Increased automation in the design of industrial facilities

Automation insights

• Automation in industrial facilities is evolving to be more flexible, enabling production lines to handle a variety of products with minimal downtime and reprogramming.
• The increasing implementation of smart technologies and heightened concerns over cybersecurity are driving innovation and necessitating robust protection measures in industrial and manufacturing facilities.

• Jarron Gass, PE, CFPS, Fire Protection Discipline Leader, CDM Smith, Pittsburgh
• Justin Milne, PE, PMP, Senior Engineer, Jensen Hughes, Allen, Texas
• Jonathan Sajdak, PE, Associate Principal / Fire Protection engineering director, Page, Houston
• Michael Whalen, PE, LEED AP BD&C, Project Manager, HDR Engineering, New York

From your experience, what systems within industrial and manufacturing facilities are benefiting from automation that previously might not have?

Michael Whalen: The production lines in manufacturing facilities, specifically repetitive and unsafe tasks and the movement of heavy objects, are becoming increasingly automated. The use of robotics has been a prevailing trend that has become more sophisticated recently. When production lines were designed in the past, they would typically have a fixed automation system that focused on the production and manufacturing of only one product. Now, automation is becoming more flexible, allowing for a larger variety of products to be produced without the need for complex reprogramming and little to no downtime as the production system changes.

A continental structural plastics manufacturing facility and office. Courtesy: Page

Is your team using building information modeling (BIM) in conjunction with the architects, trades and owner to design a project? Describe an instance in which you’ve turned over the BIM to the facility maintenance team for long-term operations and maintenance (O&M) or measurement and verification (M&V).

Jonathan Sajdak: BIM is an extremely useful process for the design and construction industry, which is highlighted in industrial and manufacturing facilities. Having the capability to model systems in 3D, assign parameters to equipment and link in other system models allows for in-depth coordination to occur. This mitigates risks and issues that may arise during construction. Software such as Revit and Navisworks have become tools used industrywide for communicating and documenting design for these complex facilities. Once the design is complete, models can be handed off to the contractors for further detailing, and eventually to the owner so they can be used for system maintenance and documenting as-builts. Having all the information accessible in one consolidated location also allows for efficient renovations and modifications for future projects.

One recent example we had was submitting our life safety systems model that contained all fire alarm, security and toxic-gas monitoring systems to the owner. They were able to take this model to navigate parameters such as power requirements, room locations and equipment schedules to optimize their maintenance procedures.

Michael Whalen: It is unusual now for a project to be completed without the use of BIM, starting with preplanning stages through operation and management. The use of BIM throughout the whole lifecycle of the facility helps owners manage their assets in terms of maintenance cycles, costs and energy usage. As architects and engineers, BIM significantly helps the profession to evaluate a building’s energy consumption, analyze different alternatives as well as improve the quality and workflow of our product.

Have smart technologies (defined as a system with controls that self-monitor, analyze and report using technology) come up in discussion or been implemented on such projects? Has this integration impacted the project? If so, please give an example.

Jarron Gass: Yes, the topic of new or smart technology seems to come up in most industrial projects now. I believe this is because it helps drive innovation with an eye toward the future, as well as toward effectiveness, sustainability and efficiency. Taking advantage of technology, where prudent and cost-effective, will foster the continued return of manufacturing to the United States. Technology has transformed the workforce and labor needs, increased worker and workplace safety, and continues to drive innovation and further advancements upwards.

Jonathan Sajdak: The implementation of smart technologies is becoming more popular, and most of the time is preferred by the system owners. Fire alarm systems have some emerging technologies that offer benefits to the end users when it comes to testing, maintenance and daily monitoring. One example is air sampling smoke detection in cleanroom applications of semiconductor fabrication facilities. These are highly sensitive areas that have specific airflow and air quality requirements for production reasons. The ability to monitor for even the slightest trace of smoke particles is very useful to detect an incipient fire. These smoke detection systems have the capability of relaying specific obscuration percentages at any point in time, which can be monitored by the system owners.

Cybersecurity and hacking are increasing concerns — are you seeing such concerns impacting your work on industrial and manufacturing facilities?

Jarron Gass: In the realm of fire alarm systems, the growing desire for more wireless devices that can be placed in difficult locations is accompanied by major concerns about protecting these connections from cyberattacks or hacking, which could cause false alarms or misuse of emergency services. These concerns have slowed the deployment of wireless technology in fire alarm system design and implementation.

Justin Milne: Since fire alarm systems rely on computer control technologies and can transmit data signals through radio waves, these communications can be intercepted, revealing potential vulnerabilities to intelligence and presenting significant cybersecurity risks. Any fire alarm system connection point to IP pathways has the potential to be a vulnerable point of cyberattack. Emergency response entities such as hospitals, fire departments, police stations, prisons and military facilities, represent some of the more severe targets for a fire alarm system cybersecurity attack. For more information, reference the NFPA Research Foundation report on Cybersecurity for Fire Protection Systems.

Michael Whalen: We are seeing an increase in projects that include some aspect of cybersecurity design. This is certainly becoming a more common concern by owners when it comes to protecting their information and production. With an increase in plant automation and the use of robotics, cyber threats have become more of a reality. Managing these threats and protecting assets is important because the result of a cyberattack could have a significant impact on production and loss of revenue.

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