ABB Partnership Focuses on Integrated Turbomachinery Controls

ABB has joined forces with Energy Control Technologies, a U.S.-based company specializing in turbomachinery control systems, to leverage one another's strengths. The collaboration will focus on developing an integrated turbomachinery controls solution for use within ABB’s Ability System 800xA distributed control system.

Turbomachinery often consists of large, complex machinery that transfers energy between a rotor and a fluid in industries like oil and gas, biofuels, and power generation. Image used courtesy of ABB

ABB and Energy Control Technologies

ABB will supply Energy Control Technologies with hardware, software, and technical support to create the turbomachinery solution for ABB’s 800xA distributed control system (DCS) platform. At the same time, Energy Control Technologies will contribute to the turbomachinery control algorithms, engineering design, and other resources.

ABB estimates that the companies’ combined technologies could lead to a 20% reduction in automation and electrical capital expenditure for integrated projects. The integrated turbomachinery controls solution, the ABB-Energy Control Technologies integrated compressor controls (ICC), features an integrated control safety system (ICSS). It is aimed at providing customers with a versatile solution designed to minimize the size and complexity of their plant control systems.

As part of the companies’ joint agreement, turbomachinery controls will be integrated into the ABB Ability System 800xA distributed control system platform. Image used courtesy of ABB

What Is Turbomachinery?

Turbomachinery are machines that transfer energy between a rotor and a fluid, often air or a liquid, through a series of rotating and stationary components. Turbomachinery usually includes large turbines, compressors, and pumps. These machines are essential to different industries, including power generation, oil and gas, aerospace, and manufacturing, which are known for their high energy demand.

Many turbomachines are designed to handle large fluid volumes at high pressures, which requires considerable energy input, especially in applications like gas turbines or compressors. While modern turbomachines are fairly efficient, they still operate in demanding conditions where efficiency may drop, especially under varying loads or during start-up and shutdown phases.

For many industrial applications, turbomachines are part of complex systems involving multiple energy conversions, leading to energy losses. This means that a noticeable increase in efficiency, as promised by ABB under its latest partnership with Energy Control Technologies, can lead to energy savings on a larger scale. Better control methods can greatly reduce costs associated with turbomachinery.

Since turbomachinery has such a high energy use, efficiency gains in turbomachinery technology can greatly affect total energy usage. Image used courtesy of Energy Control Technologies

Improving Turbomachinery Efficiency

ABB and Energy Control Technologies aim to create an integrated control system for large turbomachinery systems and equipment. Using integrated controls gives operators a clearer view of equipment performance, which helps improve energy efficiency and lowers risks and costs. It also helps to reduce infrastructure costs by eliminating the need to create an interface between different control systems. This can also reduce overall system complexity and lower infrastructure start-up costs.

The ABB-Energy Control Technologies ICC removes old, complex control systems and combines everything into the same 800xA ICSS System. This eliminates the need for separate workstations, networks, servers, and other extra systems. As a result, machines can start up faster and operate with a higher level of safety and reliability. A common platform can also help users reduce the system's complexity and allow operators to monitor both compressors and DCS controls through the same platform.