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The use of DCS process alarm classification control plays a crucial role in the safety of the site. According to relevant data surveys, the selection of alarms has a significant impact on the level of alarm safety factor. When using this technology, attention should be paid to the selection of alarms. 

This article proposes several principles for selecting alarms through the study of different control systems, ensuring that alarms can fully play their role in the system.

The hierarchical control technology can ensure that alarms in different areas are independent. Different alarms are used for alarm monitoring in each area, which can ensure timely alarm in case of abnormal situations within the detection range to attract the attention of operators.

DCS process alarm classification control technology can effectively improve the safety of the operation site, effectively ensuring the safety of construction personnel and enterprises. This article is based on the concept and characteristics of DCS, and studies the application of toxic and harmful gas alarms and key operating parameter alarms, in order to provide reference for scholars in this field.

1. DCS multi-layer hierarchical control system

The basic design concept of DCS is to adopt the idea of decentralized control, centralized operation and management, and achieve a multi-level hierarchical control and cooperative structure. At present, it is mainly used in fields such as metallurgy, power, and petrochemicals.

DCS is a system that implements multi-layer hierarchical control, which has two basic hierarchical links during use: on-site control unit and operation station.

DCS basic grading process

● On site control unit:

A control system that is used near the site and is far away from the control center, and can monitor and control the site based on the DCS’s own structure. The use of on-site control units requires the preparation of different devices, such as configuration plugins, which are configured according to the requirements of the system with corresponding central processing unit plugins, power plugins, and communication plugins, laying the foundation for later hierarchical control;

Redundancy configuration is one of the important links in hierarchical control systems, and during the configuration process, it is necessary to implement redundant configuration for host plugins, power plugins, and communication plugins; Implementing on-site hierarchical control and monitoring requires adding DCS to different hardware to ensure the reliability of hierarchical control.

● Operation station:

The operation station records and displays different data in the control system, which is a place for displaying human-computer interaction. Commonly used operation stations include host control, display devices, and keyboard input devices, which are mainly used for manual operation recording and feedback. It mainly realizes various important functions such as displaying different data, alarms, and operations.

2. Application of DCS process alarm classification control technology

Toxic and harmful gas alarm

Through the study of different DCS process alarm classification control technologies, it has been found that the DCS devices used in current on-site work mainly detect and alarm toxic, harmful, and flammable gases. When these gases are detected, an alarm will be triggered. The alarms on the market have diverse characteristics, and to ensure the normal operation of DCS, standardized alarms should be used.

In the process of selecting alarms, the following rules should be noted:

● It must be able to provide power supply for monitoring toxic and harmful gases and other connecting components;

●Being able to emit appropriate alarm signals after detecting toxic and harmful gases until someone discovers them, greatly improving the effectiveness of the alarm function;

●The range of combustible gas monitoring should be within the normal explosion range;

●Adapt to the concentration and measurement range of toxic and harmful gases, ensuring the detection of harmful gases within the normal range;

●Indicating alarm equipment is quite important and the key to determining whether it can alarm correctly. In the process of selection and purchase, alarm equipment with fire protection and interlocking protection functions should be selected;

●The alarm should have independent monitoring and alarm functions, ensuring that each alarm only monitors toxic and harmful gases within its scope of responsibility;

●The installed alarm should have a continuous alarm function. If toxic and harmful gas leaks are found during use, the alarm function should be activated. When the concentration decreases, the alarm also needs to continue to sound to ensure timely detection of toxic and harmful gas leaks.

Alarm is the key to alarm classification control technology. In the use of modern DCS process alarm classification control technology, responsible personnel can select and use alarms based on the above principles to ensure the safety and standardization of the control site.

Key operating parameter alarm

Each parameter in the DCS process alarm classification control technology using computer control systems needs to be strictly set and controlled. If the parameters are too high or too low, it will cause incalculable losses to the site. It is required to achieve the accuracy and standardization of alarm parameters through strict data analysis when setting alarm parameters.

When setting the alarm mode, a pop-up window or voice alarm can be used to effectively increase the attention of staff, provide the best solution time for staff, and avoid more serious accidents and losses.

Pop up alarm mode

When setting up pop-up alarms, the operator achieves the accuracy of the alarm process through on-site monitoring and control. The pop-up window should be set in the center position of the control display page, making it convenient for the staff to pay attention to the location of the alarm and the direction of the problem at the first time, providing more preparation time for the operator to effectively solve the problems that occur during the process;

● Voice alarm method

The use of voice alarm function requires staff to record the voice alarm in advance according to possible situations on site, and play the alarm information through the computer’s voice output function.

1. The new generation of electromagnetic flowmeter product portfolio simplifies the original product series, dividing ABB electromagnetic flowmeters into two powerful categories: ProcessMaster and AquaMaster

2. The new ProcessMaster and AquaMaster product lines integrate high performance, modularity, and IoT connectivity capabilities, optimizing the choices of industrial and utility customers

3. The new product line will ensure customers’ future investments, and existing devices can be directly upgraded and connected to various latest IoT environments on the provided module upgrade path without the need for large-scale reinvestment

ABB has launched a new generation of electromagnetic flowmeter product portfolio, bringing high-precision, high connectivity, and high flexibility flow measurement experience to utility and industrial applications. This product portfolio strategy simplifies the electromagnetic flowmeter product portfolio, divided into two categories of powerful ProcessMaster and AquaMaster products. These products integrate high performance, modularity, and IoT connectivity capabilities.

Ms. Han Meina, Global Head of ABB’s Measurement and Analysis Instrumentation Business Line, said, “Customers expect us to continuously expand the functionality and performance boundaries that instrumentation can provide. By integrating high-performance, modular, and IoT connectivity capabilities, we redefine our electromagnetic flowmeter products based on customer expectations, ensuring that they achieve high precision, high connectivity, and high flexibility in various applications

The new ProcessMaster series is suitable for flow measurement applications “inside” industrial and utility factories, while the AquaMaster series is designed for “outside” facility applications in factories, providing excellent measurement accuracy in water distribution and trade metering.

Modularity is key to the new product portfolio, stemming from ABB’s commitment to providing sustainable and future oriented solutions and “reducing waste” for customer operations and ABB’s own operations. All models in the new flowmeter series come from a common technology platform, allowing customers to seamlessly switch transmitter and sensor combinations, customize communication options as needed, simplify the upgrade process, while maintaining backward compatibility with the previous generation of electromagnetic flowmeters. Overall, modularity enables customers to adapt to constantly changing technological environments and operational requirements without the need for major maintenance. This reduces overall cost of ownership and extends the product lifecycle.

The IoT connectivity feature has been embedded in all new flow meter models. Users can choose high-speed communication options based on factory on-site measurement or remote applications to enhance the application performance and control of flow meters, strengthen data analysis and process control.

The new ProcessMaster and AquaMaster production lines also adopt intelligent new manufacturing methods, which can shorten delivery time.

The ABB Process Automation Division provides automation, electrification, and digital solutions for industrial operations, meeting a wide range of user needs from energy, water, and material supply to product manufacturing and transportation. With advanced technology and service expertise, the ABB Process Automation Division’s approximately 20000 employees worldwide are committed to helping customers in process industries, hybrid industries, and maritime industries improve operational performance and safety, empowering a more sustainable and efficient future.

ABB is a technology leader in the field of electrical and automation, committed to empowering a more sustainable and efficient future. ABB integrates engineering experience and software technology into solutions to optimize manufacturing, transportation, energy, and operations. With over 140 years of outstanding history, ABB’s approximately 105000 employees worldwide are dedicated to driving innovation and accelerating industrial transformation. ABB has comprehensive business activities in China, including research and development, manufacturing, sales, and engineering services, with approximately 30 local enterprises and 15000 employees in nearly 130 cities. Its online and offline channels cover approximately 700 cities across the country.

1. Heavy display of ABB’s latest robots, frequency converters, and high-efficiency motors, with multiple new products welcoming their debut and debut

2. Jointly released the latest industry white paper with Porsche Consulting, providing insights into the future trends of the consumer electronics market

3. Rich booth live streaming activities and prize winning interactions bring immersive experiences to both online and offline audiences

From September 24th to 28th, the 24th China International Industrial Fair will be held at the Shanghai National Convention and Exhibition Center. ABB will showcase its latest industrial robots and the next-generation robot control platform OmniCore at booth E001 in Hall 8.1 and booth B171 in Hall 6.1 ™、 Dozens of innovative products, services, and solutions such as cloud drives, frequency converters, high-efficiency motors, and servo motors will be released, and industry white papers will be released to support users in various industries to accelerate transformation, upgrading, and sustainable development.

This year marks the 50th anniversary of ABB’s robot innovation journey. At this milestone, ABB will introduce multiple new products, technologies, and applications, and release the GoFa ultra high precision feature options for collaborative robots, modular large robots IRB 7710 and IRB 7720, showcasing the new generation of robot human control platform OmniCore ™ All members, the fusion of two ABB robots and the flexible track system of B&R ACOPOStrak, vividly interpret the core theme of “being a robot, but also infinite possibilities”. Among them:

1. The newly launched Ultra Accuracy leading feature will provide excellent operational accuracy and speed for the ABB GoFaTM collaborative robot series. Compared with other collaborative robots on the market, its path accuracy has increased by more than 10 times, supporting precision manufacturing in the electronics, automotive, aerospace, and metalworking industries.

2. ABB’s new generation robot control platform OmniCore, with a research and development investment of 170 million US dollars ™ Provides a faster, more precise, and sustainable intelligent automation platform, with a 25% increase in operating speed and a 20% reduction in energy consumption compared to previous ABB controllers. This architecture will realize the comprehensive integration of artificial intelligence, sensors, cloud computing and edge computing systems, and create advanced and autonomous robot applications.

3. ABB’s new IRB 7710 and IRB 7720 series of large robots provide unprecedented flexibility, including 16 models that are widely suitable for high load assembly and high-precision applications. They can efficiently handle various application processes in the production of electric vehicles, hybrid vehicles, and traditional vehicles, including stamping, body in white, electric vehicle battery assembly, and vehicle final assembly, and can save up to 30% of energy consumption.

On the first day of the CIIE, ABB Robotics will join hands with Porsche Consulting to jointly release the latest industry white paper on site, insight into the future trends of the consumer electronics market, and reveal the revolutionary application of robot technology in the field of surface treatment. ABB Robotics will also lead everyone to visit the nearly 800 square meter ABB Robotics exhibition hall through rich live streaming activities, watch new product releases and expert interpretations, and bring limited time discounts and surprise gifts to online users through live streaming sales.

The Profinet to CANopen gateway (NY-N831) is like a silent bridge that tightly connects the various parts of the smart stage. It cleverly leads the SE-C series stepper drivers, which were originally limited to CANopen communication, onto the stage of Profinet networks, bringing unprecedented vitality to stage control.

In the weaving of the configuration process, the first step is to carefully select a suitable gateway. This is like selecting a reliable guide, ensuring that it is proficient in the CANopen protocol of the SE-C series stepper drive and coexists harmoniously with the Profinet network on site. Subsequently, through the delicate delineation of hardware connections, the CANopen interface of the SE-C series stepper driver was tightly connected to the gateway, like blood vessels, and the Profinet port of the gateway was cleverly integrated into the Profinet bus of the stage.

Parameter configuration is a carefully planned ceremony. The IP address of the Profinet to CANopen gateway (NY-N831) serves as its unique identifier, ensuring smooth communication in the Profinet network. The detailed adjustment of CANopen network parameters, such as baud rate, node ID, etc., needs to be coordinated with the settings of the SE-C driver, like a harmonious symphony. In the Profinet network, we carefully weave device description files (GSDML files) to enable PLCs or control systems to accurately identify gateways and their connected drivers.

The configuration of PLC or control system is like giving soul to the intelligent stage. Add Profinet to CANopen gateway (NY-N831) devices to PLC or control systems, perform necessary I/O mapping, and then write control logic according to stage control requirements, allowing drivers to perform brilliant dance steps on stage.

In the parameter mapping process of Profinet to CANopen gateway (NY-N831), we ensure that the data objects of the CANopen driver, such as position, velocity, acceleration, etc., are mapped onto the Profinet network like threads, so that the PLC can send precise control commands, like a conductor’s baton, guiding every rhythm of the stage.

During the testing and debugging phase, we act like lighting technicians on stage, powering on all devices and checking if the gateway has successfully registered with the Profinet network. Perform basic motion tests, such as starting, stopping, and positioning movements, to ensure that motion control is as exciting as expected. Based on the test results, we are like a stage manager, finely adjusting every detail until we achieve optimal performance.

In the long journey of monitoring and maintenance, we are like guardians of the stage, continuously monitoring the status of gateways and drivers, conducting timely maintenance and troubleshooting, ensuring that the system operates like an evergreen tree and runs stably for a long time.

Through the careful weaving of the above steps, the SE-C series stepper driver is able to fully demonstrate its charm in the Profinet network environment, achieving automated control and efficient operation of the intelligent stage, just like a dancer dancing gracefully on the stage, showcasing unparalleled brilliance.

ABB has released a report exploring carbon capture, hydrogen energy, and electrochemistry as the main decarbonization pathways in steel production. This report focuses on the innovative methods and new technological developments in fossil free steel achieved by Brazil, China, India, Sweden, and the United States, including insights from leading global steel manufacturers such as SSAB, Tata Steel, and Aperam, as well as experts from the American Steel Institute and ABB.

The steel industry accounts for approximately 8% of global energy demand and produces 7-9% of global carbon dioxide emissions, with the majority coming from coal combustion. The new report by ABB titled ‘The Development Path of Fossil Free Steel – How to Achieve a Sustainable Future’ explores the current decarbonization challenges, including the cost and complexity of transitioning to low-carbon technologies and accessing hydrogen energy, clean electricity, high-grade iron ore, fossil free carbon, and lime.

The current steel production is a carbon and energy intensive industry, classified as one of the six “difficult to decarbonize” industries. In order to achieve the climate change target set by the United Nations’ Paris Agreement of keeping global temperatures within 1.5 ° C of pre industrial levels, the steel industry must achieve net zero emissions by 2050. This requires a thorough transformation of the steel industry, especially against the backdrop of an expected 30% increase in global steel demand during the same period.

This report introduces the actions that steel producers can currently take to reduce carbon emissions in the short to medium term, as well as the steps they can take to collaborate with industry suppliers and partners towards a fossil free steel future.

Regulatory, commercial, and social drivers are accelerating the decarbonization process in the steel industry, “said Frederik Esterhuizen, Global Head of ABB’s Steel and Nonferrous Metals business.” However, in order to address the core challenges mentioned in ABB’s report and gradually phase out fossil fuels, the steel industry needs strong comprehensive solutions and collaboration at all levels of the global steel supply chain to achieve success”

Through cooperation, a digital, autonomous, and fossil free steel industry can be achieved. ABB is adopting a collaborative and cooperative approach to integrate innovative technologies with ABB’s existing product portfolio for the steel industry. Throughout the world, the steel industry is committed to achieving a sustainable future, and multiple promising technologies are being implemented. Through innovation and cooperation, the future of green steel is promising.

• ABB Ability ™ The leadership of the Genix APM suite has earned ABB recognition as a leading provider of Asset Performance Management (APM) solutions
• Verdantinx analysis report documents ABB’s progress from challenger to industry leader in just 12 months
• This recognition highlights ABB’s continued investment in digital innovation and commitment to the development of APM solutions

ABB was recognized as a leader in the Asset Performance Management (APM) solution report for the Verdantinx Green Quadrant in 2024, which evaluates software suppliers across 18 competency areas and nine strategic success factors.

Verdantinx has placed ABB in the leadership quadrant, recognizing the advanced features and strategic advantages provided by its solutions. ABB is also recognized for its interoperability, expertise, and ability to integrate third-party systems.

ABB’s promotion from challenger to industry leader is also attributed to its successful integration of first principles models with advanced artificial intelligence capabilities to enhance asset health and fault prediction. ABB is also heavily investing in several innovative projects that are currently under development, such as developing in the fields of automation and artificial intelligence to create dynamic Failure Modes, Utility, and Criticality Analysis (FMEA), Effects and Criticality Analysis, Abbreviated as FMECA, digital twin extension, and Genix APM Copilot based on generative artificial intelligence.

These advancements will accelerate the deployment of asset maintenance management software, shorten the time to deliver value, improve user experience, provide richer scenario based support, and support safer and more sustainable operations.

The Verdantinx report particularly emphasizes ABB’s “market leading platform development capabilities and robust data management support,” giving the Genix APM platform and suite the highest score of 3.0 for the development environment provided.

Stacey Jones, Portfolio Manager of ABB Energy Industry APM, said, “Asset intensive industries are facing multiple pressures, and the evolution towards predictive maintenance solutions is the trend. Verdantinx believes that this is the strongest growth area before 2030 ABB adopts a modular APM approach, which enables us to meet the various needs of our customers, regardless of their asset management level, as we can gradually expand our corresponding capabilities. Verdantinx’s recognition demonstrates our continuous efforts to provide leading APM solutions, optimize asset performance and operational efficiency, and support our customers on their journey towards digital transformation, energy management, and sustainable development.

Verdantinx also recognizes ABB’s powerful asset health workflow, which can provide asset health management above market average, including comprehensive tracking of asset health and performance, predicting failures, and providing recommendations for equipment maintenance. In addition, ABB has performed well in utilizing pre built libraries and AI based analytical capabilities, providing in-depth insights into asset health.

ABB’s flagship digital energy management and optimization system, ABB AbilityTM OPTIMAX ® The latest version of can achieve coordinated control of multiple industrial assets and processes, improve energy efficiency, and reduce pollutant and carbon emissions.

Upgraded ABB Ability ™ OPTIMAX ® 6.4 will feature artificial intelligence modules that can enhance the accuracy and precise coordinated control of multiple assets in industrial sites and hybrid power plants.

This digital energy management and optimization system unlocks the efficiency password of multi user, multi energy forms of industry, reducing the cost and emissions of complex systems.

Modular systems are easy to install and can achieve automated and semi automated software updates and upgrades.

ABB launches ABB Ability ™ OPTIMAX ® 6.4 version, which is the latest version of its flagship digital energy management and optimization system, can achieve coordinated control of multiple industrial assets and processes, improve energy efficiency, reduce pollutant emissions and carbon emissions.

The performance and availability upgrades of OPTIMAX include an AI module that can enhance predictions of load demand, energy production, and energy prices without the need for manual intervention. This will significantly improve the accuracy of daily and mid day predictions when power plants supply power to the grid, helping to avoid fines or other penalties that may arise due to failure to supply power according to predictions.

“At ABB, we believe that the greenest energy is unused energy, so improving efficiency throughout the entire energy value chain is crucial,” said Dr. Sleman Saliba, Global Energy Efficiency Management and Optimization Product Manager at ABB Energy Industry. “OPTIMAX aims to accelerate industrial carbon reduction by upgrading and incorporating the latest technologies, targeting the latest market opportunities, to help protect resources, integrate and optimize energy systems, industrial sectors, and energy utilization methods, and promote more efficient, environmentally friendly, and sustainable energy conversion and utilization.”

The latest version of OPTIMAX combines digital technology and modular solutions, simplifying user interface presentation and providing an updated optimized environment to address energy management challenges faced by industrial enterprises and energy suppliers. In a complex thermal power plant in Germany, OPTIMAX saved an additional 1.5% in energy costs in the first six months, achieving a one-year return on investment for customers.

At present, industry accounts for about a quarter of global energy related carbon dioxide emissions, and ABB is continuously expanding the areas served by OPTIMAX to accelerate industrial carbon reduction. At present, OPTIMAX has helped operators in various fields, including heating and power generation, green hydrogen, electricity to X, carbon capture and storage (CCS), wastewater treatment, electric vehicles, regional heating and cooling, improve energy efficiency through strategic planning of energy flow and asset utilization.

In addition, the modular design of OPTIMAX makes it easy to install, and each component can be ordered separately. Modular platforms support automatic and semi-automatic updates and upgrades.

By combining Power Process Management (PMS), Advanced Process Control (APC), and Digital Twin technology, ABB provides the entire value chain solution from front-end engineering design (FEED) to operations and services for industries including power generation, oil and gas, chemical, and hydrogen.

ABB Process Automation Division provides automation, electrification, and digital solutions for industrial operations, meeting a wide range of user needs from energy, water, and material supply to product manufacturing and transportation.

With advanced technology and service expertise, ABB’s Process Automation Division has approximately 21000 employees worldwide dedicated to helping customers in the process industry, hybrid industry, and maritime industry improve operational performance and safety, empowering a more sustainable and efficient future.

ABB is a technology leader in the field of electrical and automation, committed to empowering a more sustainable and efficient future. ABB integrates engineering experience and software technology into a solution to optimize manufacturing, transportation, energy, and operations. With a history of over 140 years of excellence, ABB’s approximately 105000 employees worldwide are dedicated to promoting innovation and accelerating industrial transformation.

ABB has comprehensive business activities in China, including research and development, manufacturing, sales, and engineering services. It has about 30 local enterprises and approximately 15000 employees in nearly 130 cities, with online and offline channels covering approximately 700 cities nationwide.