Riddle – September 2023 Newsletter
Answer: A hole
Improving efficiency and safety with Programmable Logic Controllers (PLCs)
Programmable Logic Controllers (PLCs) are used by businesses around the world to automate their manufacturing processes to ensure accuracy, consistency and improved efficiency and safety.
PLCs were originally developed in the late 1960s by the US automotive industry to replace relay logic systems. These systems were difficult to update or alter the automation process due to being hard-wired. Any changes to the automation process, using relay logic, meant rewiring and updating documentation. Even a single misplaced wire or failed relay could render the the whole system faulty, making troubleshooting a time-consuming process.
In comparison, PLCs use a tiny computer that takes inputs from data capture points and human input points such as switches and buttons. Based on its programming, the PLC then decides whether or not to change the output. PLC outputs can control a wide range of equipment including motors, solenoid valves, lights, switchgear, safety shut offs and many more.
Advantages of PLCs
- Control & Automation
PLCs allow the automation of complex tasks such as managing production lines, regulating temperature and pressure, coordinating machinery, and controlling robotic systems.
PLCs provide precise and reliable control over your processes by monitoring various sensors and input signals and making logical decisions based on predefined programming.
- Flexibility & Adaptability
PLCs are easy to programme or reprogramme to accommodate changes in production requirements or process parameters. They allow for the integration of new devices or components without requiring extensive rewiring or hardware changes.
- Reliability & Fault Tolerance
PLCs offer support features such as backup power supplies, self-diagnostic capabilities and error handling techniques that help identify faults and minimise your downtime.
- Safety & Protection:
PLCs play a crucial role in ensuring the safety of personnel, equipment and processes. They can implement safety protocols, monitor critical parameters and trigger emergency shutdowns or alarms in the event of hazardous conditions.
- Data collection and analysis:
PLCs can gather and process real-time data from various sensors and devices within the control system. The data collected via PLCS can also work with other data collection systems to improve data analysis, reporting and optimisation.
The EAS team have extensive experience working on projects utilising PLCs. If you’re looking for assistance with installing or upgrading your processes with PLCs, get in touch with the EAS team today on 07 834 0505.
Riddle Answer – August 2023
A puzzle piece
KEEPING YOUR GENERATOR IN TOP NOTCH CONDITION
In the event of a power outage, a generator is essential to keeping your your facility running. However, to ensure you have a truly reliable backup power system your generator must be regularly maintained so it is ready to operate when you need it.
By implementing an electrical preventative maintenance plan for your generator, you ensure:
- Reliability and Availability:
Regular maintenance can prevent unexpected breakdowns and minimise downtime. - Efficiency and Performance:
Regular electrical maintenance ensures the generator will operate at optimum efficiency. - Cost Savings:
Regular maintenance helps prevent major electrical failures that can be expensive to repair. Additionally, well-maintained generators tend to have a longer lifespan, reducing the need for premature replacements. - Safety:
Generators involve high-voltage electrical systems, and faulty or neglected electrical components can pose significant safety hazards.
Electrical Preventative Maintenance Checks for your generator:
Your generator electrical preventative maintenance plan should include:
- Visual Inspections:
- Inspections of all electrical components, including cables, connectors, and terminals, for signs of damage, corrosion, or overheating.
- Checking for loose connections and tightening them if necessary.
- Verifying all electrical enclosures and panels are clean, properly sealed, and free from debris.
- Voltage and Frequency checks:
Regularly measuring the output voltage and frequency of the generator to ensure they are within the specified range. - Circuit Breaker and Protective Device testing:
- Inspections and testing of all circuit breakers, relays, fuses, and other protective devices.
- Checking for any signs of overheating or damage, such as tripped breakers or blown fuses.
- Exercising circuit breakers to prevent them from becoming stuck or corroded.
- Grounding System checks:
- Inspecting the grounding system, including ground rods, grounding conductors, and connections, for integrity and proper bonding.
- Testing the resistance of the grounding system to ensure it meets the required standards.
- Battery System inspections:
- Including checking battery terminals and cleaning them.
- Testing battery voltage and conducting load tests to assess battery health.
- Control Panel and Wiring checks:
- Checking the control panel for any loose connections, damaged wiring, or faulty components.
- Ensuring all control panel switches, indicators, and meters are functioning correctly.
- Inspecting all wiring insulation for wear and tear and repairing or replacing, as necessary.
- Transfer Switch testing:
- Testing the automatic transfer switch (ATS) to ensure it can safely and reliably transfer the load between the utility power and the generator.
- Load Testing:
- Periodic load bank testing assesses the generator’s performance under various loads. This will help identify any issues with voltage regulation, transient response, or frequency control.
- Infrared Thermography:
- Thermal imaging can identify hotspots in electrical connections and components which can indicate loose connections, overloaded circuits, or other electrical problems.
By prioritising electrical preventative maintenance for your generators, you can minimise the risk of unexpected failures, ensuring the safety of your team and equipment and achieve long-term cost savings with optimised performance.
If you would like to get an electrical preventative maintenance plan in place for your generator to give you peace of mind that you’ll have power when you need it; get in touch with the EAS team today on 07 834 0505.
Ammonia Detectors – Keeping your people & plant safe
Ammonia is widely utilised in industrial processes and refrigeration systems due to its cost-effectiveness and energy efficiency. It also boasts an environmentally friendly profile with an Ozone Depletion Potential (ODP) of 0 and a Global Warming Potential (GWP) of 0, making it a popular choice for industrial refrigeration.
While there are significant benefits to using ammonia, we must still remember it is a toxic gas capable of causing harm to both human health and the environment. In the event of a leak whether
due to equipment malfunction, human error, or system failure; ammonia has the potential to cause serious health issues for your team including respiratory problems, eye irritation, skin burns, and in severe cases, even death. Additionally, ammonia concentrations between 16-25% can also pose an explosion risk.
Fortunately, the risks associated with ammonia usage can be mitigated with the use of ammonia gas detectors. These detectors serve as an early warning system, alerting operators to the presence of ammonia gas before it reaches hazardous levels. This allows swift action to be taken, including isolating the source, activating ventilation systems, and implementing safety protocols to protect workers and prevent the situation from worsening.
Gas detectors can either be fixed or portable.
Fixed detectors are permanently installed onsite. They continuously monitor an area around the detector, typically a 5m radius. Fixed detectors work in a similar manner to fire and smoke alarms, where if gas levels reach a certain level, audio and visual alarms are triggered. More advanced installations may also be able to alert other monitoring systems or activate the shutdown of systems.
Portable gas detectors are designed to be carried or worn clipped to an item of clothing. They form part of a person’s PPE. They are designed to provide alarms to the wearer when target gas levels exceed safety limits.
Whichever form of gas detector you use, it is essential that they are regularly maintained and calibrated. The EAS team recommends six monthly calibrations of your ammonia sensors to ensure they maintain optimal functionality and reliable measurements.
If you’d like to find out more about gas detectors or set up a regular calibration plan, get in touch today on 07 834 0505.
June 2023 – Riddle Answer
I can be written,
I can be spoken,
I can be exposed,
I can be broken.
What am I?
The news
May 2023 – Riddle Answer
Q: What has a heart but doesn’t beat?
A: An artichoke
Thermal Imaging Checks
One of the tricky things about electrical systems is that you often can’t see faults without taking things apart.
Thermal imaging or thermography is a non-intrusive, non-contact method of detecting electrical faults that are hidden to the naked eye. During a thermal imaging survey, we use our specialised camera to capture images of the heat energy emitted by your electrical equipment.
The thermal camera measures the temperature of the electrical components and creates an image that shows the temperature distribution across the surface of the equipment
Thermal imaging should be an important part of your preventative maintenance plan as these checks can indicate faults that you may be completely unaware of before they become a serious problem. Heat is often an early symptom of equipment damage or malfunction, and by detecting these problems early, corrective action can be taken before the damage becomes more extensive reducing the risk of equipment failure, reducing the costs of reactive maintenance and unplanned downtime and it can also help extend the lifespan of your assets.
Thermography checks should be performed regularly as part of your routine maintenance plan, however other events can also mean a thermography check should be done, including:
- after any major changes or upgrades to the electrical system
- if there are signs of overheating or burning smells coming from your electrical equipment
- if there have been any electrical system failures or intermittent faults
- if there has been a power surge or electrical storm which may have caused damage to the electrical system.
Thermal imaging can be used to check:
- Electrical panels
to detect hot spots caused by loose connections, overloading, or other issues that may lead to equipment failure or fire hazards. - Circuit breakers
to detect hot spots caused by overload or faulty operation, which may result in equipment failure or electrical fires. - Motors
to monitor the temperature of bearings, windings, and other components to detect signs of wear or damage that may lead to equipment failure. - Switches
to detect hot spots caused by overload or faulty operation, which may result in equipment failure or electrical fires. - UPS systems
to monitor the temperature of batteries, components, and wiring to detect signs of wear or damage that may lead to equipment failure or power interruptions. - Generators
to monitor the temperature of bearings, windings, and other components to detect signs of wear or damage that may lead to equipment failure.
The EAS team are trained and highly skilled in carrying out thermal imaging. To book a thermal imaging check of your vital equipment get in touch with the EAS team today on 07 834 0505.
Protecting your essential equipment with an uninterruptable power supply (UPS)
An Uninterruptible Power Supply (UPS) provides emergency power when the power source or mains power fails. A UPS differs from an emergency power system or standby generator in that it provides near instantaneous protection from power interruptions by supplying energy stored in batteries, supercapacitors or flywheels. The on-battery run time of most UPS is generally short (minutes rather than hours) but is sufficient to start a standby power source or properly shut down the equipment.
A UPS is designed to protect your vulnerable, and often expensive hardware from physical or memory-based damage if they’re suddenly disconnected from mains power. UPS’ are typically used to protect hardware such as computers, data centres, telecommunication equipment or other essential electrical equipment such as emergency lighting or alarm systems.
While a UPS’ main role is to provide short-term power when there is a power failure, most UPS units can also, in varying degrees, correct common utility power problems such as voltage spikes, sustained over voltage or momentary or sustained reduction in input voltage
What size UPS do I need?
Any UPS you install must be large enough to support all the equipment plugged into it. This means you need to calculate the load required. The load is the total amount of power drawn in watts of all the devices that are or will be plugged into the UPS. Once you know the load, you can select a UPS with the right capacity for your needs. The capacity is how much power a UPS can provide (measured in watts) if needed.
The runtime required in the event of power outage will also determine the size UPS you need. Runtime is the number of minutes a UPS can support the attached devices during a blackout. The minimum runtime should be the time needed to complete proper equipment shutdown.
The smaller the wattage load connected to the UPS the longer the batteries will last. To determine the runtime you need, start with the number of minutes required to completely shut down the connected devices. If a long runtime is required you can upsize your UPS so the connected load is a smaller percentage of the capacity or, with some UPS units, you have the ability to add additional battery modules to extend the runtime.
Different types of UPS
- A Standby UPS is an offline unit that can detect a mains power failure and switch to battery power automatically. In normal operation the load is fed directly by mains power.
- A Line-interactive UPS conditions the mains power by regulating input voltage up or down in a buck-boost transfer, before allowing it to pass through to your protected equipment. In the event of a mains power failure, battery power is provided automatically.
- An on-line UPS converts power twice. First an input rectifier converts AC power into DC and feeds it to an output inverter. The output inverter then converts the power back to AC before sending it on to the protected equipment. This double conversion process insulates critical loads from dirty mains power completely to ensure that the connect equipment receives only clean reliable electricity.
UPS Maintenance
UPS’ should be regularly maintained to ensure that they are ready to function when you need them. Investing in a planned maintenance programme for your UPS can improve both reliability and the overall lifespan of your system. A well maintained and regularly serviced UPS needs less power to run, as well as being far less likely to fail and cause critical downtimes.
Preventative Maintenance Checks for your UPS:
- internal and external checks
- calibration of all metering and protective features if required
- functional testing of all transfer conditions
- inspection of on-line performance of equipment with load
- visual check of batteries and battery environment
- testing of battery voltage.
The EAS are highly skilled in sizing, installing and maintaining Uninterruptable Power Supplies (UPS). If you would like to discuss protecting your essential equipment with a UPS get in touch with the EAS team today on 07 834 0505 or [email protected].