Session Type: Paper
Paths(s): Technician Management Executive Engineer Academia/R&D/Scientist
In this paper session, industry experts will discuss the leveraging of technology and services to improve overall plant performance. Areas of focus include process automation system support services, intelligent device enabled asset monitoring, and real-time energy demand management.
Analysis from a number of automation systems in multiple industries indicate that up to 75% of the automation investment is not providing benefit and is often creating process problems instead of solving them due to the lack of a comprehensive modern service program. No longer is service limited to mechanical devices. As automation improves and industrial plants become more integrated, the need to expand the definition of service to include the automation systems and process applications is required. ABB is an industrial automation solution provide and delivering solutions to such industries as pulp and paper, oil and gas, minerals and mining, power, and marine and turbo for years. As a result of our experience we have noticed significant trends in services needed to extend the life cycle of an automation system as well as improving the performance of those solutions. We now have over 1000 years of service activity recorded and are able to define service distribution models that address today's service requirements regardless of the manufacturer. This paper highlights these service models with consideration of preventive maintenance, reactive maintenance, and optimization (process) maintenance. Today's service requires advanced solutions based on the latest technology coupled with proven methods to ensure the optimal distribution of service effort.
Asset monitoring sources include IT, control systems, process equipment, and field instrumentation. Smart instrumentation for measurement of process variables alone is archaic. Intelligent device integration provides greater flexibility and process intimacy for decision support resulting in safer, more reliable, and optimized processes at lower cost. This session will present strategies that leverage the rich information embedded in intelligent devices to improve plant safety and performance.
Many companies incorporate sustainability goals into their core corporate objectives. After upgrading lighting and installing VFDs, industrial facilities are seeking other ways to reduce utility spend, without impacting production throughput. While large energy efficiency gains may be difficult to achieve without an overhaul of a manufacturing process or upgrading equipment, reducing peak electrical demand, which accounts for a significant portion of the overall industrial electric bill, is possible with a supervisory energy management system. This presentation will discuss the benefits of automating the facility’s use of energy, specifically electrical demand, to reduce peak demand charges, automate demand response participation and react to real time pricing changes.
A demand management system allows the real-time use and price of energy and demand to be a factor in production decisions, enabling a facility to control their energy costs. A successful demand management system must be designed to leverage and extend the capabilities of existing automation infrastructure within a facility. The system must integrate with existing systems in such a way that there is minimal or no impact to production throughput and no compromising of product quality or safety.