Dalilin Da Ya Sa Kashi 72% Na Tsayawar Petrochemical Marasa Tsari Ke Komawa Ga Kayan Sarrafa da Ba Su Dace Ba
Masana’antar petrochemical na aiki awa 24 a rana ba tare da damar tsayawa ba-zata ba. Bayanai na masana’antu daga ayyukan sarrafa kansa 47 na duniya sun nuna cewa kashi 72% na tsayawar da ba a tsara ba suna da alaƙa kai tsaye da rashin dacewar kayayyakin sarrafawa na ƙasashe daban-daban. Kowace tilas tsayawa na haifar da asarar samarwa na sa’o’i 8 zuwa 14. Ga matatar mai matsakaita, abin da ya faru sau ɗaya yana wuce dala $280,000 na kuɗaɗen kai tsaye. Yiwuwar zubewar iskar da ke da haɗari tana ƙaruwa da kashi 41% idan siginar sarrafawa ta sami jinkirin amsawa.
Shekaru goma sha biyar na aiki a fannin injiniya na duniya sun nuna fili wata al’ada. Zaɓen samfuri bisa ƙananan kuɗi yana ta gaza a kai a kai a cikin tsauraran yanayin aiki. Hade-haden na’urorin sarrafawa masu arha suna ƙara yawan gazawar shekara-shekara daga 1.2% zuwa 9.7% a ƙarƙashin yanayin zafi mai yawa da girgiza. A wata masana’anta a Kudu maso Gabashin Asiya, amfani da PLC marasa ƙarfafawa a kusa da murhun cracking ya haifar da tsayawa shida cikin watanni takwas. Yawancin ƙungiyoyin saye suna watsi da sigogin muhalli na shafin aiki a farkon matakan zane. Wannan sakaci yana haifar da haɗurran da ba za a iya gyarawa ba tun kafin a fara shigarwa.
DCS da PLC: Iyakoki Masu Bayyani Bisa Bayanai na Yawan Gazawa da Aiki da Farashi
Injiniyoyin sarrafa kansa da dama suna rikita aikace-aikacen DCS da PLC a cikin sarrafa ci gaba (continuous process). Distributed Control System (DCS) na ƙwarai a manyan raka’o’in aiki kamar distillation da cracking. Dandamalin DCS na kiyaye ƙimar gazawar kayan aiki a ƙasa da 0.8% na dogon lokaci. Suna tallafawa redundancy cikakke 1:1 don sarrafa aiki ba tare da yankewa ba na awanni 24. Amma kuɗin aikin injiniyan DCS yana da kashi 27% ya fi na PLC na al’ada.
Programmable Logic Controller (PLC) ya fi dacewa da ƙananan aikace-aikacen na’ura daban-daban (discrete) masu buƙatar saurin sarrafa lissafi. PLC na sarrafa sigina cikin 10ms ga ayyukan interlock masu matuƙar buƙatar lokaci. Tsarinsu mai sassauci wajen faɗaɗa I/O yana rage kuɗin gina tashoshin taimako da kashi 32%. Saboda haka, tsarin matakai biyu na DCS da PLC a haɗe yana ba da mafi kyawun daidaito tsakanin farashi da amfani ga shuke-shuken petrochemical. Wannan zane yana cika buƙatun tsaro na IEC 61508 SIL 3 da ake wajabta a ayyukan sarrafa kansa na man fetur da gas. Wata matatar kasar Sin da ta rungumi wannan tsarin matakai biyu ta rage kuɗin tashoshin taimako da $210,000 a shekara.
Tsararren Matsayi na DCS da PLC na Manyan Alamu Bisa Bayanai na Shekaru Biyar na Aiki a Filin
Manyan Alamu Uku na DCS Domin Raka’o’in Cracking, Distillation, da Reaction na Asali
Raka’o’in tsari na asali suna buƙatar dandamalin DCS da aka tabbatar da SIL3. Yokogawa CENTUM na gaba da kashi 0.42% na yawan gazawar kayan aiki a shekara bisa bayanai daga ayyuka 47 na duniya. Honeywell Experion na samar da kashi 99.998% na samun tsarin a cikin yankunan da ke da kariya daga fashewa. Siemens PCS 7 na bayar da ingantacciyar damar haɗa na’urorin masana’antu masu alamu daban-daban da ɗaga bayanai zuwa manyan tsare-tsare. Shawara ta aikace-aikace: a guji amfani da Honeywell DCS ga raka’o’in distillation na al’ada. Ƙarin module na tsaro da yake da su na ƙara kuɗin kayan banza da kashi 22% a sassan da ba su da babban haɗari. Wata masana’antar petrochemical a Turai ta ajiye $340,000 ta hanyar zabar Yokogawa maimakon tsarin Honeywell mai ƙayyadaddun tsaro sama da na buƙata domin crude unit ɗinta.
Alamomin PLC da Aka Tabbatar Don Girgiza Mai Ƙarfi da Zafin Muhalli 55°C
Ƙananan bita na taimako a shuke-shuken petrochemical suna fuskantar girgiza na dindindin da matsakaicin zafin muhalli 55°C. Allen-Bradley jerin 1769 na aiki cikin kwanciyar hankali a ƙarƙashin girgizar injiniya ta dindindin har 5G. Schneider M580 PLC na haɗuwa ba tare da tangarda ba da na’urorin kariya na ƙaramin ƙarfin wuta. Mitsubishi FX5U PLC na bauta wa ƙananan ɗakunan famfo da raguwar kuɗin saye da kashi 40%. Dukkan PLC da aka dace su ne dole su tallafawa ka’idojin sadarwa na masana’antu Profinet da OPC UA. Daidaiton ka’ida na hana jinkirin haɗa na’urori masu tsada a wurin aiki. Wata masana’antar iskar gas a Gabas ta Tsakiya ta rage lokacin debugging da kashi 35% bayan ta tilasta amfani da OPC UA a dukkan alamomin PLC.
Ka’idojin Daidaita Tsarin TSI Don Kariya Ga Injin Juyawa
Injin juyawa suna haifar da kashi 38% na duk gazawar kayan aiki a layukan samar da petrochemical. Turbine Supervisory Instrumentation (TSI) na sa ido kai tsaye kan girgiza, karkacewar axial da zafin bearing. Bently Nevada 3500 TSI har yanzu shi kaɗai ne tsarin da ke da ƙudurin aunawa na karkacewar shaft 0.1mm. Yana tayar da kariyar interlock cikin 200ms idan an gano bayanan injiniya marasa daidaito. Kayayyakin TSI na ɓangare na uku suna nuna jinkirin sigina da kashi 29% idan aka haɗa su da manyan dandamalin DCS. Injiniyoyi dole ne su tanadi tashoshin sadarwa biyu masu redundancy tun a matakin zane na farko. Wannan shiri yana kawar da cinkoson sadarwa a lokacin commissioning. Wata matatar mai a Indiya ta kaucewa gazawar compressor da ta kai dala $1.2 miliyan saboda Bently Nevada ta gano karkacewar shaft mintuna 15 kafin a kai iyakar haɗari.
Daidaita Kayan Kare Wuta Don Jure Canje-Canjen Gidan Wuta
Rikice-rikicen wutar lantarki daga grid suna haifar da kashi 21% na faduwar tsarin sarrafa masana’antu a masana’antun sinadarai. Kwararrun relays na kariya suna daidaita bambancin ƙarfin wuta a cikin ±5% na ƙimar da aka ƙayyade. ABB REF615 relays na cimma kashi 99.99% na daidaiton aikin kariya ga dakunan wuta masu ƙarfin lantarki mai yawa. SEL 751 relays na gano matsala cikin 15ms a lokacin tashin ƙarfin wuta kwatsam. Dukkan kayan wuta da na sarrafawa suna buƙatar daidaita lokaci na millisecond iri ɗaya. Ba tare da daidaiton lokaci ba, rikodin jerin abubuwan da suka faru ba su da amincewa don binciken tushen matsala. Bayan shigar da SEL relays tare da daidaita lokaci ta GPS, wani hadadden petrochemical a Thailand ya rage lokacin warware matsala daga awa 8 zuwa mintuna 45 a kowane abin da ya shafi wuta.
Tsare-Tsaren Daidaita Kayan Aiki Biyu da Aka Tantance da Lamba Ga Daban-daban Yanayin Tsari
Tsari Na Ɗaya Don Manyan Raka’o’in Ethylene Cracking Masu Haɗari
Manyan crackers na ethylene suna buƙatar ƙaruwar sahihancin aiki. Honeywell Experion DCS tare da SIS na bayar da sarrafa tsari na asali. Bently Nevada 3500 TSI na sa ido kan duk kayan juyawa gaba ɗaya. ABB relays na ƙarfin lantarki mai yawa da aka haɗa suna kula da kariyar rarraba wuta. Sakamakon aiki na ainihi ya nuna cewa an rage tsayawar da ba a tsara ba a shekara zuwa awanni 0.3. Wata masana’antar ethylene a Malaysia da ta yi amfani da wannan tsari ta kai kwanaki 1,800 ba tare da wata kuskuren aiki na interlock na tsaro ko ɗaya ba.
Tsari Na Biyu Don Tashoshin Taimako na Ruwa Mai Zirkulo Masu Ƙananan Haɗari
Tashoshin ruwa mai yawo a masana’anta na iya jure mafita masu ƙarancin farashi. Siemens S7-1500 PLC tare da modules na decentralized I/O na biyan bukatun sarrafa asali. Bently Nevada 1900 compact TSI na sa ido kan girgizar kayan aiki cikin tattalin arziki. Kayan wutar lantarki masu kaifin basira na Schneider na kare rarraba wuta. Wannan tsari na ajiye kashi 31% na jimillar kuɗin gini yayin da yake kiyaye kwanciyar hankalin aiki. Wata matatar mai a Indonesia ta aiwatar da wannan tsari ga tashoshin famfo ruwa guda shida ta kuma ajiye $470,000 idan aka kwatanta da amfani da cikakken DCS a duk wuraren.
Kuskuren Zaɓe Uku da Ake Maimaikawa da Sakamakon Asarar da Aka Auna
Ƙungiyoyin injiniya suna maimaita kurakuran zaɓen alama guda uku a cikin ayyukan ƙetare ƙasashe.
Kuskure na ɗaya shi ne maye gurbin DCS da PLC don raka’o’in tsari na asali. Yawan gazawa na tashi zuwa 7.8%, yana haifar da awanni 6 zuwa 10 na tsayawar shekara-shekara. Wata matatar mai a Afirka ta rasa dala $1.8 miliyan a shekara guda bayan ta yi amfani da PLC don sarrafa babban fractionator ɗinta.
Kuskure na biyu shi ne amfani da na’urorin TSI na gama gari don manyan turbin na tururi. Rashin samun gargaɗin gazawa tun da wuri na haifar da kusan dala $450,000 na kuɗin gyara a matsakaita. Wata masana’anta a Kudancin Amurka ta biya $620,000 don sauya farfajiyar turbine bayan wani TSI da ba a tabbatar da shi ba ya gaza gano girgizar subsynchronous.
Kuskure na uku shi ne watsi da daidaita ka’idar Ethernet na masana’antu ɗaya tak. Lokacin debugging a wurin aiki na ƙaruwa da kwanakkin aiki 18 tare da mafi girman kuɗin aiki. Gwajin daidaituwar ka’idar sadarwa yana kasancewa dole kafin sayen kayan sarrafawa da yawa. Wata kamfanin EPC na Turai ya rage lokacin commissioning da kwanaki 22 ta hanyar gwada daidaiton Profinet tun a matakin masana’anta kawai.
Alamomin Cigaban Sarrafa Kanshi na Masana’antu ga Petrochemical 2026-2028
Tsarin sarrafa petrochemical na ci gaba da komawa tsarin hadewar gefen na’ura (edge) da gajimare (cloud). Manyan masana’antun DCS da PLC yanzu suna ƙara modules na tattara bayanan edge computing na asali. OPC UA zai maye gurbin Modbus RTU gaba ɗaya a matsayin ka’idar sadarwa ɗaya ta wurin aiki. Hankali mai annabta gyara (predictive maintenance) zai zama na yau da kullum a cikin tsarin TSI. Maganin sarrafa kanshi na alama guda ɗaya daga kasa zuwa sama zai ragu da kashi 26% cikin shekaru uku. Tsararren daidaita alamomi daban-daban (cross-brand hybrid matching) na musamman zai mamaye manyan ayyukan turnkey na petrochemical na ƙasashen waje. Injiniyoyin da suka ƙware wajen haɗa alamomi daban-daban za su samu gagarumin fa’ida a gasa.
Shari’ar Aiki a Fili: Aikin Sabunta Matatar Mai 600,000 Ton a Shekara
Wata matatar mai a Gabas ta Tsakiya ta maye gurbin tsohon tsarin sarrafa kansa na alama guda a 2024. Tsohon tsarin yana haifar da awanni 12 na tsayawar da ba a tsara ba a shekara tare da raunin haɗin bayanai. Maganin da aka inganta ya yi amfani da Yokogawa CENTUM DCS don distillation na man ƙasar. Allen-Bradley PLC ya sarrafa rukunin famfon jigilar mai. Bently Nevada TSI ta sa ido kan duk compressors. SEL relays suka kare rarraba wutar gaba ɗaya ta shuka.
Bayan watanni 12 na aiki, an rage tsayawar da ba a tsara ba daga awanni 12 zuwa awanni 0.6 a shekara. Ingancin debugging a wurin aiki ya ƙaru da kashi 42%. Jimillar kuɗin aiki da kulawa na shekara-shekara ya ragu da kashi 21%. Babu ko ɗaya daga cikin kuskuren aiki na interlock na tsaro da ya faru a duk lokacin. Matatar ta kuma ruwaito gaggawar binciken tushen matsala da kashi 97% saboda daidaitattun timestamps ɗin bayanai a duk na’urori. Wannan shari’a ta tabbatar da cewa daidaitar alamu daban-daban bisa bayanai na zahiri na kawo ribar da za a iya aunawa.
Kammalawa
Zaɓen alamomin kayan sarrafa kanshi na masana’antu na ƙetare ƙasashe dole ne ya dogara da bayanan aiki maimakon suna kawai. Masu zane su rarraba ƙayyadaddun buƙatun sarrafa tsari na asali da na taimako cikin tsauri. Tsarin DCS da PLC matakai-matakai na daidaita tsaro da farashin rayuwar amfani. Daidaita alamomi daban-daban ta hanyar hankali na tabbatar da samun mafi girman ƙima daga sarrafa kansa ga masana’antar petrochemical.
Rubutawa daga Gu Jinghong, injiniyan sarrafa kanshi na masana’antu da ya ƙware a mafita na PLC & DCS ga masana’antar man fetur, gas da sinadarai.
