Sabunta Tsofaffin DCS don Hankali a Gudanar da Makamashi: Jagorar Aiki Zuwa Daidaiton Hayaki (Carbon Neutrality)
Tsawon lokaci masana’antu suna dogara da Distributed Control Systems (DCS) don sarrafa tsari masu sarkakiya da ke gudana ba tare da yankewa ba. Saboda bambanci da na’urorin sarrafa tushe, DCS na daidaita daruruwan “loops” da dubban maki na I/O a fadin dukan masana’anta. Amma yawancin tsofaffin dandamalin DCS sun fi bai wa kwanciyar hankalin aiki muhimmanci, ba inganta cinye makamashi cikin sauri da motsi ba. Wannan gibin zane yanzu yana hana masana’antu da dama cimma burin daidaiton hayaki. A matsayina na injiniya da ya sabunta irin waɗannan tsarin sama da 30, ina ganin hanya a fili. Dole mu duba sabunta DCS a matsayin ayyukan ƙirƙira daga tushe masu mayar da hankali kan makamashi, ba kawai sauya kayan aiki na jiki ba.
DCS da PLC – Dalilin da yasa Tsarin Gini na System yake da Muhimmanci don Rage Hayaki
PLC suna da ƙwarewa wajen sarrafa injuna ɗaya-ɗaya da ke aiki cikin sauri. Suna duba lissafi cikin milisakan amma ba su da ginanniyar tsarin bayanai na dukan masana’anta. DCS, akasin haka, yana sarrafa tsare-tsare daga farko zuwa ƙarshe tare da ginanniyar “history” da “sequence of events (SOE)” na ajiya. Wannan tsarin gini yana sa DCS ya dace sosai don inganta cinye makamashi a sassa daban-daban na masana’anta. Misali, DCS zai iya daidaita murhu, “heat exchanger”, da “turbine” a lokaci guda. Cibiyar PLC za ta buƙaci shirin “gateway” mai sarkakiya da daidaita bayanai da hannu. Don haka, idan manufar ita ce rage hayakin masana’antu, sabunta DCS yana ba da fa’idodi masu faɗi kuma masu dorewa fiye da gyare-gyaren da suka takaita ga PLC kaɗai.
Jagorar Fasaha: Koyaushe ku binciki zagayowar duba mai sarrafawa (controller scan cycles) na yanzu. Tsofaffin DCS galibi suna gudana a 500ms ko fiye da hakan a hankali. Don inganta cinye makamashi, ku nufi 100ms ko fiye da haka cikin sauri don “gas flow” da “pressure loops”.
Asirin Kuɗin Injiniya na Tsofaffin Tsarin DCS
Yawancin tsofaffin DCS ba su da tsarin sa ido kan cinye makamashi a ainihin lokaci. Suna adana canje-canjen tsari (PVs) amma ba karfin makamashi da aka ciye a kowane yanki na fitarwa ba. Sakamakon haka, asarar makamashi marar lissafi tana taruwa a tsarin tururi, iska da aka matse, da tsarin dumama. Haka kuma, tsoffin sigar DCS ba sa iya magana kai tsaye da hanyoyin makamashi masu sabuntawa kamar “solar inverters” ko adana makamashi ta batir. Sau da yawa suna dogara da tsoffin “fieldbus” kamar Modbus RTU ko Profibus DP, waɗanda ke da ƙarancin “bandwidth” kuma ba sa ƙunsar ɗaure lokaci (time stamping) don bayanan ingancin wutar lantarki. Wannan ratar haɗin gwiwa na tilasta masana’antu su ci gaba da kona man fetur a matsayin madadin na dindindin. A ƙwarewata, saka “Modbus-to-IEC 61850 gateway” guda ɗaya na iya dawo da damar haɗa makamashi mai sabuntawa, amma masana’antu da dama ba sa lura da wannan sauƙaƙƙen gyara.
Jagorar Fasaha: Duba nau’in katin DCS I/O ɗinku. Katin shigar da siginar analog mai ƙudurin 12-bit na kawo kuskuren aunawa na ±0.5%. Don lissafin hayaki, ku sabunta zuwa katin 16-bit ko 24-bit. Wannan ƙaramin gyara yana inganta rufewar taƙaitaccen lissafin makamashi har zuwa 2%.
Manyan Fasahohi da ke Sauya Sabunta DCS Mai Mayar da Hankali kan Makamashi
Akwai manyan fasahohi uku da ke tafiyar da ingantaccen sabunta DCS don daidaiton hayaki. Na farko, “edge computing”. Sanya “edge node” a kan magudanar mai sarrafawa na aiki da bayanan makamashi a gida. Wannan yana rage jinkiri daga 500ms (zuwa gajimare da dawowa) zuwa ƙasa da 20ms. Aikin gida kuma yana ba da damar gargaɗi a ainihin lokaci idan makamashi ya yi tsalle. Na biyu, “machine learning (ML)” da aka haɗa kai tsaye a DCS. Sabbin masu sarrafawa suna gudanar da ƙananan samfuran ML da ke hango tsalle-tsallen cinye makamashi daga tasgarorin da ke zuwa tun daga baya. Misali, canjin saurin isar da abinci (feed rate) zai iya tayar da gyaran dumama tun kafin tsallen ya bayyana. Na uku, bin ka’idar IEC 61850. Wannan ƙa’ida tana tabbatar da haɗin DCS cikin sauƙi da “smart grid systems”. Tana tallafawa sakonnin GOOSE don saurin rage lodin kaya da MMS don sarrafa tsarin kulawa. Ba tare da IEC 61850 ba, DCS ɗinku zai yi wuya ya yi amfani da makamashi mai sabuntawa idan mitar grid ta yi canji.
Jagorar Fasaha: Lokacin zabar samfuran ML, fara da “regression tree” mai sauƙi. Yana cinye ƙasa da 1% na lokacin CPU na mai sarrafawa. Ku guji “deep learning” a matakin mai sarrafawa; ku tura shi zuwa sabar “edge”.
Hangen Nesa na Injiniya – Gujewa Kurakuran Sabunta DCS da Aka Fi Yawan Yi
Bayan shekaru 15 a fannin sarrafa masana’antu ta atomatik, ina ganin kuskure guda uku da ake maimaitawa a sabunta DCS don daidaiton hayaki. Kuskure na farko: gaggawar sabuntawa ba tare da yin cikakken binciken cinye makamashi ba. Ba za ka iya gyara abin da ba ka auna ba. Ku kashe makonni biyu kuna tattara bayanan DCS na yanzu don gano wuraren da cinye makamashi ya fi yawa. Yi amfani da hakan don fifita “loops”. Kuskure na biyu: rufe dukan tsarin gaba ɗaya don sabuntawa. Maimakon haka, aiwatar da sabunta tsarin a sassa, ta hanyar maye gurbin mai sarrafawa ɗaya-zuwa-ɗaya. Yi amfani da “staging rack” don gwada sabbin modul na I/O yayin da tsohon “rack” ɗin ke ci gaba da samarwa. Wannan yana daidaita ƙirƙira da ci gaba da aiki. Kuskure na uku: watsi da daidaituwar bayanai. Sabon DCS ɗinku dole ne ya iya yin OPC UA ko MQTT don haɗuwa da manyan dandamalin kula da hayaki. Idan mai siyarwa ya nace da wani yarjejeniya ta mallaka kaɗai, ku ƙyale shi. Tsaruka marasa jituwa za su soke ma mafi ci-gaban fasahohin makamashi.
Jagorar Fasaha: Ku kafa “shadow DCS” a layi ɗaya na tsawon wata ɗaya kafin ku yi sauyi gaba ɗaya. Ku kwafi dukkan I/O na samarwa zuwa sabon system amma ku bar ikon sarrafawa a kan tsohon system. Ku kwatanta lissafin makamashi kullum. Ku yi sauyi ne kawai idan kuskuren ya sauka ƙasa da 0.5%.
Manyan Dandalin DCS – Bincike da Kwatanta Fasaha
DCS ɗin DeltaV na kamfanin Emerson yanzu yana ɗauke da kayan aikin sarrafa makamashi da AI ke ƙarfafa. Modul ɗinsa na “Energy Advisor” da aka gina ciki yana daidaitawa da canjin buƙatun samarwa da shigar makamashi mai sabuntawa. DeltaV kuma yana tallafawa CHARM I/O don nau’o’in sigina masu gauraya, yana rage sararin kabad da 40%. DCS CENTUM VP na kamfanin Yokogawa yana haɗa lissafin hayaki kai tsaye a fuskar aiki ta mai kula. Yana lissafa CO2 a kowace “batch” a ainihin lokaci ta amfani da ma’aunin ISA-95 na ma’aunin kayan abu. CENTUM VP kuma yana ba da yanayin “Green Controller” wanda ke iyakance cinye makamashi a hankali lokacin da ƙarfin hayakin grid ɗin ya kai kololuwar mataki. Duka dandamalin suna tallafawa shirye-shiryen IEC 61131-3 (LD, FBD, ST, SFC). Wannan yana da muhimmanci domin injiniyoyin masana’antar ku sun riga sun san waɗannan harsuna. Ku guji sabunta DCS da zai tilasta muku amfani da lambar mallaka ta musamman kaɗai.
Jagorar Fasaha: Ku nemi gwajin “hardware-in-the-loop (HIL)” kafin ku sayi. Ku gudanar da ainihin samfurin tsarin ku a kan DCS da aka gabatar na tsawon mako guda. Ku auna yadda kowanne system ke amsawa ga saukar makamashi mai sabuntawa na gaggawa 20%. Wannan gwajin yana nuna ingancin aiki na gaske.
Misanin Gaskiya na Sabunta Shuka Karfe – Cikakken Bayanin Fasaha
Baoshan Iron & Steel ta sabunta DCS na murhun narkar da baƙin ƙarfe zuwa DeltaV na Emerson. Tsohon system ɗin yana da maki 2,400 na I/O, nauyin mai sarrafawa 78%, da kimar “scan” ta 800ms. Sabuntawar ta haɗa da sa ido kan gudanawar iskar gas a ainihin lokaci ta amfani da ma’aunin Coriolis (4-20mA HART, ƙudurin 16-bit), daidaita zafin murhu ta hanyar AI (samfurin hasashe ana sake horar da shi kowane mako), da kuma sabunta mai sarrafawa zuwa DeltaV M-series, wanda ya rage kimar “scan” zuwa 150ms. Sakamakon bayan watanni 18: an rage amfani da makamashi da 12%, an rage hayakin carbon shekara-shekara da tan 110,000 (8% sama da abin da aka sa a gaba). Nauyin mai sarrafawa ya sauka zuwa 42%, yana barin sarari don ƙarin faɗaɗa a gaba.
Darasin Injiniya: Muhimmin abin da ya sa aka yi nasara shi ne zagayowar sake horar da AI. Masana’antu da yawa suna kaddamar da ML sau ɗaya kuma su manta da shi. Baoshan suna sake horarwa kowane mako ta amfani da bayanan kwanaki 30 na baya. Wannan ya kama tasirin canjin yanayin zafi na yanayi.
Misanin Shukar Siminti – Faɗaɗa DCS na Karɓar Zafin Shara
Wata babbar masana’antar siminti a China ta sabunta DCS ɗinta na Rockwell PlantPAx don haɗa sabon tsarin samar da wutar lantarki daga zafin shara. Tsohon DCS ɗin yana da maki 2,200 na I/O, nauyin mai sarrafawa 85% a kan jerin ControlLogix L6, da ƙarancin “backplane bandwidth”. Sabuntawar ta ƙara maki 380 na I/O da kuma wani mai sarrafawa na jerin L8 da aka haɗa ta EtherNet/IP. Ƙungiyar ta saita DCS ɗin don daidaita murhun siminti, tukunyar zafin shara, da “steam turbine” na 12 MW. Muhimman bayanan injiniya: yanzu ana daidaita yawan iska mai sanyaya tsarin “sintering” bisa matakin ruwa a cikin “boiler drum” (daidaita PID da lokacin sassautawa na sakan 60); sarrafa matsin tururi yana amfani da “cascade loops” (babba: saurin turbine, ƙaramar: bawul na “bypass”); tsarin rage lodi yana sauke nauyin turbine kafin tashin hankali daga murhu. Sakamako: an ƙara samar da wutar lantarki shekara-shekara da 15%, an rage amfani da man fetur, an rage ɓarnar makamashi a “sintering” da 18%. An rage hayakin carbon shekara-shekara da tan 92,000. Nauyin mai sarrafawa L8 yana gudana a 60%, idan aka kwatanta da L6 tsoho a 85% – babban samun kwanciyar hankali ne.
Darasin Injiniya: Koyaushe ku tsara girman mai sarrafawa ku ne don ya tsaya a 60% nauyi a yanayin aiki na dindindin. Wannan yana barin sarari don “algorithms” na inganta makamashi. Tsohon L6 na masana’antar siminti ya yi nauyi sosai, yana haddasa rawar “scan” na ±50ms. L8 ya rage rawar zuwa ±5ms.
Tsarin Dabaru don Sabunta DCS da Ya Mayar da Hankali kan Daidaiton Hayaki
Ina ba da shawarar tsarin injiniya mai matakai huɗu. Mataki na 1 – Taswira: Yi amfani da bayanan “historian” na DCS na yanzu don lissafa yawan cinye makamashi a kowane ton na samfur. Gano manyan masu cinye makamashi guda uku. A yawancin masana’antu, waɗannan su ne murhuna, “compressors”, da tsarin tururi. Mataki na 2 – Haɗin gwiwa da mai siyarwa: Rubuta bayanin fasaha wanda ke buƙatar OPC UA server, IEC 61850 client, da aƙalla ƙudurin analog na 16-bit. Ku nemi sakamakon gwajin HIL a matsayin ɓangare na tayin. Mataki na 3 – Aiwarar da ake yi a hankali: Ku fara da layin samarwa guda ɗaya. Ku shigar da sabon DCS a layi ɗaya. Ku yi aiki da shi na kwanaki 30 da “dual control” (sabon system yana lura, tsohon system ne ke bada umarni). Sannan ku sauya. Mataki na 4 – Binciken makamashi: Ku yi duba lissafin makamashi kowane wata ta amfani da sabbin bayanan DCS ɗinku. Ku kwatanta adadin ajiya na gaskiya da wanda aka yi hasashe. Ku sake daidaita PID loops kowane kwata saboda lalacewar kayan aiki na sauya yanayin tsarin.
Jagorar Fasaha: Yi amfani da ƙa’idar 80/20. 80% na ajiye makamashi na fito ne daga 20% na “loops”. Ku mayar da ƙoƙarin injiniyarku kan manyan motoci, murhuna, da “compressors” na farko.
Hasashen Gaba – DCS a Matsayin Cibiyar Rage Hayakin Masana’antu
A cikin shekaru biyar masu zuwa, gyaran kayan aiki da AI ke hango matsala kafin ta faru (AI-driven predictive maintenance) zai zama ka’ida a DCS. Zai gano raguwar ingancin “compressor” da wuri, ya hana ɓarnar makamashi. “Digital twins” za su bai wa masana’antu damar kwaikwayon sabunta DCS kafin a canza ko da guda daga cikin kayan aiki. Za ku gwada sabon “algorithm” na inganta makamashi a cikin masana’antar kwaikwayo da farko, sannan ku tura shi zuwa ainihin DCS. Bugu da kari, dandamalin DCS za su ƙara haɗuwa da dandamalin sarrafa hayaki na girgije ta amfani da MQTT a kan 5G. Wannan yana ƙirƙirar hangen nesa na rage hayaki daga farko har ƙarshe – daga na’urar auna sigina har zuwa allon tashar dorewar kamfani.
Hasashen Injiniya: Babban ƙa’ida ta gaba ita ce IEC 62443 don tsaron DCS a tsarin sarrafa makamashi. DCS da aka yi masa kutse na iya ƙaga ƙarin cinye makamashi don lalata lissafin hayaki. Ku fara tsara tsaron damar shiga daga nesa tun yanzu.
Yanayin Aikace-aikacen Sabunta DCS (Injiniya-zuwa-Injiniya)
Masana’antar karfe: Sabunta mai sarrafawa daga kimar “scan” ta 500ms zuwa 100ms; ƙara ma’aunin gudanawar gas da ke amfani da sadarwa ta dijital (ba analog ba); aiwatar da “cascade control” don matsin murhu da yawan iskar man fetur.
Masana’antar siminti: Ƙara wani mai sarrafawa na musamman don karɓar zafin shara; yi amfani da I/O na “high-speed counter” don saurin turbine; aiwatar da “feedforward control” daga zafin murhun kiln hood.
Masana’antar petrochemical: Maye gurbin tsohon “fieldbus” da Profinet ko EtherNet/IP; ƙara OPC UA “aggregation layer” don haɗa sassan DCS da dama; tura ML don inganta daidaiton tururi.
Samar da wutar lantarki: Sanya “IEC 61850 gateway” don sadarwa da mai kula da grid; aiwatar da saurin rage lodi (ƙasa da 40ms) idan makamashi mai sabuntawa ya yi canji; ƙara hasashen tsabtace hayakin murhu (predictive soot blowing) don ingancin tukunyar wuta.
Rubutacce daga Song Mingyuan, injiniyan atomatik mai ƙwarewa a PLC, DCS da manyan alamomin sarrafa masana’antu na ƙasa da ƙasa don aikace-aikacen petrochemical.
