By Levi | 23 November 2020 | 0 Comments
Construction Plan for Intelligent Plant
The construction plan is disassembled as follows：
Details for the construction of intelligent plant are in the picture bellow.
About visualization:
Increasing LO measure points:
All meters should be intelligent, except for meter cannot be intelligent. The following transmitter measure points are suggested: (wired or wireless)
| Objectives of intelligent plant: | ||
| 1 | Intelligent operation and maintenance, with least manpower; automated and unmanned plant as the final goal; maintaining sustainability of production at the lowest human resource cost. | |
| 1 | Confirming application objective and pre-control logic of APC. | |
| 2 | Intelligentization of control-related meters. | |
| 3 | Historical data collection of objective. | |
| 4 | Establishment of pre-control objective’s offline model. | |
| 5 | Estimation and addition of missing meters. | |
| 6 | Confirmation of pre-control logic offline parameters. | |
| 7 | Online debugging of pre-control logic. | |
| 8 | In service. | |
| 9 | Maintenance of APC logic parameters. | |
| 2 | Optimizing process control, outputting the best product at the highest efficiency and lowest cost. | |
| 3 | Process controlled by artificial intelligence to guarantee the best decision for operation, reduce or spare the interaction with operator and notify operator remotely through cellphone to arouse attention and get confirmation. | |
| 1 | Intelligentization of control-related meters. | |
| 2 | Maintaining the data integrity of AMS control meter. | |
| 3 | Completely automated control throughout the whole flow scheme. | |
| 4 | Realization of alarm optimization (1~2 times/hour) . | |
| 5 | Safety interlock system entirely in use. | |
| 6 | Digitization of the whole operating process to fulfill sequence control. | |
| 7 | All manual operation replaced by automated operation. | |
| 8 | Fully accomplishing statebased control. | |
| 4 | Automated start-stop, with few or none interaction with operator. | |
| 5 | Intelligent equipment diagnosis; predictable maintenance; automated adjustment of operating strategy to avoid halt, so as to prolong the life span of equipment. | |
| 6 | Autonomous halt when malfunction occurs and automatic restart when repair is done. | |
| 1 | Data collection in abnormal equipment condition. | |
| 2 | Intelligentization of monitors for equipment abnormality. | |
| 3 | The establishment of network for data backhaul. | |
| 4 | The employment of diagnostic model for equipment malfunction. | |
| 5 | The employment of APP notification system for equipment malfunction. | |
| 7 | Notifying maintenance personnel remotely and immediately through cellphone to arouse attention when malfunction occurs. | |
| 1 | Improvement and supplement of monitoring points for energy consumption. | |
| 2 | Intelligentization of energy consumption monitors. | |
| 3 | Establishment of data backhaul network. | |
| 4 | Storage of database. | |
| 5 | Design of management interface. | |
| 6 | Data presentation. | |
| 8 | Interconnection plant management of optical fiber, electricity, chemical and water consumption/loss. | |
| 1 | Formulation of KPI. | |
| 2 | The integrity of KPI data collection. | |
| 3 | Establishment of data backhaul network. | |
| 4 | Storage of database. | |
| 5 | Design of management interface. | |
| 6 | Data presentation. | |
| 7 | The employment of APP notification system for KPI data. | |
| 9 | The realization of all the analyses of production status, operation and process, KPI, OEE and suggestions displayed on the instrument screen being sent to cellphones as notifications. |
About visualization:
Increasing LO measure points:
All meters should be intelligent, except for meter cannot be intelligent. The following transmitter measure points are suggested: (wired or wireless)
- To fulfill entirely automated control of the plant, all valves should be automatic. (feedback device can be employed for the valves which cannot be intelligent or are too expensive to be intelligent )
- For traditional designs of transmitter which are not designed to be intelligent, manual patrol and record are needed. ( These non-intelligent designs should be applied to conditions such as long path, high position, place out of reach or leak risk existing preferentially)
- Measure points for equipment which are not important to the control system of the plant and ignored in traditional design, but closely related to the maintenance of intelligent devices, such as important pumps, important compressors, pipeline of easy corrosion for transporting acid or alkalic material, semi-finished product tank, finished-product tank and blower, should be set up.
- Measure points beneficial to the stability of process monitoring, such as voltage of electrolyzer, heating furnace, boiler, temperature of reaction still and freezing water pipe, should be set up.
- A flattening wired network, integrating all systems (DCS, SIS...) the plant uses into a whole system, should be built to lay the foundation for the unified database in the future.
- Considering that the measure points set up in the first place may be imperfect, the complete coverage of wireless network is suggested to prepare for the possible addition of measure points in the future. Among which, wireless network of instruments (WirelessHART) can be supplied by Emerson, while as for wireless network for intelligent petrol and maintenance of the plant, WIFI established by Emerson or 4G may be the choice.
- The system must be equipped with all tools need to realize alarm management, optimizing control, automated start-stop, data interchange with up-layer database and management of intelligent meters.
- Seamless integration with other subsystems (package excluded) must be accomplished to reduce data island.
- Process database and equipment database must be set up.
- APP for diagnosing condition of equipment can predicate the healthy level of equipment and output alarm information, based on process data and equipment data.
- Advanced control servers are employed to optimize production management.
- Servers for mobile information pushing are employed to notify conditions of process control and equipment healthy level.
- DMZ area must have the ability to prevent the whole network from virus attack and hacker attack, so as to secure the network.
- Energy management system
- KPI presentation system
- KPI pushing system
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