk of operational errors. Incorrect Sequencing Causing Inefficiency The inability to adapt to changes in demand or load can present a challenging issue. This can often result in incorrect sequencing equipment due to simple control implementations, leading to lower overall system efficiency. A common instance of incorrect sequencing is having the largest piece of equipment either always running or brought online when demand is lower, which can be less efficient in its operation and energy consumption. Keeping in mind, these systems can also be slow to start or restart if personnel are not quickly notified when a fault or issue occurs. Lack of Integration into Larger Control Systems Even if a modern system has been implemented, it is less likely that it is part of a Building Management System (BMS) or Distributed Control System (DCS) that could better control these utilities based on what is actively … Continued

| September 19, 2022

A Life Sciences East Project is Coming to a SMASHING End!

One of E Tech Group’s Life Sciences East customers is the Johns Hopkins University Applied Physics Lab. The lab supplies space craft programs to NASA for scientific research. Life Sciences East supports one of its test facilities, maintaining the industrial control systems of the Thermal Vacuum chambers. One of the missions Johns Hopkins University tested in the facility LSE supports is getting ready to come to a SMASHING conclusion later this month. JHU tested the DART spacecraft in its lab. The DART mission is NASA’s demonstration of kinetic impactor technology, impacting an asteroid to adjust its speed and path. The Dart spacecraft is scheduled to crash into the asteroid on September 26, 2022. Project Overview The LSE Industrial Controls project showcases E Tech Group’s expertise in industrial automation and control system integration. The project involved implementing complex control strategies to enhance operational efficiency and system reliability. Key Achievements Outcomes of the project included: Client and Industry Impact This project demonstrates E Tech Group’s ability to deliver high-quality automation solutions that optimize performance and support long-term business objectives for industrial clients. Several people from LSE have worked on projects supporting JHU during the 6 years they have been a customer to maintain and upgrade the systems at JHU. To learn more about DART and its program and mission, click here.

| August 12, 2022

E Tech Group Automation Engineer Shares Expertise on Control Engineering Magazine Webcast

E Tech Group Lead Automation Engineer, Kevin Tom, shared his knowledge and expertise on Best Practices for Effective Automation Applications for Control Engineering Magazine‘s webcast on August 16th, 2022, where he discussed the nuances of control system applications. Highlights from the Control Engineering Magazine Webcast During the webcast, Kevin discussed several key topics: When Should a Process be Automated? Kevin explains the criteria that a company should consider when weighing whether or not to apply automation to a process: In considering automation, goals and constraints must also be hashed out: These questions are all addressed early on in a project’s inception, as stakeholders hold the keys to the budget needed for an automation project. However, control system engineers should also be consulted early on to give insight into the specifics of these questions, like cost, ROI, and improvement caps. The Importance of Knowledge Sharing in Automation Automation is a fast-evolving field, and staying current with best practices, emerging technologies, and industry standards is essential. By participating in webcasts, podcasts, and public forums, engineers can: Applying Automation is as Much Planning as Execution Kevin Tom’s cohost noted that, for many manufacturers, delaying automation is no longer viable given labor constraints and growth targets. It may sound histrionic, but the labor shortage is a real and pervasive issue, especially when manufacturers are trying to scale. Increased production goals mean hiring more people. But there aren’t enough people to be found, and/or high turnover, and/or lack of qualified professionals, which all present labor bottlenecks. Automation is the best (and only) solution to avoiding the obstacles associated with labor shortages. However, it isn’t as simple as design-build-implement. For the transition to automation to run smoothly, the system first needs to be analyzed and verified virtually. This is another reason control system integrators should be involved in … Continued