Over the years, with the onset of Industry 4.0, the implementation of sophisticated industrial automation solutions has changed the way processes are handled in manufacturing, machinery, and production processes.

However, the use of sensory devices, PLC systems, Internet of Things (IoT) devices and other electrical equipment is only guaranteed if all industrial automation parts can survive in harsh environments. For this reason, systems must be able to withstand high temperatures, humidity, electric and magnetic fields, and other challenging conditions to ensure functionality.

 

In this article, we take a look at some important factors to consider if you operate within a harsh industrial environment.

 

What is an industrial harsh environment?

Harsh industrial environments are those that cause excess physical stress exertion on equipment and its components. It is common to find these kinds of environments in oil and gas rigs, industrial manufacturing plants,  wind farms, and so on. 

Many factors may contribute to a harsh industrial environment, including:

• Extreme temperatures: Generally considered a working environment where the temperature is outside the range of -40°C to 125°C, which can impede the functioning of certain components.
• Changing temperatures: Temperatures that change rapidly can put stress on machines as they adapt to these inconsistencies. 
• Dust: Increased amounts of dust can build up in cooling systems and have the potential to cause short-circuits or fires.
<listyle="float: none; list-style-type: disc;">Vibrations: They can cause equipment fatigue which can lead to failures. 
• Sun exposure: Over time, this can cause equipment to overheat and weaken materials. 
• Electromagnetic Interference: This can cause components or entire systems to fail or functionality to become unpredictable. 

 

The impact of harsh industrial environments

If machines and their parts are not built for harsh industrial environments, it can have numerous consequences for manufacturers and other industrial automation companies and the individuals that work in them.

 

 

Harsh industrial environment factors can cause component failures and other operational issues, which can lead to downtime and financial losses for your company. If uncontrolled, hostile environments can damage entire systems and have knock-on effects on the entire supply and demand chain. Another potential outcome is incidents involving the health and safety of workers.

The development of Industrial IoT has led to the “smart” connected systems being utilized in a range of different environments, including those that operate under harsh conditions.

However, implementing these solutions in harsh industrial environments can be challenging, but this is often where they are required to monitor certain parameters among potentially strong magnetic and electric fields. When IoT systems cease to function, it can lead to hazardous consequences, loss of control, and downtime.

 

Enhance safety and productivity in harsh industrial environments

Below are some ways to improve safety and productivity in harsh industrial environments to maintain your operations. 

Chose solutions with robust and reliable designs 

The first consideration when operating in harsh industrial environments is to ensure equipment has a robust and rugged design that’s built to withstand tough conditions, whatever they may be.

 

Investment in reliably designed solutions means there is a reduced need to replace or repair these solutions, and less likelihood of hazards being caused. For instance, all electrical equipment should be designed to reduce the risk posed by a flammable atmosphere. 

Industrial IoT machinery is those solutions that feature sensors and industrial equipment maintenance software to gather, organize, and process data in real-time. As these solutions rely on electrical components to function, engineers must ensure they are designed with protection for harsh industrial environments in mind.

 

Remote connectivity and device management

Choosing streamlined solutions that offer remote connectivity can save the hassle of setup and maintenance. Solutions that rely on emerging technologies for remote connectivity allow the remote installation of updates and maintenance that can be conducted from anywhere in the world. This means there is a reduced need to compromise the safety of employees when it comes to operating in harsh environments.

 

Scalability

In today’s digital age, advances in technology happen so quickly that it can be challenging to prevent industrial automation machinery and electrical parts from becoming obsolete. Moreover, it can become increasingly costly and complex to repair or replace systems. Instead, industrial automation companies should choose systems and solutions that are built on scalable platforms that can be customized to different environments and adjusted to your company's needs and changes in demand.

 

Predictive maintenance

Integrating a predictive maintenance schedule can help to ensure machinery is operating in an optimal condition at all times and can prevent malfunctions or system crashes when operating in harsh environments. By anticipating malfunctions and other issues with machinery, you can reduce unplanned downtime as well as data and financial losses.

Predictive maintenance relies on insights from data analysis to pinpoint the times and severity of potential breakdowns, which allows manufacturers to ramp up their maintenance efforts when challenging conditions arise.

 

Industrial automation equipment for hash environments with Preferred Spares 

If you operate equipment in harsh environments, you need to be sure that the system parts you invest in are industrial-grade and built to withstand these conditions. 

As one of the leading industrial tools and equipment suppliers for industrial automation companies in the UAE, Preferred Spares delivers robust spare parts from the world’s top manufacturers. Whether you need cooling system spares, lighting solutions or other industrial automation parts, Preferred Spares guarantees expedient and reliable delivery through the UAE.

 

Visit the website to view Preferred Spares catalog of industrial automation tools and equipment.