Last updated on Mar 31, 2024

What do you do if your control system is malfunctioning?

A control system is a device or a set of devices that manages, commands, directs, or regulates the behavior of other devices or systems. Control systems are essential for many engineering applications, such as robotics, aerospace, manufacturing, and automation. However, control systems can also malfunction due to various reasons, such as sensor errors, actuator failures, environmental disturbances, or design flaws. In this article, you will learn some basic steps to troubleshoot and fix your control system problems.

Key takeaways from this article

Root cause analysis:

When your control system hits a snag, think like a detective. Dig into the heart of the problem with root cause analysis to uncover the real culprit behind those pesky symptoms. This is your key to a reliable fix.
Preventive measures:

To keep your control system running smoothly, up your defense game with regular maintenance and risk mitigation strategies. Think of it as your system's personal health plan, preventing issues before they even start.

This summary is powered by AI and these experts

1 Identify the symptoms

The first step to diagnose a control system malfunction is to observe and record the symptoms. What is the expected output or performance of your system? What is the actual output or performance? How does the system respond to different inputs or conditions? Are there any warning signs, alarms, or error messages? You can use various tools and methods to collect data, such as graphs, charts, logs, tests, or simulations.

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Gustavo Chavez

Industrial Engineer
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Analisis del sistema total y de los elementos claves, los cuales mostrarán datos de dónde se debe re-diseñar dichos controles.

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2 Analyze the causes

The next step is to analyze the possible causes of the symptoms. You can use different techniques to narrow down the source of the problem, such as root cause analysis, fault tree analysis, or Ishikawa diagrams. You can also consult the system documentation, manuals, or experts for guidance. You should try to identify the primary cause, as well as any secondary or contributing factors.

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3 Evaluate the solutions

Once you have identified the cause, you can evaluate the potential solutions. You can use criteria such as effectiveness, feasibility, cost, time, safety, and reliability to compare and rank the solutions. You can also consider the pros and cons, benefits and risks, and short-term and long-term impacts of each solution. You should try to select the best solution that meets your requirements and constraints.

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4 Implement the solution

After you have selected the solution, you can implement it according to a plan. You should follow the instructions, procedures, and standards for installing, modifying, or repairing your system. You should also use appropriate tools, equipment, and materials to ensure quality and safety. You should document the changes, results, and observations for future reference.

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5 Test the solution

The final step is to test the solution to verify its effectiveness. You should repeat the data collection and analysis methods that you used in the first step to measure the output or performance of your system. You should compare the actual results with the expected results and check if the symptoms are resolved. You should also evaluate the solution for any side effects, drawbacks, or new problems.

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Ivan Maravilla, ECE

SCADA Engineer | Automation, Control, Telecommunication | Electronics Engineer | Facilities Engineer
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After implementing the solution, make sure it actually fixed the problem. Monitor the system performance on how well the system works and compare it to how it should be working to be sure the issue is acceptably solved.

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6 Learn from the experience

A control system malfunction can be a valuable learning opportunity for improving your skills and knowledge. You should reflect on the process and outcome of your problem-solving and identify what worked well and what did not. You should also seek feedback from others and apply the lessons learned to prevent or minimize similar problems in the future.

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Ivan Maravilla, ECE

SCADA Engineer | Automation, Control, Telecommunication | Electronics Engineer | Facilities Engineer
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Implement measures to stop the malfunctions, issues from coming back in the future. These include refining procedures, enhancing trainings, preventive maintenance or adding additional protection measures to mitigate risks and ensure the stability of the control system.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Sujeet Gopal

Process Automation | DCS | Honeywell | Yokogawa | ABB
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Documentation and recording the findings could add an added advantage if the same problem comes in future it can be solved without wasting too much time identifying the root cause again and again.

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What do you do if your control system is malfunctioning?

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1 Identify the symptoms

2 Analyze the causes

3 Evaluate the solutions

4 Implement the solution

5 Test the solution

6 Learn from the experience

7 Here’s what else to consider

Control Engineering

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