Khaled Mostafa, ABB Electrical Industries, Nov. 2012. New Trends in process Automation Power of Integration.

Khaled Mostafa, ABB Electrical Industries, Nov. 2012.

New Trends in process AutomationPower of Integration

What is Automatic Control ?Definitions

Automatic controls make some automatic actions based on measuring some parameters and referring to pre-defined conditions to:-

1- Avoid human errors2- Get faster action3- Get more accuracy4- Insure people and equipment’s safety

INPUTS LOGIC OUTPUTS

Process AutomationBasics

Hard wiring

Logic Gates

Micro Controller

Control Systems / Hard Wiring

24 V

0 V

StartS1

StopS2

ContactorK1

K1

F1

Low LevelS10.1

High LevelS11.1

Inlet ValveSV1

K1 F1

RunH1

Fault

H2

LowH3

HighH4

Low LevelS10.2

High LevelS11.2

T1

T1

Control Systems / Hard Wiring

The Process IndustryHardwiring

Control Systems / Logic Gates

24 V

0 V

StartS1 K1 Stop

S2F1

AND

OR

ContactorK1

S / R

Low LevelS10.2

High LevelS11.2

Inlet ValveSV1

K1 F1

RunH1

Fault

H2

LowH3

HighH4

Low LevelS10.2

High LevelS11.2

Control Systems / Logic Gates

The Process IndustryLogic Gates

24 V

StartS1 K1 Stop

S2F1 Low Level

S10.2High Level

S11.2

0 V

ContactorK1

Inlet ValveSV1

RunH1

Fault

H2

LowH3

HighH4

Control Systems / PLC

Control Systems / PLC Program

Control Systems Low Maintenance Cost

The Process IndustryOperator Interface

Process IndustryThe Complete package. . .

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3BSE053778 en B

Process IndustryThe Complete package. . .

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3BSE053778 en B

Process IndustryThe Complete package. . .

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3BSE053778 en B

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Industrial Control SystemsCentral I/O Signals

Cables

Field DevicesControl cabinets

© ABB Group April 10, 2023 | Slide 18

Industrial Control SystemsRemote I/O Signals

Control cabinets

Remote I/Os

Industrial Control SystemsField Buses

Control cabinets

Field Devices

o Initial System Costo Installation Costo Staff Training Cost

o Engineering costo System cabling costo Commissioning timeo Fault finding timeo System extension costo System modification costo Integration cost

Process IndustryGo Deeper in control system evaluation. . .

system, I/O remote I/O fieldbus-bus

time

I/O signals

System I/O

Remote I/OFieldbus-devices

today2000

Industrial Control SystemsTechnology Trends

Reduction of “total cost of ownership”

Customer benefits of field bus technology

DesignDesign

InstallationInstallation

CommissioningCommissioning

ProcurementProcurement

Other studies show savings of 37% when maintenance considerations are taken

into account

Traditional 4-20mA

Traditional 4-20mA

14%14%

26%26%

53%53%

7%7%

% of Totalcost

11%11%

17%17%

3%3%

44%44%

Field bus

25% Saving25% Saving

=100%

CommissioningTesting and commissioning with remote device access

CommissioningTesting and commissioning with remote device access

Installationwiring effort and marshalling panel

Installationwiring effort and marshalling panel

DesignSimplification of P&IDSimplified documentation

DesignSimplification of P&IDSimplified documentation

Procurementnumbers of power suppliesEEx i barriers

size of the equipment room lighter cable

Procurementnumbers of power suppliesEEx i barriers

size of the equipment room lighter cable

=75%Source: McDermott Engineering

ABB Control SystemsSystem Selection

800xA - The Power of IntegrationKey areas for Asset Optimization

Understanding condition monitoring of connected devices and equipment

Instrumentation, HV/MV/LV electro systems, vibrations, IT and process equipment

Device integration using fieldbus technologiesProfibus&HART, Wireless HART, FF, IEC61850

Maintenance WorkplaceConfiguration, monitoring and root

cause analysis tools

AM Custom built Asset

monitors

CMMS integrationONE single maintenance

workflow from real time condition monitoring to

CMMS

Calibration integrationDevice calibration

administration

The Process IndustryOrdinary Controls

ProcessControlProcessControl

OperationsOperations

EngineeringEngineering

“Traditional” DCS/OCS

InformationManagement

Asset Optimization

Quality Control Systems

ProgrammableLogic Control

Advanced Control

Motor ControlCenters

Safety

The Process IndustryModern Controls

An IndustrialIT System

Instrumentation& Drives

InformationManagement

AssetOptimization

Quality ControlSystems

Safety

Motor Control Centers

Advanced ControlAnd Industry Solutions

Process and Logic Control

OperationsOperationsEngineeringEngineering

The Process IndustryPaper Mill / Stock Preparation

The Process IndustryPower Management System

0.0 1.8 1.8 2.13.3

2.50.11.54.83.9

MW MWMW MW

MW

MW

MW

Hz

kV

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Energy Index ImprovementSugar Industry

Khaled Mostafa, Nov. 2012

The Energy Index ImprovementPotential Areas

• Steam Generation

• Steam Distribution

• Steam Utilization

• Heat Exchangers

• Pumps and Fans

• Control loops & valves

The Energy Index ImprovementExample

Steam Turbines Driving Sugar Cane Mills, Fans and Pumps

30% Efficiency

The Energy Index ImprovementSteam Turbines in Sugar Mills

The Energy Index ImprovementReplace Steam Turbines with VSD

The Energy Index ImprovementElectric Drives

Steam Turbines to drive Electric Generators, feeding VSD

45% Efficiency

Electric Motors vs Steam Turbines

Higher Efficiency

Flexible Control

Easy Maintenance

Use of excess Power

Less Footprint, space saving

Simple Construction

© ABB Group April 10, 2023 | Slide 36