Control loop performance optimization for metals manufacturing

ABB Ability™ collaborative digital service that uses continuous data collection and analysis with on-site or remote access to identify, classify and prioritize control loop improvement opportunities specific to metals plants

An ABB analysis of control systems worldwide revealed that up to 75% of a typical plant’s automation investment is not providing benefits. In other words, the systems are not operating as designed or intended.
  • Are the automatic controls at your metals plant switched on?
  • Are your control systems actually causing problems instead of solving them?
  • Does your process automation system operate at maximum potential?

Ensuring that PID control loops are regularly tuned and optimized enables you to use less raw material, reduce energy consumption, increase production, enhance product quality and troubleshoot more rapidly and effectively.

Proactively servicing control loops is just as important as serving your equipment,  though it's not quite as simple as checking physical attributes on a piece of hardware such as a motor. Fortunately, digital technologies gives us new tools which, when combined with proven methodologies and expert guidance, provides for a powerful performance improvement service.
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ABB's approach to control loop tuning

Related resources:
> Download whitepaper
> Download brochure
> Watch video
> Order book

The performance optimization for control loops service is accessed through the ABB Ability™ Collaborative Operations for metals service delivery platform - conveniently deployed on any control system at your location. Data is viewed through a web-based user interface that is easily accessible by customer or ABB personnel.

This service continuously analyzes data to greatly reduce the time and effort needed to identify loop volatility. Data is classified based on specific KPI's to provide a list of issues that are then prioritized based on severity, process area, criticality and/ or financial impact. Problem areas are isolated and disturbance sources, such as dead time, inverse response and outliers, are identified. This analysis helps find the root cause of the problem and trend performance history more accurately, providing actionable information that will reduce process variability.

  • More accurate troubleshooting with configurable KPI's
  • Simplified view of data and analysis
  • Expert analysis helps detect potential problems
  • Critical notifications when it matters most

References

Improving thickness tolerances for a two-stand aluminium cold rolling mill with additional control loops
Loop control and speed cascade control of bar and wire rod mills
  • ABB Ability™ Performance Optimization for control loops has successfully improved the performance of control systems across the globe.

    Many customers have scheduled this service as part of their ongoing annual service agreements, while others have implemented Loop Performance Monitoring to continuously diagnose, monitor and resolve system and process performance issues.
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Partner with ABB to accelerate your digital transformation journey

Getting to the stage where a plant can gain maximum results from digitalization demands planning a business relevant and executable path
Digital transformation in metals industry
Why ABB?
  • Experienced provider OT and IT stack
  • Third party and legacy integration
  • Domain knowledge and metals industry knowledge
  • Efficient transformation projects, focus on ROI
  • New tools such as cloud, analytics
  • Development model with partners to jointly develop solutions

>> ABB references in metals industry

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