Simple Solutions That Work! Issue 6

In order to pursue a control system upgrade project at your facility, there are things that equipment suppliers need to know in order to be able to quote, design, build, and supply an integrated solution: • Clear definition of the Issue to be overcome. What is the problem that we are attempting to resolve with a controls upgrade? • Clear photos of the mechanical equipment that is in need of upgrade. Take clear photos of left/right/front/back. Also, take clear photos of the inside and outside of any existing control cabinets, pump cabinets, hydraulic units, conveyors, etc. • Document the horsepower, voltage, and amperage of any electric motors that are to remain in the system to be upgraded. • Provide any mechanical drawings of the equipment to be upgraded that are available. • Provide electrical schematics, pneumatic schematics, hydraulic schematics, or any other pertinent drawings of the existing equipment that are available • For larger systems, provide any drawings that are available of the facility showing the existing equipment in place. If equipment is being relocated, suppliers can often help with choosing the best new location to maximize productivity within the facility. • Provide a clear definition of the finished system expectations – “MORE” is not a number! We all want to do more, but how much more in comparison to current is actually needed? With the items above, an equipment supplier can provide a quotation for the control system that will be clearly defined as to what capabilities it has and what rates it will be able to achieve. Upon order and beginning of the actual design process, it is imperative that there is a Project Manager on both the customer and vendor sides who will work together for the duration of the project. The most successful projects we have seen are ones where there is open communication, clarity, and a “living project document” that is updated, saved, and dispersed regularly. All project specific information should be saved to that specific document. For larger systems beyond just a single piece of equipment, an Operational Description becomes very important. This description should be part of the living document and should include items such as: • Operator station locations as well the actions of each button/ switch in the Operator station • Sand level switch locations – The mechanical state that the switch will measure (full versus empty); the action that will occur when the switch is tripped. • Photoeyes and/or proximity sensors – The mechanical state that causes the sensor to trip; the action that will occur when the sensor is satisfied and the permissives that need to occur in order for a mechanical action to begin. This living document will often be initiated by the equipment vendor, but agreement and understanding of it are both the customer and vendor’s responsibility. With so many forms of communication available to us such as face-to- face, phone, email, and texting, it is even more important that the customer/vendor work together to update this living document and maintain clarity of communication. Doing so will ensure all project requirements are met, system performance is achieved, and targeted production goals are realized. Contact: RICH McNEELY rich@palmermfg.com 15