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Process control systems

Johno12345
Hi,


I'm looking at some plant in the facility where I work, which uses a significant amount of energy. Some of it needs replacing because its worn out and I think its a good opportunity to look at the process and potentially upgrade the controls with a view to saving energy. 


I spoke to our energy advisor, which didn't give me a great amount of confidence.


It basically consists of systems that cool a liquid (cooling towers), move the product hydraulically, and stir the liquid. In total, there are 15 motors up to about 25kW and it all runs star-delta, manually controlled, part has a thermostat but that brings on the whole plant where only a small part could be on. 


I think a lot could be run with inverters, based on the process temperature and outside temperature, along with other inputs.


This is where it gets beyond me, I can describe how I want it to operate, and what I want to achieve, but all the people I speak to seem to fail to grasp the system as a whole, and can only focus on a tiny part, like 2 or 3 motors or pumps.


I'm obviously looking for a specialist but don't know what they would be called, or where to look. Does anyone know where or who i could speak to? 


Thanks
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  • Former Community Member
    0 Former Community Member
    Hi Jono,


    I note that a BMS system has been recommended below, I don’t think that is the solution that would fit your needs.


    As Dave Z suggests you need to start with a functional design specification (FDS), this should be as detailed as you can make it and needs to describe the process flow and function of the system.


    It does sound like automating the process could not only save energy, if the right selections are made, but it could also improve product quality, plant reliability and diagnostics, and in the long term, reduce costs.


    This is no small piece of work, and as Dave has rather simplistically said a PLC and re-designed control panel are basically what is required.


    However, legislation would dictate that it is slightly more complex, but, don’t be afraid of the legislation, if you embrace it from the start and used the relevant harmonised standards to assist you in your design, the legislatory aspects could be easily resolved.


    You are looking for a. process integrator I would recommend one that is a partner of one of the large controls companies such as Schneider or Siemens, others do exist.


    Then there is also the functional safety aspects.


    If I were better I could be in a position to advise you on this.


    I do though work with a few integrators dotted around the country, some work nationally, some, regionally, some locally.

    If you want to take this forward, then I am more than willing to try and assist, within the limits of my hospital bed!

    (Can’t sleep due to the pain at the moment, hence the crazy hour for the post!)


     By the way, your FDS should form part of your request for quotation (RFQ).


    As I say, if you want more guidance, please let me know.

    It will help me keep my sanity, though I can’t always respond to things immediately.
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  • Former Community Member
    0 Former Community Member
    Hi Jono,


    I note that a BMS system has been recommended below, I don’t think that is the solution that would fit your needs.


    As Dave Z suggests you need to start with a functional design specification (FDS), this should be as detailed as you can make it and needs to describe the process flow and function of the system.


    It does sound like automating the process could not only save energy, if the right selections are made, but it could also improve product quality, plant reliability and diagnostics, and in the long term, reduce costs.


    This is no small piece of work, and as Dave has rather simplistically said a PLC and re-designed control panel are basically what is required.


    However, legislation would dictate that it is slightly more complex, but, don’t be afraid of the legislation, if you embrace it from the start and used the relevant harmonised standards to assist you in your design, the legislatory aspects could be easily resolved.


    You are looking for a. process integrator I would recommend one that is a partner of one of the large controls companies such as Schneider or Siemens, others do exist.


    Then there is also the functional safety aspects.


    If I were better I could be in a position to advise you on this.


    I do though work with a few integrators dotted around the country, some work nationally, some, regionally, some locally.

    If you want to take this forward, then I am more than willing to try and assist, within the limits of my hospital bed!

    (Can’t sleep due to the pain at the moment, hence the crazy hour for the post!)


     By the way, your FDS should form part of your request for quotation (RFQ).


    As I say, if you want more guidance, please let me know.

    It will help me keep my sanity, though I can’t always respond to things immediately.
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