“Chance Favors the Prepared Mind.”

When Louis Pasteur famously said this, he captured a universal truth: Preparation isn’t just helpful, it’s powerful. In the world of automation control systems, preparation is what separates reactive troubleshooting from reliable, long-term performance. Whether it’s a batch chemical plant, a pharmaceutical vial filling line, or a robotic pick-and-place system, every automation control system demands careful planning. Before a new installation, a modernization project, or even a minor system change, automation system integrators rely on proven tools and techniques to anticipate challenges, reduce risk, and set the stage for success. Let's explore some of these tools. 

FEED

The use of a Front-End Engineering Design (FEED) can apply to almost any project and industry. A FEED is an engineering tool used to plan out a project to determine the cost and schedule prior to committing capital. FEED can occur across all aspects of a project (e.g. civil, piping, etc.) but it is critical not to overlook automation.

FEED for the automation portion of a project allows an expert to ask the right questions to adequately define the project scope. For a greenfield project, it is important to gather requirements to determine what level of automation is appropriate, how the process data will be utilized, cybersecurity implementation steps, and more. In a modernization project or a minor change, the FEED looks at constraints already in place such as physical space, existing wiring, and integration with other systems on site.

Technical knowledge and automation expertise are an increasingly critical part of comprehensive FEED development. When the FEED is performed by an automation system integrator with years of automation experience, knowledge of multiple automation platforms and support from automation suppliers, the results can deliver the much-needed preparation for a successful project.

HAZOP

Hazard and Operability Study (HAZOP) is a structured process used to identify hazards and is well known among most chemical companies. The IEC 61511 safety lifecycle includes hazard identification and other requirements to best mitigate risks. HAZOP can help eliminate design issues, improve efficiency, and contribute to the sustainable growth and success of operations.

The first step of the HAZOP process involves forming a multi-disciplinary team, including automation, which can provide a variety of perspectives. However, some chemical or manufacturing facilities have limited automation resources, so an automation systems integrator can help to fulfill that role.

Automation system integrators understand how to configure control systems and the various failure modes they introduce. They also understand the limitations of technology as protection layers and the operator process view.

Cybersecurity Tabletop Exercise (TTX)

The last preparation tool is in the realm of cybersecurity. For a site’s OT cybersecurity, preparing for a cyber incident is crucial in understanding how to respond, and one tool that can be employed is a cybersecurity tabletop exercise.

The tabletop exercise gathers all individuals who are responsible for reacting to an incident and sets up a realistic and relevant scenario to test the response plan. By identifying gaps in response strategies, processes, and procedures, the site can be ready for any future incidents.

After the tabletop exercise is complete and the results are reviewed, the site can prepare by developing better backup and restoration procedures, enhancing documentation, or training cyber first-responders.

Preparing for your next automation project

If the control system is operating at peak efficiency and has been configured properly, the risk of failures will decrease, and downtime will be minimized. Engaging with an automation system integrator with extensive platform and technology expertise, along with the use of preparation tools, can guide the project to success.

If you would like to learn more about these tools and techniques, or just want to be prepared for your next automation project, reach out to Applied Control Engineering.