Key Challenges & Solutions for Successful Skid Integration in Batching Operations

Whether it is a new process or the extension of an existing one, skid-mounted equipment is a better alternative to traditional process systems if the goal is faster implementation. Original Equipment Manufacturer (OEM) skids not only accelerate deployment but also ensures top quality and cost-effectiveness for both utility and main processing tasks.

Integrating skid equipment can be streamlined with data collection and minimal interaction to work with the main SCADA or DCS system. However, hassle-free integration of skid equipment into batching operations can get challenging in the absence of a modular approach.
It needs a much higher level of cohesive interaction to achieve peak efficiency.

Key Challenges of Skid Integration in Batching Operations

Integrating an OEM skid design into the overall process enables easy coordination of both upstream & downstream processes with a common operational goal.

Ideally, equipment skids deliver the desired output at a specific capacity, on-demand. In contrast, OEM skid equipment act as a piece of the puzzle in a comprehensive process that needs additional coordination between the upstream & downstream units for optimum equipment utilization.

Most skid components come complete with a dedicated I/O and processer for independent functioning. This means that they work without any visibility into the upstream feed or knowledge of downstream demands.

Commonly, the overall process works around the functional specifications defined by the OEM. In many situations, the operational specifications of such skids are preprogrammed. This means that the skid equipment is not designed to act as per the master controller or the process coordinator.

The independent operations of OEM skids are a result of cookie-cutter solutions. Modifications made to an existing function pose a risk to the vendor and they are generally hesitant to enhance system function on demand.

Integrating skid packages into a batching system is tedious because most packages are not programmed in compliance with ISA S88.01 standards.

Not utilizing the best industry practices, over-complicating the system software app with several processing functions, and partnering with a risk-averse vendor can create several obstacles in successful skid integration.

Effective Ways for Skid Integration in Batching Operations

For seamless integration of skid equipment into a batch management system, you need a clearly defined communication channel between the DCS & SCADA systems.

With simple commands, the operator does not have visibility into the system. Additionally, if an exceptional condition occurs, a simple master command does not help you find and fix it. You must go to the equipment’s local HMI to detect and troubleshoot the issue.

This results in unwanted operational delays and increases the overall batch cycle time, having a cascading effect on equipment utilization and operational efficiency. The best way to tightly integrate a slave OEM system is by following these 4 steps:

Designate the operating modes
Adhere to standard operating states
Specify status feedback
Define standard communication

The solution is to sync two independent components of equipment by establishing a standard method of interactions. An agile batch solution rests upon respective isolation between different functions, which establishes uniformity in how they interface with the other functions.
This enables different equipment entities to function independently, thereby promoting the reuse of base code and accelerating the overall engineering timeline.

Designate the Operating Modes
Can the equipment operator make any modifications locally if the control variables have already received the commands remotely? Do the control variables freeze if a specific operational status is changed?

Operating the different modes in remote equipment can become a tedious task if you don’t define the boundaries clearly.
These are a few points that should be considered when integrating any remote equipment. The operating guidelines and interface specifications between the slave and the master system should be clearly outlined to ensure a uniform and uninterrupted interface between the two systems.

Adhere to the Standard Operating States
Standardizing operational states creates a uniform mechanism for managing a challenging event that takes place outside of the desired behavior of the process. Managing, processing, and recovering from such exceptional conditions is a vital aspect of batch production.
Not only is exception handling crucial from the safety perspective but it is also vital for ensuring quality and efficiency. Programming exceptions account for up to 70% of the total programming effort and should be treated as a goal in the design process.

Specify Status Feedback
This is a vital aspect of efficient operations between two independent systems. This data must be defined and structured for operating states, modes, and error conditions. While the representation of standard modes and states should be common across equipment, error conditions should be very specific to each component of equipment.
Specific feedback on errors from a remote system can provide visual clarity into the existing operational conditions. Error states can also be used to identify preventative measures for the optimum use of the equipment and increased system productivity.

Define Standard Communication
Seamless communication between two siloed systems can be achieved efficiently by using single integer value designations. The communication can be very basic single-word commands to the slave system. The general command status can be common for operating states and modes.
System variables or additional parameters may need to be predefined to the slave PLC. Standardizing the communication type for 3rd party equipment that is remotely operated enables easy maintenance and enhances the service life of the control system. The designing of the communication standards must be broad enough to suit different application types but specific enough to add value.

Modular Skid Design — The Key to Optimized System Efficiency
With safety and accuracy as a guiding philosophy, modular skid design focuses on delivering design efficiency without compromising on compliance regulations, deadlines, and budget.

Modular skid design solves complex business challenges while ensuring:

*Faster execution of upgrade requirements
*Lower operational and labor costs due to shorter timelines and efficient use of resources
*Reduced safety risks for fabricators
*Consistency across the system with clearly defined guidelines
*Common interface solutions are provided as per the user requirement *specifications to match the OEM standards
*Remote system configurations comply with the established operational *standards
*Standardized interactions that include exceptions conditions to ensure easy operations and periodic maintenance to achieve peak efficiency.

Scaling your process with a modular skid design will help you ensure the high-quality fabrication of equipment while avoiding interruptions in batching operations.