Process Automation is the study and implementation of automated systems in the extraction and treatment of water, chemicals, oil refineries etc. Such systems often involve extensive networking through switches and cables for the sole purpose of interconnecting various sensors, controllers and terminals. There are different examples of automated process software which includes manufacturing execution systems, cleaning, treatment execution systems and even maintenance system solutions. The main purpose of these systems is to ensure efficient and safe operation.
Earlier, plant operators had to manually execute the process and monitor the workflow. This had potentially dangerous consequences in the form of unsafe work conditions and quality control issues. Maintenance was one aspect that suffered the most due to manual labor input. The reason being that despite the set schedules for maintenance, the human factor sometimes led to its disregard. This was catastrophic being processed like waste and water management.
The rapid advancement in technology and software development meant that such processes have to include IT technology for higher efficiency and productivity. This led to the development of automation software that would take care of work data including temperatures, pressures; scheduled maintenance etc., so that maximum operational efficiency can be achieved with the help of process automation software. Oil and gas industries have their maximum cost in the form of energy input. In some cases, it reaches as high as 50 percent of their total input cost.
Process automation software helps to present various scenarios and strategies, which can then help the management, decide on the optimal path to move forward. This ensures maximum output at minimal cost, which translates into higher profits and minimum overheads. Automated systems do this by acquiring data, storing and analyzing it and giving out the maximum output. Large areas can be covered under a single control room. This makes implementation of process automation's ergonomically attractive.
Simulation is one of the major components of automation systems. Latest software is highly advanced in that they are adaptable and constantly evolving. They change their parameters based on the constantly evolving situations. If a process requires a minimal input, the software changes the flow to the minimum. In case of large output requirement, it changes the parameters to the highest settings possible.
It constantly monitors the process for any danger signals or deviation from the process. In case of deviations, it triggers an alert and sends notifications to the concerned personnel. Even upon completion of a regular monitoring process, it sends notifications upon start and completion of a schedule.
Plant Automation and Control systems are designed to run on the least possible energy input. This helps conserve precious fuel and power resources. The usual components of an ideal automation system will include switches, micro controllers, microprocessors and multiprocessor.