Integrating intelligent automation for future-ready power plants

Intelligent automation has become a common terminology in the instrumentation world. Automation is an interconnected network of machines that uses advanced technologies such as AI and machine learning to drive automation. The terminology is causing a buzz due to its rapidly growing role in power generation.

The increasing role of intelligent automation in power plants is increasingly embracing trendsetting innovations to ensure effectiveness, reduce free time, and achieve the most significant levels of functional quality. Embracing such new ideas will help one step ahead but is, in itself, a giant leap into the direction of a strategy for the future. It will help in progress in ensuring optimal power generation performance and sustainability with rising demands, maintaining ultra-high reliability standards, and environmental responsibility.

Intelligent automation in manufacturing plants

Intelligent factory automation refers to state-of-the-art technologies, such as AI, machine learning, data analytics, and IIoT technology for manufacturing and operational processes. While traditional automation systems play a central role in control and mechanisation, intelligent automation uses real-time data, predictive analytics, adaptive algorithms and IIoT systems to deliver improved performance and decision-making.

WIKA India is evolving using data and technology. Recent innovations in its manufacturing plants include IoT devices and high-tech sensor devices that capture real-time data on equipment performance, environmental conditions, and operational parameters. It has also harnessed the power of AI and Machine Learning algorithms to discover patterns in data, predict potential failures, and improve operations.

Its computerised control systems now enable real-time processes and equipment settings based on insights from data analysis. Furthermore, we have adopted digital twins -digital replicas of critical assets -that operate in parallel with their real-world counterparts to improve performance.

Challenges and considerations

Automation systems, a massive and impeccable development in recent times, still face challenges. Integration remains complex, making it difficult to incorporate these systems into power plants’ existing infrastructure. Additionally, the increased data collection and interconnectivity increase the risk of data breaches. Moreover, deploying these systems requires expert knowledge and training.

WIKA’s IIoT solutions enhance performance

WIKA’s IIoT solutions offer organisations a range of benefits. Real-time monitoring, supported by predictive algorithms, Predictive algorithms helps keep employees up-to-date and trigger alarms in case there are any critical issues. Being ‘Smart in Sensing’ capability allows them to make automatic or manual interventions to avoid production downtime.

With Industrial IoT solutions, automating manual and time-consuming tasks to improve employee efficiency becomes easier. This is enabled by avoiding missteps and repetitive, monotonous tasks. WIKA also ensures enhanced data security through end-to-end encryption, bidirectional communication, and a cloud solution hosted in the EU. Implementing the highest security standards becomes easier for WIKA. Additionally, individuals can focus on priority tasks. This is made possible by automating maintenance actions, eliminating the need for manual reading and estimating.

This automation extends to cost reduction as well. It allows for automatic evaluation of the measured data and optimisation of all processes along the value chain, eliminating unnecessary cost drivers.

WIKA manufactures and provides IIoT solutions to its customers that can intelligently automate and simplify their functioning. This is enabled by increasing productivity, reducing downtime, and providing operational quality. With WIKA and its well-designed ecosystem, it is possible to integrate intelligent automation for future-ready power plants. 

Courtesy by WIKA Process Solutions India Pvt. Ltd.