What are the biggest challenges you have come across in your roles at ABB?
To give some context to a common problem, let’s just say that a smooth flow of water can be measured with far greater accuracy than a swirling turbulent flow and for that very reason flowmeters tend to specify a straight pipe run before and after the flowmeter to achieve the most accurate results. Manufacturer data sheets often state an accuracy, but also the reference conditions during calibration to achieve the stated accuracy.
A common question I was presented with in the water industry was, “The data sheet says we need five straight pipe lengths, but we only have room for two, can we just use that?”. Unfortunately, the answer was, “You cannot break the laws of Physics”. The solution is always to be straightforward and explain the implications on measurement accuracy when the guidelines laid out in the data sheet or manual are not followed. It may be that there is an alternative flow measuring technology we can explore, or by simply relocating the position of the flowmeter the problem is solved, but you need to look at the application as a whole to ensure you are not just exchanging one potential issue for another.
Probably the next common challenge we come across is with those that haven’t read the manual, which can then lead to a long conversation about why that instrument shouldn’t have been installed like that and what needs to be done to rectify it. As much as we try to pre-empt these challenges through training and engaging in discussions on the application we aren’t always involved early enough in the process or just don’t have visibility of the end user intention. That said I must also confess I am just as guilty of that as anyone when bringing some new shiny widget home, the manual is the tool of last resort, and I guess we are all guilty of that sometimes.
Lastly, Covid-19 has added a new layer of complexity to the day job. Problem solving is more difficult with limited access to site, but we have risen to the challenge, especially with our remote service technologies that allow us to gain access to both equipment and data to enable us to carry out tasks such as fault diagnosis and device optimisation.
What are the common challenges experienced in the process automation industry/industries as a whole?
The challenges in the process automation industry are well documented and are primarily about the reduction in numbers of highly skilled staff with years of experience. I’m sure many can relate to this as its common across the industry.
Today people tend to be multiskilled, whereas once there were specialist instrumentation engineers or electrical engineers. There are now engineers that cover Mechanical, Electrical, Instrumentation, Control and Automation (MEICA), but this can come at the expense of specific expertise. You may find a MEICA engineer who is a great electrician but not good at mechanical and vice versa. The use of automation and digital technology will help alleviate some of the challenges the reduction in skilled workforce presents but is not the answer by itself.
An early lesson I learnt as a young apprentice is that it’s always the instrument that gets the blame. In most cases, when a problem is reported the first reaction is always “those readings aren’t right”. We have numerous instruments in cars that tell us the fuel level, the speed or the oil level and as drivers we trust those readings and act upon them, but somehow that doesn’t translate into the industrial setting. If the level reading on a storage tank is unexpectedly low, the first thought is rarely there may be a leak. Instead, it is usually “Can you check that the instrument is working properly?”. The instrument should of course be checked to validate the readings, the digital electronics available in devices today are often self-checking and will tell you there is a problem before you even realise it. Instruments can and do fail, but often the problem lies elsewhere. The key here is to understand the technology being utilised and the wider application it is being applied on and trust the data provided unless you have a good reason to believe otherwise.
This is where a good partnership with your suppliers can help provide the experience, tools and the specialist knowledge required. They are the experts in their own products … and working with them is key to fill gaps in knowledge or experience, in doing so you may never need to pick up that manual except to check the contact number on the back.
What do you love about your role?
Every day is a learning day. To do this kind of role you need to enjoy the challenge of it – to see the mountain ahead and be willing to look for routes to the top.
We are also a great team in the UK – knowledgeable, good fun, with a mix of new and very experienced characters. I do enjoy problem solving which is probably why I have stuck in the world of instrumentation for longer than I dare admit (35 years and counting), but it’s about more than just the problem solving, I also enjoy helping people.