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

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Presentation on theme: "Khaled Mostafa, ABB Electrical Industries, Nov. 2012. New Trends in process Automation Power of Integration."— Presentation transcript:

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

2 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 errors 2- Get faster action 3- Get more accuracy 4- Insure people and equipments safety INPUTS LOGIC OUTPUTS

3 Process Automation Basics Hard wiring Logic Gates Micro Controller

4 Control Systems / Hard Wiring 24 V 0 V Start S1 Stop S2 Contactor K1 F1 Low Level S10.1 High Level S11.1 Inlet Valve SV1 K1 F1 Run H1 Fault H2 Low H3 High H4 Low Level S10.2 High Level S11.2 T1

5 Control Systems / Hard Wiring

6 The Process Industry Hardwiring

7 Control Systems / Logic Gates 24 V 0 V Start S1 K1 Stop S2 F1 AND OR Contactor K1 S / R Low Level S10.2 High Level S11.2 Inlet Valve SV1 K1 F1 Run H1 Fault H2 Low H3 High H4 Low Level S10.2 High Level S11.2

8 Control Systems / Logic Gates

9 The Process Industry Logic Gates

10 24 V Start S1 K1 Stop S2 F1 Low Level S10.2 High Level S V Contactor K1 Inlet Valve SV1 Run H1 Fault H2 Low H3 High H4 Control Systems / PLC

11 Control Systems / PLC Program

12 Control Systems Low Maintenance Cost

13 The Process Industry Operator Interface

14 Process Industry The Complete package... © ABB Group June 4, 2014 | Slide 14 3BSE en B

15 Process Industry The Complete package... © ABB Group June 4, 2014 | Slide 15 3BSE en B

16 Process Industry The Complete package... © ABB Group June 4, 2014 | Slide 16 3BSE en B

17 © ABB Group June 4, 2014 | Slide 17 Industrial Control Systems Central I/O Signals Cables Field Devices Control cabinets

18 © ABB Group June 4, 2014 | Slide 18 Industrial Control Systems Remote I/O Signals Control cabinets Remote I/Os

19 Industrial Control Systems Field Buses Control cabinets Field Devices

20 o Initial System Cost o Installation Cost o Staff Training Cost o Engineering cost o System cabling cost o Commissioning time o Fault finding time o System extension cost o System modification cost o Integration cost Process Industry Go Deeper in control system evaluation...

21 system, I/O remote I/O fieldbus-bus time I/O signals System I/O Remote I/O Fieldbus-devices today 2000 Industrial Control Systems Technology Trends

22 Reduction of total cost of ownership Customer benefits of field bus technology Design Installation Commissioning Procurement Other studies show savings of 37% when maintenance considerations are taken into account Traditional 4-20mA 14% 26% 53% 7% % of Total cost 11% 17% 3% 44% Field bus 25% Saving =100% Commissioning Testing and commissioning with remote device access Installation wiring effort and marshalling panel Design Simplification of P&ID Simplified documentation Procurement numbers of power supplies EEx i barriers size of the equipment room lighter cable =75% Source: McDermott Engineering

23 ABB Control Systems System Selection

24 800xA - The Power of Integration Key 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 technologies Profibus&HART, Wireless HART, FF, IEC61850 Maintenance Workplace Configuration, monitoring and root cause analysis tools AM Custom built Asset monitors CMMS integration ONE single maintenance workflow from real time condition monitoring to CMMS Calibration integration Device calibration administration

25 The Process Industry Ordinary Controls Process Control Process Control Operations Engineering Traditional DCS/OCS Information Management Asset Optimization Quality Control Systems Programmable Logic Control Advanced Control Motor Control Centers Safety

26 The Process Industry Modern Controls An Industrial IT System Instrumentation & Drives Information Management Asset Optimization Quality Control Systems Safety Motor Control Centers Advanced Control And Industry Solutions Process and Logic Control Operations Engineering

27 The Process Industry Paper Mill / Stock Preparation

28 The Process Industry Power Management System MW Hz kV

29 © ABB Month DD, YYYY | Slide 29 Energy Index Improvement Sugar Industry Khaled Mostafa, Nov. 2012

30 The Energy Index Improvement Potential Areas Steam Generation Steam Distribution Steam Utilization Heat Exchangers Pumps and Fans Control loops & valves

31 The Energy Index Improvement Example Steam Turbines Driving Sugar Cane Mills, Fans and Pumps 30% Efficiency

32 The Energy Index Improvement Steam Turbines in Sugar Mills

33 The Energy Index Improvement Replace Steam Turbines with VSD

34 The Energy Index Improvement Electric Drives Steam Turbines to drive Electric Generators, feeding VSD 45% Efficiency

35 Electric Motors vs Steam Turbines Higher Efficiency Flexible Control Easy Maintenance Use of excess Power Less Footprint, space saving Simple Construction

36 © ABB Group June 4, 2014 | Slide 36


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