Proven Automation Strategies: Delivering High Impact with Practical Solutions

Starting Small with Significant Automation Results

My automation career began without large budgets. I initially worked with a problematic machine and a basic relay panel. The solution involved a $350 PLC and HMI combination. This approach made an OEM evaporator safer and more reliable. Consequently, operators found it easier to use. This early success established my core principle: effective automation provides excellent value without high costs.

Building Expertise Across Major Industries

As an ISA Senior Member and CAP-certified engineer, I have over 15 years of diverse experience. My work spans Oil & Gas (LNG), OEM equipment, biotech, and pharmaceutical sectors. I have supported significant projects for National Grid, SI Group, and Eastman Chemical. Additionally, I’ve collaborated with ENCON Evaporators and teams at Bristol Myers Squibb (now Lotte Biologics), Lonza, and Moderna.

Implementing Discipline Through ISA Standards

Discipline is the consistent theme in my projects. Before programming, I apply established standards. ISA-5.1 brings clarity to P&ID interpretation. ISA-18 forms the foundation for alarm management philosophy. For procedural automation, ISA-106 ensures predictable startups and shutdowns. Furthermore, ISA/IEC 62443 addresses cybersecurity in interconnected systems. These standards transform individual expertise into repeatable, reliable practices.

Mastering Instrumentation Engineering and Selection

A crucial aspect of my role involves instrumentation engineering and procurement. I develop instrument specification forms based on ISA standards. Moreover, I conduct technical bid evaluations and select instruments suited to specific process conditions. This process balances performance, safety, and maintainability. This standards-based methodology allows me to work effectively across multiple platforms including Allen-Bradley, Emerson DeltaV, and Siemens.

Transforming Legacy Systems at ENCON Evaporators

At ENCON Evaporators, I led a control system modernization focused on reliability. We implemented clean ladder logic and modular design options. The system included black-box data logging and smart interlocks for foaming and over-temperature conditions. We also integrated secure remote access for faster diagnostics. As a result, service visits decreased significantly while safety and customer satisfaction improved.

Implementing Advanced Control Strategies

On a forced-circulation evaporator, I deployed a density-based concentration control system. This strategy involved careful sensor selection and precise signal handling. It also required thoughtful interlock design and operator interface considerations. Therefore, the system achieved tighter control targets while enhancing equipment protection. Additionally, I applied ANSI/ISA-5.1 to overhaul the product line’s P&IDs.

Revitalizing Critical Infrastructure

I specialize in upgrading legacy assets to perform like modern systems. One notable project involved restarting a wood-burning power plant in New Hampshire after three years offline. This required comprehensive instrument verification and control loop optimization. The approach respected the original design while addressing equipment aging issues. Consequently, the plant returned to reliable operation.

Ensuring LNG Facility Reliability

Recently at National Grid’s Providence LNG facility, I commissioned the liquefaction plant. Now I maintain this critical New England infrastructure. My responsibilities include managing complex DeltaV systems and strengthening instrumentation reliability. Additionally, I rationalize alarm systems and advance virtualization initiatives. This methodical work ensures critical infrastructure remains safe, available, and predictable.

Developing Future Automation Professionals

Mentoring next-generation engineers is a professional priority. I provide practical training in loop tuning, alarm philosophy, and commissioning techniques. These are skills rarely covered in academic curricula. Therefore, watching these engineers successfully deliver major projects represents the most valuable return on investment. Ultimately, mentoring builds essential capacity for our industry.

Advancing Through ISA Certification and Standards

ISA has been instrumental in my professional development. Achieving Senior Member status and the CAP certification demonstrated my comprehensive automation lifecycle knowledge. The CAP credential validates expertise across process control, instrumentation, and systems integration. Moreover, my volunteer work with CAP content helps maintain high professional standards for emerging automation specialists.

Practical Innovation in Industrial Automation

My approach emphasizes practical innovation over technological complexity. I prioritize clear interlocks rather than sophisticated code. Similarly, I design robust HMIs instead of visually impressive ones. Furthermore, I create architectures that technicians can quickly master. This philosophy scales effectively because it’s rooted in fundamental principles rather than individual preferences.

Practical Application: Control System Modernization

Challenge: Aging control system causing operational inefficiencies and reliability issues.

Solution Components:

✅ Modern PLC/HMI implementation
✅ ISA-standard alarm rationalization
✅ Secure remote monitoring capabilities
✅ Comprehensive documentation update

Outcome: 40% reduction in downtime, improved operator effectiveness, and lower maintenance costs.

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Frequently Asked Questions

How important are ISA standards for small to medium automation projects?

ISA standards provide crucial frameworks regardless of project scale. They ensure consistency, enhance safety, and facilitate future expansions. Even basic implementations benefit from standardized approaches to documentation and alarm management.

What is the most cost-effective first step in automation modernization?

Begin with a critical assessment of existing instrumentation and control logic. Often, optimizing sensor placement and implementing proper alarm management delivers significant improvements with minimal investment before considering complete system replacement.

How does the CAP certification benefit practicing automation professionals?

The CAP credential validates comprehensive expertise across the automation lifecycle. It demonstrates proficiency in integrating process control, instrumentation, and safety systems – essential skills for delivering reliable automation solutions.

_{As the International Society of Automation (ISA) celebrates 80 years of advancing the field of automation, we asked the automation community to share their personal experiences and stories. You can view all the submissions here.}