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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. . .
© ABB Group April 10, 2023 | Slide 14
3BSE053778 en B
Process IndustryThe Complete package. . .
© ABB Group April 10, 2023 | Slide 15
3BSE053778 en B
Process IndustryThe Complete package. . .
© ABB Group April 10, 2023 | Slide 16
3BSE053778 en B
© ABB Group April 10, 2023 | Slide 17
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
© ABBMonth DD, YYYY | Slide 29
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
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