The digitalisation of an industrial operation
Introduction
Stream were asked to help a global producer of packaging film to measure steam usage at various remote locations across the complex manufacturing site.
Customer Challenge
The topography of the site, coupled with where the steam meters were located, posed significant challenges for traditional installations, which would require extensive cabling and dedicated power supplies.
The customer also required real-time access to multiple measurements including flow, pressure, and temperature from vortex flow meters, with seamless transmission to a centralised PLC system.
Solution
Stream proposed the use of Ethernet-APL (Advanced Physical Layer), new standard allowing Ethernet to power and communicate with process instrumentation over long distances via a single twisted pair shielded cable. This simplifies wiring and drastically reduces installation cost: two challenges the customer was facing.
By integrating Advanced Physical Layer technology, the ABB vortex flow meters can be used in Zone 1 area which is not possible with classic industrial ethernet devices. It also enhances the flexibility of flow meter placement as field instruments can be installed in locations without a power source.
Crucially, Ethernet-APL supports the transmission of multiple process variables such as flow, pressure, and temperature using standard Ethernet protocols, ensuring seamless integration with the site’s existing PLC infrastructure.
Outcome
Four distinct advantages arose from opting for ABB’s Ethernet APL flow meters, including:
- Reduced installation complexity and cost through significantly reduced cabling and installation costs.
- Enhanced data granularity, with numerous measured process variables transmitted from each instrument
- Seamless integration into the site’s PLC using standard Ethernet protocols.
- Improved operational efficiency, with better understanding of steam usage in the various parts of the site to optimise boiler consumption and reduce energy consumptions and costs.
