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by traditional marshalling – are so tightly integrated during design , development , testing and commissioning , simple I / O changes can cause major project delays . However , an innovative technology known as electronic marshalling with characterisation modules ( CHARMs ), removes the complexity of marshalling field wires . CHARMs enable field wiring of any signal type to be terminated in any location . This gives design teams the flexibility to add I / O on demand anywhere in the plant , wherever and whenever it is needed .
Smart commissioning accelerates project timelines
Green steel projects can be delayed by traditional automation system commissioning practices , which involve sequential tasks and manual processes . These include wiring verification , binding , device configuration , loop testing and creating documentation . To make device commissioning faster and easier , and help accelerate project timelines , automation vendors now provide smart commissioning , which reduces trips to the field , eliminates tasks and enables late project changes to be accommodated .
Modern distributed control systems and device management software incorporate functionality that enables improved device binding configuration , testing and documentation , resulting in a device being commissioned in minutes rather than days , thereby shaving weeks off project schedules . Smart commissioning eliminates potential errors by automatically finding and identifying all smart devices , before binding them to the configuration . To further accelerate implementation , the device configuration is pushed to all devices based on preconfigured templates . Testing is easily and safely done from the control room by using digital communication , with no personnel required in the field for confirmation . The use of smart commissioning tools can help manufacturers reduce project engineering hours by up to 40 %, reduce instrumentation and control project schedules by as much as 25 %, and lower total installed costs by up to 40 %.
Digital twins drive operational excellence and process improvements
Green steel manufacturing is one of many industries in which digital twin technology is proving to be a game-changer . A digital twin is a software-based virtual replica of the complete physical assets of a plant , including its control system , process equipment , instrumentation , operator displays and alarms . With this replica , the operation of these assets is modelled and simulated through their lifecycles .
A digital twin provides a highly accurate representation of the behaviour and dynamics of the process , making it an invaluable tool to analyse various ‘ what if ’ design scenarios . It can also validate optimised control and safety schemes , including advanced control models and start / stop procedures .
Running an exact digital replica in parallel with a live green steel plant also creates a valuable means of training control room operators and technicians , familiarising them with the control system and processes before start-up . Digital twins expose personnel to what they will experience in their actual control rooms , but in an offline and risk-free environment , thereby equipping them to successfully control any process upsets or abnormal situations that arise .
When the plant is operational , a digital twin can provide data and insight into equipment and system health , helping plant management to test and improve processes offline , optimise preventative maintenance practices and avoid costly unscheduled downtime . In addition , the accuracy of the digital twin can be constantly enhanced with data taken directly from the process as it becomes available .
36 Green Steel World | Issue 9 | November 2023