1. Khaled Mostafa, ABB Electrical Industries, Nov. 2012
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 equipment’s safety
INPUTS
LOGIC
OUTPUTS

3. Process Automation Basics
Hard wiring
Logic Gates
Micro Controller

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

5. Control Systems / Hard Wiring

6. The Process Industry Hardwiring

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

8. Control Systems / Logic Gates

9. The Process Industry Logic Gates

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

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
April 1, 2017 | Slide 14
3BSE en B

15. Process Industry The Complete package. . .
© ABB Group
April 1, 2017 | Slide 15
3BSE en B

16. Process Industry The Complete package. . .
© ABB Group
April 1, 2017 | Slide 16
3BSE en B

17. Industrial Control Systems Central I/O Signals
Cables
Control cabinets
Field Devices
© ABB Group
April 1, 2017 | Slide 17 17

18. Industrial Control Systems Remote I/O Signals
Control cabinets
Remote I/Os
© ABB Group
April 1, 2017 | Slide 18 18

19. Industrial Control Systems Field Buses
Control cabinets
Field Devices 19

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

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

22. Customer benefits of field bus technology
Traditional 4-20mA
% of Total cost
Field bus
Commissioning Testing and commissioning with remote device access
25% Saving 7%
Commissioning
Installation
Installation wiring effort and marshalling panel 3%
26%
17%
Design Simplification of P&ID Simplified documentation
Design
14%
11%
Procurement
44%
Procurement numbers of power supplies EEx i barriers size of the equipment room lighter cable
53%
This detailed cost study by BP and McDermott engineering company estimated cost savings for fieldbus technology at around 25% over traditional technology.
This is an estimation study based on best practice and accumulated project implementation experience. IT made the following assumptions:
Fieldbus devices had the same functionality as smart devices i.e.
first generation devices.
Non I.S. application.
500m home run cables, 10m drop cables.
1000 Analog transmitters, 100 analog actuators.
1000 status inputs, 500 two state outputs.
Other studies show savings of 37% when maintenance considerations are taken into account
=100%
=75%
Source: McDermott Engineering
Reduction of “total cost of ownership”

23. ABB Control Systems System Selection

24. 800xA - The Power of Integration Key areas for Asset Optimization
CMMS integration
ONE single maintenance workflow from real time condition monitoring to CMMS
Maintenance Workplace
Configuration, monitoring and root cause analysis tools AM
Custom built Asset monitors
Calibration integration
Device calibration administration
Device integration using fieldbus technologies
Profibus&HART, Wireless HART, FF, IEC61850
Understanding condition monitoring of connected devices and equipment
Instrumentation, HV/MV/LV electro systems, vibrations, IT and process equipment
What are the key areas for 800xA Asset Optimization in the big 800xA ”The Power of Integration” picture?
All modern field devices, electrical equipment etc contain (often) very advanced diagnostic information which is needed from a maintenance perspective. ABB offers market leading products in instrumentation and electrification for industrial plants and therefore has a deep knowledge and understading of different type of condition monitoring. This also includes knowledge in condition monitoring of mechanical equipment, process equipment and IT infrastructure equipment.
Fieldbus technology plays an important role in a control system to get access to diagnostic data from field equipment. Traditional hardwired connections limit the amount of diagnostic data that can be used for maintenance analysis.
When the diagnostic/maintenance data is collected 800xA empowers the maintenance users with a specific workplace, the Maintenance Workplace. From this workplace the maintenance users can monitor equipment and make the right decisions based on real-time diagnostic data.
To promote collaboration and and streamline the overall work processes related to maintenance one must connect and share maintenance data between the DCS system and a CMMS system. 800xA Asset Optimization offers a unique level of integration to CMMS (typical MAXIMO and SAP/PM).
Another important part to promote collaboration is integration to calibration systems for calibration of process instrumentation. 800xA supports all required open standards to integrate to a 3:rd party calibration system. There are several systems on the market and customers often have different levels and strategies for calibration.
Finally 800xA Asset Optimization offers a unique possibility combine equipment data and process data to customize any type of condition monitoring. A typical example could be that maintenance interval on an asset is a combination of equipment carachteristics and maybe the outdoor temperature. The AO SDK software enables any type of condition monitoring based on the AO framework. The result is one single way of working for all types os condition monitoring.

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

26. The Process Industry Modern Controls
An IndustrialIT 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
0.0
1.8
2.1
3.3 2.
50.1
1.5
4.8
3.9 MW Hz kV

29. Energy Index Improvement Sugar Industry
Khaled Mostafa, Nov. 2012
Energy Index Improvement Sugar Industry
© ABB
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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
30% Efficiency
Steam Turbines Driving Sugar Cane Mills, Fans and Pumps

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
45% Efficiency
Steam Turbines to drive Electric Generators, feeding VSD

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
April 1, 2017 | Slide 36