About Electro Houshmand Dimand
Electro Houshmand Dimand Technical and Engineering Company was established in 2012 with the aim of consulting and implementing industrial automation projects. Our colleagues in this group have more than 15 years of experience in implementing industrial automation projects. Our view at Electro houshmand Dimand company has always been to implement new automation solutions in various automation pyramids for our customers, and in line with this goal, we have especially turned to implementing ERP-MES-SCADA-PLC-Field systems.
Setting up and implementing industrial automation
Today, industrial automation has made production processes more efficient. Many concerns have been raised about the effects of industrial automation on skills, employment and unemployment. Using technologies and machines to perform tasks is called automation. In general, automation can be defined as the use of electronic equipment, machines and computer systems to control processes, with minimal human intervention. In industrial automation, processes are executed without human intervention and by control programs and instructions. Today, industrial automation exists in all industry functions, including manufacturing, production, installation, and maintenance, and they are fully controlled automatically. With more than two decades of brilliant experience in consulting and setting up production lines, maintenance and industrial automation, Electro Houshmand Dimand Industrial Group is at your service to successfully automate your production line.
Advantages of industrial automation
Industrial automation has countless advantages and is able to make a significant impact on quality, speed and productivity. It can even achieve results beyond human capabilities. The use of machines will reduce costs and, most importantly, increase performance. The purpose of industrial automation is to liberate personnel from dangerous, boring and polluted jobs. Improve quality by eliminating errors and reducing costs to increase productivity, improve safety, improve quality and increase acceleration. Some of the most important advantages of industrial automation are mentioned below:
Accurate control and monitoring
Process flexibility
Improve performance
Increase efficiency
Increased safety
Increased security
Increase income
Saving costs
Increase production
Creating a wide range of creativity and innovations in products
Increasing the quality of products
Better service delivery
Reducing the possibility of failure of motors, electric machines and microprocessors
Collecting better and more useful data
Reduced working hours
Reducing employee fatigue
Implementation stages of industrial automation projects
Industrial automation in a factory or an industrial process may include various steps. including design, product supply, programming, launch, etc. Today, with the progress of various industries and the great competition that has arisen among all types of manufacturing and industrial factories, the necessity of using newer devices that are able to produce products with higher quality and at the same time lower production cost and also reduce the amount of human errors in removed, it is needed more than before.
In between, the industries that optimize their production lines and devices faster, or implement the best industrial automation in their factories at the beginning of their journey, using accurate and reliable advice. They are definitely more durable among their competitors, because the first and least effect that the use of the correct implementation of industrial automation will bring for them will be a significant reduction in costs and an increase in the quality of products. An industrial automation project from zero to one hundred. It includes various steps. In this article, we have tried to express and explain the desired steps with a fully operational point of view and according to the standards of the day. The desired steps are the result of designing and implementing countless industrial automation projects by Electro Houshmand Dimand Industrial Group.
1) Receive customer requests
The first step in carrying out industrial automation projects is receiving the customer’s request. Because the request must exist so that the need can be met with an appropriate engineering solution. First, we will review the range of customers. We know that all industries need industrial automation. But here we will name some of them:
Oil and gas and petrochemical industries
Food industry
Pharmaceutical industry
Automotive industry
Packaging Industry
2) Consultation and preliminary evaluations
At this stage, the employer and our consultants and experts in the Electro Houshmand Dimand Group are coordinated with each other and a series of basic information about the project desired by the employer should reach the Electro Houshmand Dimand Group consultants. Our experts and consultants at Electro Houshmand Dimand Group also try to guide the employer to achieve their goals based on their knowledge and experience. Electro Houshmand Dimand Group offers software and hardware tools to the employer to solve the concerns and needs of the employer.
At the top of these tools is the knowledge and experience, expertise, skill and commitment of Electro Houshmand Dimand Group engineers and specialists who will design an integrated and efficient control system that will cover the client’s final needs in the best possible way. Of course, before the consultants and experts of Electro Houshmand Dimand Industrial Group can provide accurate advice in the field of industrial automation, they must have useful information about the process or factory. This information must be delivered by the employer to the Electro Houshmand Dimand consulting group before consultation and estimation. The primary documents are introduced below:
Process Flow Diagram (PFD)
P&ID drawings
List of engines
List of sensors and instruments
List of valves and operators
And …
3) Visit in person
After the initial information and documentation of the process has reached the experts and engineers, it is the turn of Electro Houshmand Dimand engineers to personally visit the production lines and machines. Because no matter how much the documentation is organized and clear, and no matter how much the employer has succeeded in describing his needs. But the experienced and committed experts and engineers of Electro Houshmand Dimand Group must visit the factory and production lines and collect field information before any practical action to start the project. The experts of Electro Houshmand Dimand Group will have their own point of view in the field of industrial automation, based on their experience, and they will make sure that the best and most suitable services are provided to the employer.
4) control system architecture design and technical proposal
In this step, we have reached the point where we have enough technical and environmental information about the process and the factory. As a result, the engineers and specialists of Electro Houshmand Dimand Industrial Group will be able to provide a technical proposal according to the client’s needs. The parameters considered by Electro Houshmand Dimand Group engineers in the selection of components and control system architecture are as follows:
The type of process and its workflow
Request and need of the employer
Technical experience of the contractor
Domestic market inventory
The possibility of importing parts
And … The architecture of the control system indicates the type and number of industrial automation parts, the way they communicate with each other, the type and number of industrial networks, etc. In the considered technical proposal, apart from the architecture of the control system, the method of communication of the control system with process operators such as motors, valves, and precision instruments will also be mentioned. By studying the technical proposal, the employer will be able to get a better view of the automation system he needs. According to the employer’s opinion, this technical proposal can be reviewed or the initial version can be approved by them and the next step can be taken. Therefore, the approval of the employer must be considered in this step.
5) Providing a schedule and financial proposal
The interaction between the employer and the engineers and experts of Electro Houshmand Dimand Industrial Group at this stage was such that based on the necessity of the employer and the level of busyness of Electro Houshmand Dimand Group experts, a specific and precise schedule for starting the project and planning the next stages of the project was agreed upon by both parties. will receive. But before that, the parties must reach a common conclusion on the financial issues of the project. The cost of an industrial automation project includes the following: Costs of components such as: PLC, modules, control and power panels, low voltage components, panel assembly equipment, drive and soft start, HMI, etc.
Control and monitoring system programming expenses
Assembly costs of control and power panels (MCC, Incoming, etc.)
Design and documentation costs
Shipping costs
Education expenses
FAT expenses
SAT expenses
Project start-up costs
6) Signing the contract and receiving the advance payment
The contract between the employer and the industrial group will show all the technical and legal details that should be the criteria for the parties’ actions from the beginning of the project to its end. The most important things that will be mentioned in a project contract are the following: Complete details of the parties to the transaction
project cost
Payment method
Guarantees that the contractor must leave with the employer
Description of duties of both parties
Description of the project
How to arbitrate when there is a dispute
Contract termination conditions
Project start and end date
And …
Payment of the advance payment agreed by the employer means the official start of the contract, and after that the implementation of the project will be started by Electro Houshmand Dimand Group.
7) Receiving control system logic from the employer
Any process will need a logic and rules to be implemented in order to perform its process correctly. This logic determines the starting point and the ending point of the process. It will determine the performance of each operator. How does the feedback of the sensors affect the operation of motors, valves, hydraulic and pneumatic arms, etc., until the desired process performs its task well and correctly. The set of task descriptions, process details, and their connections, which will explain zero to one hundred processes at the end of the process, is called control system logic. Mostly, the employer has engineers in his group overseeing his process who are able to write the desired logic. Or the engineers of Electro Houshmand Dimand Industrial Group, as a manufacturer of process machines and devices, will provide logic to the employer. Third mode In the third mode, experts of Electro Houshmand Dimand Group in the field of industrial automation implementation, according to their experience in the field of setting up and automating similar processes, help the employer in writing the logic text. The employer’s approval of the extracted logic is necessary due to the continued implementation of the project by the contractor, which is Electro Houshmand Dimand Industrial Group here.
Who will prepare the logic of the process?
The employer and his engineers
Electro Houshmand Dimand Group as a machine builder contractor
Electro Houshmand Dimand Group as an automation contractor
8) Design and supply the detailed design of the control system
After the preparation of the logic and the approval of the client, it is the turn of the engineers of Electro Houshmand Dimand Industrial Group to complete the proposed design of the control system, taking into account all the collected details, and to complete the final design in detail and make it the basis of the project implementation.
9) Preparation and design of project documentation
Before any action, the project documentation must be designed and prepared accurately. These documents are the basis of all subsequent designs. In fact, at this stage, a communication bridge will be established between the information and documents delivered by the employer with all the subsequent designs of Electro Houshmand Dimand Industrial Group engineers. The documents in question include information extracted from the employer’s documents, which are collected in a regular and standard way. These documents include the following:
List of inputs and outputs of the IO List process
List of motors Motor List
Valve List
Cable List
Process Logic Process Logic
Instrument List
List of parts required for the MTO project
The basis of all the designs of this stage and the preparation of documents is the Process Flow Map (PFD) which was delivered to the contractor by the employer in stage 2.
10) Designing the boards required for the project
Electrical panels are considered as the dynamic center and beating heart of a factory. Electrical panels for a factory include several categories and models. From the input power after the 20 kV transformer to the 24 V terminals for feeding the sensors, they are all part of the design of the process electrical panels.
Grouping types of electrical panels in a factory:
Incoming Panels
PLC Panels
Marshalling Panels
Distributor Panels
Capacitor Panels
Lighting Panels
MCC Panels
And …Based on the documentation of the previous paragraph, the electrical map of the process should be designed. Electrical plans of switchboards include all connections and electrical circuits from zero to one hundred of a factory. For example, the method of electrical connection of sensors with digital and analog input modules, or the method of supplying three-phase electric motors from three-phase busbars to the head of the engine. These maps will be designed by eplan, AutoCad or AutoCad Electrical software. At this stage, we have to design the boards required for the process. These boards are mainly used in two types of standing and wall cells, although the wall model is only used in small processes. The design of the boards is very important because a correct and engineering design can play a significant role in increasing the safety of the boards and their lifespan. The layout of electrical panels is mainly done by AutoCad software.
What does the control panel design (Panel Layout) include?
Arrangement of Automation parts
Power parts arrangement
Placement of insulators and busbars
Arrangement and size of Duct tapes
Arrangement of Command and Power Terminals
Accurate arrangement of Trays and panel doors
And …
11) supply of parts needed in the project
At this stage of industrial automation implementation, based on the MTO collected in stage 9, the parts needed in the industrial automation implementation project should be procured. Since the main items of industrial automation projects are produced by foreign companies, the supply of these goods is done either from domestic sources or from foreign sources in the form of imports. Electro Houshmand Dimand Group has a brilliant history in importing parts and equipment needed for industrial automation. In fact, Electro Houshmand Dimand Group, both as a contractor and as a supplier of parts, will be able to supply the best quality in the fastest possible time and the most appropriate price to dear employers, and items such as PLC and its modules, pneumatics, various precision instruments, drives and soft starters. Power sources, automatic and air switches, etc. are of this kind. Also, items such as signboard frames, copper busbars, ducts and rails, terminals, etc. are among the items that powerful Iranian manufacturers produce these items.
12) Production of frames for boards
The frame of the boards is ordered and made based on the type of wall or wedge, as well as the size and space of the factory’s electrical room, as well as the plans made in section 10. Mainly an industrial automation company that professionally focuses on this topic. Like Electro Houshmand Dimand Industrial Group, it outsources its panel frames and will be prepared and supplied from domestic electrical panel manufacturers and sometimes reputable foreign companies.
13) Assembly of boards
In the first operational step for the implementation of industrial automation based on the plans designed in step 10, the construction, assembly and wiring of the panels will be done in this step. The steps of assembling the boards:
Transportation and delivery of panels frames at the workshop of Electro Houshmand Dimand Industrial Group
The size of the tray and the door of the panel based on the layout map
Cutting and installing Ducts and rails
Installation of all Trays and panel doors
Power wiring
Steering wheel wiring
Sorting and forms
14) Control and monitoring system programming
At this stage, the programming team of Electro Houshmand Dimand Industrial Group will do PLC programming as well as monitoring programming. As we know, every company producing industrial automation parts has its own special software. The latest software of Siemens company to do this is the TIA Portal software, which includes two main parts for PLC and for monitoring. The programming operation will be done based on the documentation of the previous steps. The most important step of PLC programming is as follows:
Hardware definition and configuration
Definition and configuration of Network communications
Definition of symbols and tags
Writing sub functions to perform various parts of the process
Writing the main functions
Making logical connections between functions
Considering the special and emergency conditions of the process in the program
Simulation of the program in the simulation environment
The most important stages of monitoring programming:
Description and configuration of hardware
Description of network communication between HMI/PC and PLC
Designer of graphic components of the process
Description of interface tags with PLC and other network equipment
Access level definitions
Defining and designing process alarms
Simulation of the program in the simulation environment
15) FAT test
As it is clear from the name of this step, we have to perform a series of tests on the project. FAT or Factory Acceptance Test refers to the tests that must be performed on the control system before being at the employer’s and factory’s premises. In this way, with the presence of the employer’s technical representative at Electro Houshmand Dimand Industrial Group, the control and power panel as well as the PLC and monitoring software will be tested and tested in a quasi-real form. Checking input and output addresses, monitoring schematics, manual and automatic operation of the program are among the things that will be done in the FAT test. At the end of this test, if there are points of correction desired by the employer, it will be announced to the experts of Electro Houshmand Dimand Industrial Group and the programming team of Electro Houshmand Dimand Industrial Group will include these corrections in the program. If the employer approves the plans in this meeting, he will notify Electro Houshmand Dimand Industrial Group in writing, otherwise, in another meeting where the reforms he wants will be carried out, the FAT test will be conducted again, and after that the employer will confirm in writing and after The next stage of the project can be done.
16) Carrying the board to the employer’s place
Hardware project boards are considered industrial automation projects. Therefore, after ensuring its correctness and hardware and software tests of the program, these boards should be transported to the site (factory).
17) Physical installation of signs
The installation and setup of electrical panels in every factory is in the electrical room. Before transferring the panels to the factory, according to the standard and the opinion of Electro Houshmand Dimand Industrial Group as an automation contractor, the electrical room should be installed in the best and most accessible place in the factory. The panels will be placed in the electrical room and placed at the installation site.
18) Installation and commissioning of precision instrument equipment
Project precision instruments such as digital sensors, transmitters, gauges, indicators and detectors, etc. must be installed in their special place based on the PFD and P&ID plan in the factory.
including precision instrument equipment:
Proximity sensors
LT level transmitters
PT pressure transmitters
FT discharge transmitters
TT temperature transmitters
gauges
I to P actuators of proportional valves
And …
19) Using trays, conduit pipes and cables
Now it’s time to determine the cabling routes. Conduit and flexi trays and pipes should be installed and control and power cables should be drawn. Cables are used as signal transmitters for precision instruments, feeding parts, powering motors and actuators, etc. As a result of not choosing the correct cables, not installing them correctly in the cable trays, not properly guiding the cable from the conduit pipe and flexi pipe and not observing all the points and details of industrial cabling, it can lead to severe damage to the equipment and also in the long term. Loss of life to personnel. Cabling operation will be done based on Cable List documents.
20) Cable health testing operation
After the end of the cabling operation and before the final connection of the cables (termination) to the sub-terminals of the panel as well as the termination to the process equipment, the correctness of the cables must be checked. Because if there is a problem with the cables. After electrifying the cables, it results in severe damage. Among the most important tests that are performed on cables:
Loop Check
Phone Check
Megger Test
21) Table top and precision instruments
Now it is time to connect the cables from both sides. The first side is under the terminals of the panels and the second side is for connecting to operator equipment and precision instruments. The correct way of wiring, tagging and labeling, not injuring the cable, using suitable glands, correct measurement of the cable for cutting, firmly connecting the wires to the terminal and electrical connections, etc. are among the most important and noticeable parameters in the cable termination operation. Are.
22) Calibration of precision instruments
In this step, the initial settings of transmitters and operators should be done. Also, by the calibrator equipment, their calibration operation will be done until the precision instrument equipment is actually coordinated with the process fluid and product and the target points of the process are set in the precision instrument equipment.
23) Establishing systems and boards
Now it’s time to connect the main power of the Incoming board. Then, turning on the automatic switch or the main air switch of the panel, other panels will be energized. In turn, the automatic switches of other panels are also turned on, and various equipment such as power supplies, HMI, PLC, thermal switches, etc. can be turned on.
24) Installation
Servers Monitoring systems Program transfer to PLC and SCADA
Industrial computers, which are the server and client of the industrial automation set, must be installed in their proper place inside the rack. The server rack should be installed in the control and monitoring room. The monitoring table will be equipped with relevant monitors and the location of the process operators will be determined. The engineering team of Electro Houshmand Dimand Industrial Group will also be temporarily located in the monitoring room and will install and operate the computer systems related to the automation project. Another activity of this stage will be loading the control and monitoring program on the PLC and monitoring systems (HMI/PC). As we know, an automation project includes two parts, software and hardware. The hardware part has been completed in step 17, and the installation and setup of the software part will also be done in this step.
25) Cold testing of the production line
Now we are at the stage where the commands will be applied to the factory process first. Cold test means starting each of the industrial automation tools and parts in no-load mode. For electric valves, transmitters, sensors, jacks, etc., a cold test will be done and the checklist will be completed. The result of the cold test is to ensure the cabling, ensure the internal wiring of the panel, ensure the correct addressing of the PLC and ensure the correct operation of the sensors and actuators. The correctness of the cold test results means the correctness of coordination and synchronization of the software and hardware of the automation project.
26) Loop tuning and basic settings
After ensuring the complete coordination of the hardware and software of the project, the initial settings of the process can be made. The most important of these settings are:
Organizing the set point of PID loops
Organizing set point and hysteresis of digital loops
Apply Auto Tuning for PID loops
Organizing P, I and D values
Organizing the flow of thermal, automatic, air switches, etc.
Organizing drives and soft starters
Entering process time and value settings into the monitoring system
And …
27) Warm test without product
The automated process will be tested and executed in the warm test phase. Mainly, the control programs of an industrial automation project are categorized into two parts: Manual and Automat. The manual part of the project is evaluated in the 25th stage. And the Automatic part will be tested at this stage. Warm test without product means that the control program is executed from zero to hundred. But there will be no fluid or product in the production line. Of course, instead of the main fluid, water can be used in the production line so that more realistic conditions are considered and the sensors can send feedback close to reality. At this stage, the defects of the automatic program can be identified and corrections can be made in the program. It is also possible to observe the operation of production line machines and devices and identify mechanical and electrical defects and corrections and try to fix these defects.
28) Warm test with the product
In this step, it is easier to start the automatic process in real conditions. Actual conditions mean that the actual product will flow through the process. Production can be done. Of course, with careful monitoring and being ready for any quick reaction. The fact must be accepted that there are modifications in the control and monitoring program until the last moment when the team of the automation implementation contractor, which is Electro Houshmand Dimand group of expert engineers, leaves the factory door. Because when we want to implement the process in a completely real situation and with the presence of a real product, there will definitely be some points to improve, modify and fix the defects of minor or general issues that must be implemented on the program.
29) Test (temporary delivery SAT)
When the complete and correct operation of the control system is verified for the contractor, it is time to deliver the control system to the employer. SAT test (Site Acceptance Test) means that the final control system after it was installed and started in the factory (site); be delivered to the employer. At this stage, the employer will carefully examine his expectations from the control system. And the final product of the line is also observed and evaluated. If the item was fully satisfied. He gives the final approval to the engineers of Electro Houshmand Dimand Industrial Group. Otherwise, he will announce his point of view in writing until the final amendments are made.
30) Personnel training
The personnel and technical force of the employer must take over the control system from the engineers of the industrial group. Therefore, they should acquire the necessary familiarity and training in order to use the system. This initial training will be done by the team of engineers and experts of Electro Houshmand Dimand Group in the best possible way. The employer’s personnel will be given operational training by Electro Houshmand Dimand Industrial Group according to their level of expertise and education as well as the level of involvement in the production process.
31) Trial production period
Usually when the industrial automation implementation project is finished (end of step 30); The work and duty of Electro Houshmand Dimand Industrial Group engineers in the industrial automation implementation project has also been completed. But Electro Houshmand Dimand Industrial Group considers it their duty to provide services to the employer beyond their defined duties. As a result, a trial production period will be considered for the employer, during this time any possible problems that may arise will be resolved by the technical team of engineers and experts of Electro Houshmand Dimand Industrial Group. The training of the employer’s personnel has been completed and the whole new factory will start to take steps under the strict supervision of compassionate, committed and experienced engineers and experts of Electro Houshmand Dimand Industrial Group.
32) Preparation and design of AS-BUILT project documentation and supply to the client
As-Built plans means to include the project corrections that we manually applied on the maps, after the completion of the project, by the relevant software in the documents and maps, and so called the maps as Final and or As-Built. As-Built plans are the final documents and plans that will be delivered to the client at the end of the project.
33) definitive delivery of the system
At this stage, the engineers of Electro Houshmand Dimand Industrial Group will deliver the control system definitively and finally to the client during their special formalities. But we at Electro Houshmand Dimand Industrial Group still consider it our obligation to provide 24-hour support services.
34) Warranty period
During the warranty period, Electro Houshmand Dimand Industrial Group is committed to repair and fix software problems as well as replace or repair hardware parts.
35) After-sales service of industrial automation implementation projects
In this period, Electro Houshmand Dimand Industrial Group undertakes to perform troubleshooting and troubleshooting services of the control system.
36) Periodic maintenance period
Every industry and factory needs a team for maintenance. Net operation or production line PM can be implemented by two groups. A group that is the employer’s personnel or a group that wants to undertake this task as a contractor and from outside the employer’s group, since the specialists and engineers of the Electro Houshmand Dimand Group are very much in charge of their system. The best option for repair and maintenance are the experts and engineers of Electro Houshmand Dimand Industrial Group. Fortunately, Electro Houshmand Dimand Industrial Group will provide the most specialized services in this field. With Electro Houshmand Dimand Industrial Group, step on the golden path of production with confidence. We will be your reliable companion with the best in every field.
Electro Houshmand Dimand Industrial Group is proud to be with you in the mentioned cases:
Design of industrial automation systems
Setting up production lines
Calculation and implementation of cabling projects
Carrying out industrial network projects
Purchase of specific industrial automation items
Advice for buying industrial automation items and precision tools
Carrying out tank weighing projects
Setting up a dairy and ice cream production line along with formulation for all dairy products
Design and manufacture of dairy and food filling machines
Updating old devices and production lines
Providing services related to industrial cattle farms
Creation and construction of CIP system in dairies and cattle farms with the most up-to-date method and the lowest cost
Optimizing the power consumption of factories
Programming and setting up PLCs and HMIs with different brands
SCADA programming
Optimizing them with special facilities and features for easier use by forces with any level of literacy
…
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