Emerson da ABB – Kwatancen Fasaha don Sabunta Tsarin Dijital na Shuke-shuken Sarrafa Tsari
Dalilin da ya sa Zaɓin Mai Kaya Yake Tasiri Kai Tsaye ga Ayyukan Shuka
Shuke-shuken sarrafa masana’antu suna fuskantar muhimmin zaɓi na tsarin aikin atomatik. Yawancin masana’antar sinadarai, petrochemical da tace ruwan sha suna zaɓen tsakanin Emerson da ABB. Dukkan alamu biyu suna ba da ingantattun tsarin kula da sarrafawa. Sai dai kuma falsafar ƙirarsu ta bambanta ƙwarai. Injiniyoyi dole su daidaita kowane tsari da takamaiman manufofin samarwa. Wannan jagorar tana ba da kwatancen fasaha da aka tabbatar a fagen aiki tare da ainihin bayanan aiki.
Tsarin Ginin Kwamandan Tsari – Rarrabuwar Dogaro da Kai vs Sassaucin Haɗaɗɗe
Emerson na amfani da cikakken tsarin DCS da aka rarraba gaba ɗaya don sarrafa ayyukan tsari. Wannan tsari yana daidaita manyan ayyukan ci gaba da ke gudana ba tare da yankewa ba cikin inganci. Ga matatar mai mai ton 200,000 a rana, Emerson DCS yana kiyaye samun aiki kashi 99.999 bisa ɗari a tsawon zagayen watanni 12. ABB kuwa tana amfani da tsarin sarrafawa na hade (hybrid) guda ɗaya. Kwamandan ta suna haɗa aikin PLC da DCS na asali cikin sauƙi. Wata masana’antar sinadarai a yankin Midwest ta rage lokacin sauya batches da kashi 18 cikin ɗari bayan ta koma tsarin ginin ABB hybrid. Saboda haka Emerson ya fi dacewa da sarrafa ci gaba na ruwa, yayin da ABB ta fi kwarewa a ayyukan batch da na sassa dabam-dabam (discrete).
Tsarin Redundancy – Mafi Girman Lokacin Aiki vs Rage Kuɗin Jari
Emerson na aiwatar da cikakkiyar duplex redundancy a dukkan manyan matakai. Kwamandoshi, kayan I/O da na’urorin sauyawar hanyar sadarwa (network switches) duk suna da tsarin madadin biyu-biyu. Wani tashar LNG a Gulf Coast ta samu cikakken rashin tsayawar da ba a tsara ba tsawon watanni 36 a jere ta amfani da cikakken tsarin redundancy na Emerson. ABB kuma na amfani da sassauƙan tsarin redundancy na kayan gini (modular). Shuke-shuke suna sa kayan madadin ne kawai a kan sassa masu matuƙar muhimmanci. Wata masana’antar sinadarai ta musamman a Texas ta ajiye dala 420,000 na Amurka a kuɗin kayan aikin farko ta hanyar zaɓar modular redundancy na ABB a kan zoben taimako (auxiliary loops). Don haka tsare-tsaren da ke da babban haɗari suna fi son Emerson, yayin da ayyukan da ke son rage kuɗi suka fi son ABB.
Daidaita Masana’antu – Ƙarfafa Aikace-aikace na Kowane Alama
Emerson na da rinjayen kasuwa a fannin mai, iskar gas da samar da wuta. Tsarin kulawarsa na TSI turbine supervision yana gano canjin rawar jiki ƙanana kamar 0.1 micron. Wata tashar samar da wutar lantarki ta combined cycle a Turai ta kauce wa lalacewar turbine da darajar dala miliyan 2.7 na Amurka ta amfani da tsarin sa ido na rawar jiki mara waya na Emerson. ABB kuma tana nuna ƙwarewa ta musamman a tace ruwan sha da hakar ma’adinai. Wata ma’adinan ƙarfe iron ore a Brazil ta rage amfani da makamashin motar drive da kashi 14 cikin ɗari bayan ta haɗa ABB VFDs da DCS ɗinta. Bugu da ƙari, ABB na tallafawa sama da tsoffin ka’idojin fieldbus 15, wanda ke sauƙaƙa sabunta tsarin da ke da masu kaya fiye da ɗaya.
Binciken Kuɗin Rayuwar Tsari – Ƙarin Kuɗaɗen Da’a ɓoye a Gyara da Sabuntawa
Kuɗin siyan farko na wakilta ne kawai kashi 30 zuwa 40 cikin ɗari na jimillar kuɗin mallaka a tsawon shekaru 15. Emerson na amfani da software na injiniya na mallakar kamfani don daidaita tsarin. Kuɗin lasisin shekara-shekara ga matsakiyar shuka na kai matsakaita dala 45,000 na Amurka. Sai dai kuma Emerson na isar da kayan gyara zuwa ƙasashe sama da 90 cikin awanni 24. ABB na ginawa dandamominta ne a kan buɗaɗɗen tsarin software. Wata hukumar ruwan sha a Philippines ta ajiye dala 210,000 na Amurka a kuɗin gyare-gyare a cikin shekaru biyar ta amfani da buɗaɗɗen ginin ABB. Ƙungiyoyin cikin gida sun koyi shirin ABB cikin makonni huɗu, yayin da ake buƙatar makonni goma sha biyu don Emerson. Saboda haka shuke-shuke masu kwanciyar hankali na dogon lokaci suna fi son Emerson, yayin da wuraren da ke faɗaɗa suke fi son ABB.
Ka’idar Zaɓi ta Asali – Babu Magani Ɗaya Tilau ga Kowa
Ƙungiyoyin shuka da dama suna kwaikwayon zaɓin mai kaya daga wuraren aiki na abokan hulɗa ba tare da cikakken bincike ba. Wannan hanya sau da yawa tana gaza. Emerson na fifita matuƙar samun aiki (uptime) da saurin tallafin duniya. ABB na mai da hankali kan sassaucin aiki da iya haɗa kayayyakin daga alamu daban-daban. Mafi dacewar zaɓi ya dogara da abubuwa uku: nau’in tsarin samarwa, matakin ƙwarewar ma’aikata, da taswirar faɗaɗa wurin. Zaɓin da aka gina kan bayanai kullum ya fi wanda aka yi bisa kwaikwayo ko ƙirar da aka yi wa kowa ɗaya.
Misalan Aikace-aikace na Gaskiya tare da Tabbacin Lamba
Yanayi na 1 – Faɗaɗa Babbar Matatar Mai Petrochemical
Wata matatar mai mai ton 300,000 a rana a Singapore ta ƙara na’urar petrochemical cracker. Injiniyoyi suka shimfiɗa Emerson DCS tare da cikakken redundancy a dukkan matakan mahimman loops. Suka sanya na’urorin sa ido na rawar jiki mara waya na Emerson a kan famfo 48 da reactoci 12. A tsawon watanni 24 wurin ya rubuta samun aiki na tsarin kula da kashi 99.997 cikin ɗari. Tsayawar aikin tsari ba zato ba tsammani ya sauka zuwa sifili. Matatar ta danganta asarar samarwa da ta guje wa darajar dala miliyan 8.3 na Amurka kai tsaye ga ginin redundancy na Emerson.
Yanayi na 2 – Sabunta SCADA na Shukar Ruwa ta Birni
Wata shukar tace ruwan sha a yankin Midwest na Amurka da ke hidimar mazauna 450,000 tana buƙatar sabunta SCADA mai araha. Wurin ya rungumi ABB hybrid PLC DCS controllers. Ya ci gaba da amfani da duk VFDs ɗin da na’urorin wutar lantarki na da daga masu kaya uku daban-daban. Daidaiton ABB da tsoffin ka’idoji ya ba da cikakken haɗin kai ba tare da an maye gurbin kowace na’ura ba. Aikin ya ajiye dala 680,000 na Amurka idan aka kwatanta da hanyar cire komai a saka sabo. Samun aiki na tsarin ya tsaya a kashi 99.98 cikin ɗari a cikin watanni 18.
Yanayi na 3 – Samar da Batch Flotation a Masakar Ma’adinan Tattarawa
Wata ma’adinan jan ƙarfe a Chile tana sarrafa ton 85,000 na ma’adinai a kullum ta layukan batch flotation. Injiniyoyi suka yi amfani da modular redundancy na ABB ne kawai a kan manyan loops guda huɗu na gauraya da flotation. Suka bar saitunan manual override ga sassa 12 na taimako da ba su da matuƙar muhimmanci. Wannan tsarin ya rage jimillar jarin tsarin kula da kashi 35 cikin ɗari idan aka kwatanta da cikakkiyar redundancy. Muhimman ma’aunin tsaro na tsari sun inganta da kashi 22 cikin ɗari, kuma jimillar kuɗin aikin ya kasance ƙasa da dala miliyan 1.2 na Amurka.
Sharhin Sauye-sauyen Masana’antu
Sabunta tsarin dijital na shuke-shuken sarrafa tsari ba sa ƙoƙarin samun mai kaya guda ɗaya da zai mamaye komai kamar da. Masana’antar na matsawa ne zuwa tsarin atomatik na musamman da aka daidaita da kowane yanayi. Emerson yanzu na inganta dacewar interface ɗinsa na buɗe hanya don haɗa kayayyaki daga masu kaya daban-daban. ABB na sabunta tsarin redundancy mai ƙarfin gaske don masana’antu masu nauyin tsari. A cikin shekaru biyar masu zuwa, zaɓin tsarin hybrid da aka yi niyya zuwa kowane yanayi zai zama ruwan dare. Injiniyoyin da suka kware a dandalin biyu za su fi kawo ƙima ga wuraren aikinsu.
Fang Zekai ne ya rubuta, ƙwararren injiniya da ya mayar da hankali kan sarrafa tsari da tsarin kulawa ga abokan cinikin mai da iskar gas na duniya.
