Upgrade of analog measuring equipment to digital: pressure, temperature, flow

Introduction

Modern requirements for energy efficiency, environmental compliance and production safety require upgrading of analog equipment in installations based on digital technologies. Upgrading pressure, temperature, and flow measurement systems not only meets regulatory requirements, but also provides significant efficiency gains, reduced energy costs, and increased equipment longevity.

Evaluation of old systems before upgrading

Before starting the upgrade, a detailed assessment of the current measurement system must be carried out. The main evaluation criteria:

Modern alternatives

Upgrading analog equipment to digital measuring devices provides increased accuracy, efficiency, and increased service life. Below is a comparison table:

Calculating Return on Investment (ROI)

Upgrading your metering system provides a significant return on investment through reduced energy consumption, reduced maintenance costs and increased efficiency. Below is an example of a calculation:

Output data:

• Number of measuring devices: 10
• The cost of one device: €2,500
• Cost of energy consumption: €0.15/kWh
• Average annual energy consumption: 5000 kWh
• Average annual maintenance costs: €600
• Energy consumption reduction: 30%
• Reduction in maintenance costs: 50%

Calculation:

• Renewal cost: 10 × €2,500 = €25,000
• Annual energy costs: 5000 × €0.15 = €750
• Reduction of energy consumption: 5000 × 0.30 = 1500 kWh
• Energy cost reduction: 1500 × €0.15 = €225
• Reduced service costs: €600 × 0.50 = €300
• Annual return: €225 + €300 = €525
• Payback period: €25,000 / €525 = 47.6 years

Thus, upgrading the metering system provides significant cost savings, although the payback period may be long. It is important to consider the long-term benefits.

Implementation plan

The upgrade of the measurement system should be carried out in phases to minimize production stoppage:

1. Planning: Evaluation of the current system, determination of needs, selection of components.
2. Purchase: Order new measuring devices via UNITEC-D E-Catalog.
3. Installation: Replacing old devices with new ones, providing electricity and communications.
4. Connection: Setting up the system, performing tests, establishing compliance with standards.

Technical problems and their solutions

The following issues may occur during the update:

• Incorrect integration: Using the correct buses and protocols, such as Modbus TCP.
• Instability of electricity supply: Installation of stabilizers and filters.
• Compatibility with other systems: Using standard interfaces and protocols.
• Misconfiguration: Using diagnostic tools and software.

Use case

10 analog pressure sensors were installed in the iron ore production plant. After upgrading to ABB digital sensors 1SDA051384R0001, the following results were obtained:

• Energy consumption reduction: 30%
• Reduction in maintenance costs: 50%
• Increasing measurement accuracy: ±0.5%
• Increased service life: 10,000 hours
• Reduction in rejections: 40%

Validation and testing

After installing new devices, confirmation and testing is carried out:

• Testing the accuracy of measurements
• Energy consumption testing
• Stability testing
• Testing compliance with standards

After passing the tests, the system is considered acceptable for operation.

Conclusion and call to action

Updating the pressure, temperature and flow measurement system is a necessary part of modern production. The use of modern technologies, such as ABB 1SDA051384R0001 digital sensors, ensures increased efficiency, energy efficiency and safety. You can find all the necessary components in the UNITEC-D E-Catalog.

UNITEC-D E-Catalog

List of references

• ABB: https://www.abb.com/
• EC Ecodesign: https://ec.europa.eu/energy/
• ISO 9001: https://www.iso.org/standard/62186.html
• EN 60751: https://www.iso.org/standard/39389.html