Ta Yaya Ake Samun Ingantaccen Kula da Matatar LNG Tare da Dandamalin DCS na Yokogawa?
Matsayin Tsarin Yokogawa a Sabbin Matatun LNG
Wuraren shigo da iskar gas da aka liƙa (LNG) suna aiki ne a ƙarƙashin mawuyacin yanayi. Suna buƙatar daidai-daidaicin kulawa da kariyar da ba ta yarda da kuskure ba. Dandamalin sarrafawa na CENTUM VP na Yokogawa da mafita ta tsaro ProSafe-RS suna bayyana akai-akai a irin waɗannan muhallai. Kididdigar masana’antu na nuna cewa waɗannan tsarin suna sarrafa fiye da kashi biyu bisa uku na ƙarfin karɓar LNG na duniya. Yaduwar da ake amfani da su ta samo asali ne daga ingantacciyar haɗa su da tsarin sa ido na tankuna da kayan sauke kaya.
Gina Tsarin Kula ɗaya (Unified Control Architecture)
Cikakken shigarwa na Yokogawa yawanci yana raba daidaita aiwatarwa (process regulation) daga ayyukan tsaro. Hanyar sadarwa ta Vnet/IP control network tana haɗa masu kula da filin (field controllers), muƙaman masu aiki (operator interfaces), da tashoshin injiniyoyi. Masu kula da tsaro suna sadarwa da DCS ta hanyoyin sadarwa da aka tabbatar. Wannan rabuwar tana tabbatar da cewa ayyukan tsaro ba su shafi abin da ake yi na sarrafa hanya (process control) ba. Haka kuma, tana sauƙaƙa bin ka’ida da takardar shaida.
Sarrafa Muhimman Yankunan Aiki
Matatun LNG suna ƙunshe da sassa da dama masu matuƙar muhimmanci a aiki. Sauke jirgin ruwa yana buƙatar ingantaccen sarrafa injin ruwa (hydraulic) na hannayen lodi. Kwamprisoshin iskar tururi (boil-off gas compressors) dole ne su kiyaye matsin lamba na tanki cikin kwanciyar hankali. Na’urorin dumama (vaporizers) suna buƙatar daidaitaccen daidaita zafin jiki don hana daskarewa. Tsarin Yokogawa yana sarrafa waɗannan ayyuka ne ta hanyar da’irar sarrafawa da aka saita (configured control loops). Bayanai daga filin a matatun da ke aiki suna nuna sarrafa matsin lamba a cikin ±0.2 kPa da kuma riƙe zafin jiki a 1°C sama da ma’aunin daskarewar LNG.
Misalin Aiki: Sabon Matatar (Greenfield) a Indiya
Wani sabon gini a gabar yammacin Indiya ya zaɓi Yokogawa a matsayin babban tsarin kulawa. Shigarwar ta ƙunshi kusan maki 7,500 na I/O a faɗin gonar tankuna, yankin sauke kaya, da layukan vaporization. Injiniyoyi sun haɗa na’urorin auna matakin ruwa na Emerson (radar level gauges) da masu kula da layin marufi na Allen-Bradley ta amfani da sadarwar Modbus. A lokacin gwajin aiki, tsarin ya nuna kashi 99.8% na samun bayanai. Matatar ta kai ƙirar ƙarfin aiki na tan miliyan 5 a shekara cikin ƙasa da watanni biyar.
Dabarun Sarrafa Gonar Tankuna
Tankunan ajiya su ne muhimmin kaya mafi girma a kowace matatar LNG. Sa ido ba kakkautawa kan matakin samfur, rabuwar zafin jiki (temperature stratification), da ƙwayar nauyi (density) yana hana faruwar hadurran “rollover”. DCS na Yokogawa yana haɗuwa da wayoyin auna zafi da aka rarraba (distributed temperature sensing cables) da na’urorin radar daga masu kaya daban-daban. Wani kamfani a Malaysia yanzu yana nuna bayanan bayanin zafin jiki a tsaye da daidaito na 0.5°C a faɗin tankuna 180,000 m³. Masu aiki za su iya gano rabuwar zafi da wuri su ɗauki matakin gyara.
Hanyoyin Saita Tsarin Tsaro
Ka’idar gaggawar kashe aiki (emergency shutdown logic) na buƙatar ingantacciyar amana da saurin aiwatarwa. Dandamalin ProSafe-RS yana aiwatar da ayyuka masu ƙimar SIL3 ga bawulolin keɓewa (isolation valves) da fitar da iskar gaggawa (emergency venting). A wani aikin kudu maso gabashin Asiya, injiniyoyi sun saita lokacin martani na milisakan 500 don yanayin matsin lamba mai yawa. Tsarin tsaro kuma yana mu’amala da na’urorin sa ido na injina Bently Nevada a kan layukan kwampriso. Karatun girgiza sama da 10 mm/s yana tayar da kashe kwampriso ta atomatik, yana hana lalacewar inji.
Binciken Lamari: Shukar Ajiyar Lokutan Ƙoli a Belgium
Wata cibiyar ajiya a Belgium tana aiki da tankuna biyu na LNG masu 50,000 m³ waɗanda ke biyan bukatun lokutan ƙaruwar amfani. Masu aiki sun sha fama da sauyin matsin lamba yayin lodin motocin tanki. Injin iyayen kulawa sun aiwatar da algoridim ɗin feedforward da ke amfani da bayanan saurin lodi daga wurin motocin. Sabon tsarin sarrafawar ya riƙe matsin lambar tanki a cikin ±0.5 kPa na saitin da aka ƙayyade. A sakamakon kai tsaye, ƙona iskar gas (flaring) ya ragu da kashi 85%, wanda ya haifar da ajiya na shekara-shekara na €200,000.
Binciken Lamari: Aiwtar da Digital Twin a Japan
Wata cibiyar a gabar Osaka Bay kwanan nan ta haɗa DCS ɗin ta na Yokogawa zuwa dandamalin digital twin. Samfuran “machine learning” suna nazarin halayen kwampriso suna kuma hango faruwar “surge”. Tsarin yana samar da gargadi na daƙiƙa 30 kafin lokaci game da yanayin “surge” da ke gabatowa. Masu aiki za su iya daidaita aikin kwampriso tun kafin matsala ta faru. A cikin shekara ta farko, wannan damar ta kawar da duk lokacin tsayawar aiki da ya shafi “surge” tare da rage kuɗaɗen kulawa da kashi 40%.
Jagororin Haɗa Tsarin a Aiki
1. Yi ƙididdigar dukkan na’urorin filin: Rubuta kowane na’ura mai auna sigina, bawulo, da mota. Rubuta nau’in hanyar sadarwa da ƙimar SIL.
2. Tsara maimaita hanyar sadarwa (network redundancy): Aiwtar da layukan kwale-kwale (control buses) biyu. Ku raba zirga-zirgar bayanan tsaro daga bayanan aikin hanya (process data).
3. Shirya haɗin na’urorin kamfanoni na uku: Don na’urorin Emerson ko ABB, ku zaɓi ƙofofin (gateways) da suka dace tun da wuri. Ku gwada hanyoyin sadarwa kafin shigarwa a wurin aiki.
4. Ƙirƙiri nunin masu aiki: Ku ƙirƙiri zane-zane masu kama-kama ga duk yankunan aikin tsari. Ku haɗa nunin sauye-sauyen yanayi (trend displays) don mahimman sigogi.
5. Yi kwaikwayo kafin commissioning: Yi amfani da ayyukan gwaji da aka gina a ciki don tantance ka’idoji. Ku yi kwaikwayo akalla kashi 80% na maki na I/O a wajen layi (offline).
6. Ku samar da tallafi a wurin aiki: Injiniyoyinmu suna taimakawa a lokacin kammala commissioning da matakan fara aiki.
Ma’aunin Ayyuka da Aka auna
Bayanai da aka tattara daga matatun LNG da dama sun nuna tsari ɗaya na aiki. Lokutan zagayen sarrafawa (control cycle times) suna matsakaita milisakan 100 a duk shigarwar. Samun tsarin (system availability) ya wuce 99.9% a wuraren da ke da tsarin maimaita na’urori (redundant architectures). Jinkirin sadarwa zuwa PLC na kamfanoni na uku yana ci gaba da kasancewa ƙasa da milisakan 50. Tsarin tsaro da ke da fiye da maɗaukaka 200 na ka’idojin SIL3 sun ba da rahoton rashin duk wani tashin hankali na ƙarya (spurious trips) a tsawon shekaru biyu na lura.
Samun Sassan Gyara (Spare Parts) na Alamu Daban-daban
Ajiyarmu ta ƙunshi kayan haɗi don dandamali na’urar sarrafa aiki da yawa. Muna ajiye module don Allen-Bradley ControlLogix, tsarin sa ido Bently Nevada 3500, GE Fanuc Series 90, Emerson DeltaV, ABB Ability, Honeywell Experion, Siemens PCS 7, Schneider Electric Foxboro, Yokogawa CENTUM, Woodward easYgen, da injin tuki Delta ASD drives. Wannan faɗaɗɗen tsari yana ba da damar gaggawar ɗaukar mataki idan aka samu gazawar kayan aiki a wuraren da ake da kayan kamfanoni masu yawa.
Ƙarfafa Jirgin Gaggawa (Emergency Logistics)
Ƙungiyar tallafin fasaharmu tana aiki ba tare da yankewa ba, sa’o’i 24 a rana, kwanaki bakwai a mako. Idan abokan ciniki suka ba da rahoton manyan gazawar kayan aiki, muna aika kayan maye nan da nan. Abokan jigilar mu sun haɗa da DHL Express, FedEx Priority, da UPS Worldwide. Umarni da aka karɓa kafin 16:00 agogon tsakiyar Turai ana tura su a rana ɗaya. Isarwa zuwa ƙasashen Turai na buƙatar kwanaki aiki ɗaya zuwa biyu. Jigilar zuwa Arewacin Amurka ko Asiya na isa cikin kwanaki aiki biyu zuwa uku. Akwai zabin isarwa a karshen mako ga ainihin yanayin gaggawa.
Sabbin Hanyoyin Fasaha
Dandamalin OMNEXUS na Yokogawa yanzu yana haɗuwa kai tsaye da tsarin CENTUM VP. Wannan haɗin yana ba da damar nazarin hasashe (predictive analytics) ta amfani da bayanan aiki. Farkon masu amfani suna bayar da rahoton gagarumin riba. Wata cibiyar a Japan yanzu tana hango faruwar “surge” na kwampriso da tazara ta daƙiƙa 30 kafin lokaci. Wata matatar tana amfani da samfuran AI don mafi kyawun jera sauyawa na vaporizers. Muna sa ran irin waɗannan damar za su zama al’ada cikin shekaru biyar masu zuwa, wanda zai iya rage lokacin tsayawar aiki na ba a shirya ba da ƙarin kashi 40%.
Tambayoyin da Aka Fi Yi (FAQ)
1. Ta yaya za mu haɗa ƙananan matakan tankuna na Emerson da muke da su zuwa sabon DCS na Yokogawa?
Tsarin Yokogawa na tallafawa Modbus TCP da RTU kai tsaye. Yawancin na’urorin radar na Emerson suna bada fitarwa ta Modbus. Za ku buƙaci ƙaramin “Ethernet switch” don haɗin TCP ko mai juyawa RS-485 don RTU. Injiniyoyinmu na iya samar da takamaiman rijistar mapping da sigogin saitawa.
2. Menene hanya mafi sauri don samun sabon module na I/O na Yokogawa?
Ku tuntuɓi layinmu na gaggawa 24/7 da lambar ɓangaren module ɗin ku. Idan abin yana cikin ajiya, muna tura shi a rana ɗaya ta DHL Express. Abokan Turai yawanci suna karɓar module cikin sa’o’i 24. Isarwa zuwa Arewacin Amurka da Asiya na ɗaukar sa’o’i 48 zuwa 72. Za mu iya shirya isarwa a karshen mako don yanayi masu matuƙar muhimmanci.
3. Waɗanne alamu (brands) na tsarin sarrafa aiki sassan gyararku ke rufewa?
Muna riƙe da ajiya don kusan manyan alamomi ashirin. Waɗannan sun haɗa da Allen-Bradley, Bently Nevada, GE Fanuc, Emerson, ABB, Honeywell, Siemens, Schneider Electric, Yokogawa, Woodward, Delta, da sauran da yawa. Kundinmu ya haɗa da katin DCS, module na PLC, na’urorin sa ido girgiza, na’urorin bayar da wuta (power supplies), da cikakkun injinan tuki (drive units).
