The plant had an existing ABB MOD 300 distributed control system (DCS), as well as ABB’s System 800xA. System 800xA is built for collaboration in a fully redundant, reliable environment. It provides connectivity to all ABB DCS systems, as well as other ABB and third-party plant systems and applications.
ABB’s proportional integral derivative (PID) controller is designed to regulate the industrial process, reduce production instability and improve operations. To maximize their capital expenditure and identify the sources of the issues that were inhibiting peak performance in their equipment and processes, plant managers decided to invest in ABB Advanced Digital Services powered by ServicePort. ServicePort is a secure, remote-enabled service delivery platform that maximizes the use of limited resources onsite. It provides daily assessments of equipment and process performance by identifying, categorizing and prioritizing Key Performance Indicators (KPIs). Then, ABB experts can help customers find and mitigate productivity variables, ensure maximum performance of their equipment and processes, and achieve higher operational efficiency.
Modern plant control systems integrate tightly with industrial equipment. As a result, a control system includes far more elements than ever before. Control loops are designed to improve quality, performance and production, but 75 percent of process automation causes more harm than good because control is either out of range, manual or actually inducing problems into the process. To monitor their complex petrochemical operations, this producer selected ABB‘s Loop Performance Monitoring Service to identify and provide 24/7 monitoring of control loop performance issues.
The producer had known that they had some control problems but had not known the entirety of the problem. Once ABB’s Loop Performance Monitoring Service was commissioned and the first data collection report completed, results showed that more than 40 percent of loops were operating in manual mode and numerous loops were having control problems. Once repaired, the producer requested that ABB increase the existing maintenance contract to include daily monitoring by two ABB control engineers. The scope of the maintenance contract includes reviewing the tuning parameters and the control structure for the three main plant units.
ABB’s Loop Performance Monitoring Service helped plant managers ensure optimum results from their control system investment. The producers decided that they had received so much value from their investment in ABB Advanced Digital Services, they asked ABB to help them improve petrochemical production at a second location, in Sicily.