Answer:  Trouble

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.

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 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.

 

Q:  What has a heart but doesn’t beat?

A:  An artichoke