The crucial role of integration engineering in turnkey automation projects

A automation has become an indispensable element in today's industrial landscape, and turnkey projects are increasingly popular.

This is because this type of project covers everything from design to final implementation and also offers a number of benefits for companies.

According to OTRS Spotlight: IT Service Management 2023, 78% of Brazilian companies have already invested in automationhighlighting this search for innovation and greater operational efficiency.

And in this context integration engineering grows in importance, since it is the area responsible for optimizing and integrating processes and systems, ensuring greater efficiency in an automation project.

That's why, in this article, we'll explain the concepts of integration engineering and turnkey projects. turnkey projects, and how these practices are related. Check it out!

What is integration engineering?

Integration engineering involves the process of connecting different systems, technologies and components within an automated environment to ensure that they function as a cohesive unit.

In the context of automationthis area works on interconnection of hardware, software, networks and communication protocols, ensuring that all elements operate together efficiently efficient and secure.

What is a turnkey?

A turnkey turnkey is a contract model in which one company manages and executes all stages of an automation project, from conception to final delivery of the system.

These projects include integration of various automated systems, such as production control, safety monitoring and energy management.

Importance of integration engineering in turnkey projects turnkey automation projects

In turnkey automation projects, integration engineering plays a key role, ensuring that all systems and subsystems work harmoniously.

An integration integration prevents communication communication failures between components, operational inefficiencies, as well as improving the reliability and overall performance of the system.

Advanced advanced techniques are used to coordinate hardware, software and processes, reducing the risks and costs associated with possible incompatibilities and technical problems.

In addition, proper integration simplifies future maintenance and possible system expansions, ensuring longevity and adaptability to customer needs.

Benefits of integration engineering in turnkey projects turnkey automation projects

Integration engineering generates several benefits in an automation project, such as improved operational efficiency and reduced costs. Check them out in more detail below: 

Centralization and optimization of processes

One of the main benefits of integration engineering is the centralization of processes, as it allows for better better control of operations and the flow of information. By integrating different systems, the visibility and traceability of projects increases.

This centralization also avoids duplication of tasks and minimizes errors.

Reducing costs and time

Another major benefit of integration engineering in automation projects is the savings time and money.

Projects turnkey projects avoid the need for constant adjustments and rework, saving valuable resources.

What's more, fast and seamless implementation allows companies to start enjoying the benefits of automation more quickly.

Improved operational efficiency

Improved operational efficiency comes about because integrated systems operate with greater precision and less margin for error, resulting in smoother operations.

Operational efficiency also increases by automating repetitive processes and reducing manual intervention. This frees up human resources for more strategic tasks.

Integration engineering steps in turnkey projects turnkey automation projects

Successful integration engineering in turnkey automation projects involves several steps. Each stage is crucial to ensuring the perfect combination of all the project elements.

1. Initial planning: Definition of the project's objectives, analysis of the client's needs and preparation of a detailed action plan.
2. Project and design: Development of drawings and technical specifications. Includes integration of automation systems and overall system architecture.
3. Technology selection: choosing the appropriate equipment and technologies based on the project specifications.
4. Implementation: involves the installation and configuration of automation components, such as hardware and software, as well as the effective integration of systems and the creation of communication interfaces.
5. Testing and validation: All systems and components are rigorously tested to verify their correct operation. Any deviation from what is expected is corrected to guarantee the functionality and safety of the project.
6. Training: operators and those responsible for maintenance receive adequate training on how to operate and maintain automation systems.
7. Documentation: all project documentation is drawn up and delivered, including operating manuals, technical specifications and maintenance records.
8. Final delivery: After all the previous stages have been completed, the project is handed over to the client. The engineering team makes sure that everything is working as planned and according to the client's expectations.

Common technologies and tools used in integration engineering turnkey

When it comes to integration engineering, various technologies and tools are employed to ensure efficient communication between systems, precise supervision and data integration. And each component plays a specific role. 

Communication protocols (e.g. MQTT, OPC UA)

Communication protocols are essential for exchanging data between devices and systems in real time. There are different types and here we highlight two.

• MQTT (Message Queue Telemetry Transport) is a lightweight messaging protocol that is ideal for networks that suffer from latency or limited bandwidth. Widely used in IoT, it facilitates communication between devices by publishing and signing messages.
• OPC UA (Unified Architecture) is a protocol used mainly in industrial automation. It offers secure and standardized communication between industrial devices and IT systems. It also supports real-time communication and data history.

The choice of protocol depends on the specific needs of each project, such as security requirements, latency and data volume.

Supervisory control systems (SCADA)

The SCADA (Supervisory Control and Data Acquisition) systems are essential for monitoring and controlling industrial processes and critical infrastructures. They collect data in real time from field devices, making it possible to view data, send commands and receive alerts about anomalies in the system.

These systems are robust and offer a wide view of variables such as temperature, pressure, flow and other essential parameters for industrial operation.

Read also: What is SCADA: A guide to industrial control technology

Integration of ERP and MES systems

In systems integration, the ERP (Enterprise Resource Planning) e MES (Manufacturing Execution System) are vital tools.

• ERP is software that manages business processes such as finance, human resources and logistics, centralizing company operations.
• MES focuses on the execution of production, monitoring the shop floor, controlling WIP (Work In Progress) and optimizing the efficiency of operations.

Integration between ERP e MES allows complete visibility of production, from planning to execution. This facilitates strategic decision-making, improves product quality and reduces operating costs.

To carry out this integration, application programming interfaces (APIs), middleware and specialized integration tools are used to ensure interoperability and data synchronization between the systems.

Integration engineering challenges and solutions in turnkey automation projects

Now that we've understood the benefits and stages of integration engineering in turnkey automation projects, it's time to look at the technical challenges. These are challenges that require multidisciplinary approaches and innovative solutions.

Common Challenges:

• Integrating systems: Combining different systems can be complex.
• Compatibility: ensure that all hardware and software components work together without conflict.
• Data management: maintaining the integrity and security of data transmitted between systems is crucial.
• Scalability: Provide solutions that allow for easy expansion and future updating.
• Maintenance: Establish effective maintenance plans to maximize system uptime.

Proposed solutions:

1. Use of open standards: Adopting open communication protocols such as OPC UA facilitates the integration of different systems and equipment.
2. Monitoring tools: Implement tools that constantly monitor the performance of systems in order to identify and correct problems quickly.
3. Detailed documentation: Maintaining clear and detailed documentation of all aspects of the project facilitates future interventions and updates.
4. Ongoing training: Providing training and capacity building for the staff involved ensures a thorough understanding of the systems and their operation.

Conclusion

As we've seen throughout the text, integration engineering plays a fundamental role in the success of turnkey turnkey projects.

It ensures that all systems and technologies work together harmoniously, centralizing and optimizing processes, reducing costs and time, and improving operational efficiency.

In addition, integration engineering not only facilitates the successful execution of turnkey automation projects, but also contributes to continuous innovation and the improvement of industrial processes.

And by facing and overcoming the challenges inherent in integration, companies can achieve more effective and competitive automation, positioning themselves better in the global market.