Abb Sras 1-07-72dpi

The corporate technical journal
of the ABB Group

ABB
Review
a
Special Report
Automation Systems
Operational profitability
page 9
Capital productivity
page 44
Risk management
page 64
Global responsibility
page 85
www.abb.com/ abbreview
2
ABB Special Report
Automation systems
Contents
Automation systems
5
ABB Industrial
IT
Building the bridge between traditional control and IT
9
Mastering the assets
ABBs Asset Master software helps curb equipment failure
13
Remote services
Revolutionizing support and service
17
Winning the battle with downtime
Streamlining maintenance with risk-based inspection
21
Drive monitor
The software with a finger on the systems pulse
25
Control loops pleasure or plague?
Keeping control systems under control
30
Not on my watch
Power management system prevents costly shutdowns
35
Experience counts
A papermaker who knows he can rely on ABB
38
Finding the right balance
Electrification solution for the pulp and paper industry
41
Peace of mind
Increased productivity in cement with ABBs System 800xA
44
Age is no issue
Evolution of automation systems upholds productivity of
older plants
48
Integrated engineering
Revolutionizing design and documentation in engineering
53
Integrated electrical and automation systems
A key to reduced capital and operational costs
57
Powerful renovation
Rejuvenating a coal-fired power plant
61
Analytics in Shanghai
ABBs Analytic Systems Integration Unit in Shanghai
Risk management
64
Process Analytical Technology
Integrated PAT solutions for the Life Sciences industry
68
Flexibility guaranteed
System 800xA libraries a unified yet flexible platform
Special Report Automation Systems
ABB Review
3
25
53
61
72
72
Center of excellence
Serving local and global metals markets from China
75
Rolling mill simulator
Cold rolling mills benefit from rolling simulations
79
The challenge of device integration
Making sure plug and play equals plug and produce
82
The system type test
Making sure 800xA really does function as it should
85
Safety management in process industries
Making sure safety is something you can trust
88
Integrated but separate
Advances in integrated safety control
93
Setting the standard
Global responsibility for quality and safety
96
Safe instruments
Safer instruments mean safer processes
ABB Review
Foreword
ABB is a glo b al le ad e r in th e su p p ly o f e le ctrical an d au to -
matio n te ch n o lo gie s. Ou r Pro ce ss Au to matio n te am is
ch arge d with d e live rin g p ro d u cts, se rvice s, an d co mp le te
in d u stry so lu tio n s th ro u gh a varie ty o f ch an n e ls. Ho we ve r
wh at we d e live r is o n ly valu e d if we can cle arly d e mo n -
strate h o w it me e ts th e critical b u sin e ss n e e d s o f cu sto m-
e rs, in p articu lar in th e are as o f o p e ratio n al p ro fitab ility,
cap ital p ro d u ctivity, risk man age me n t an d glo b al re sp o n si-
b ility.
Man y cu sto me rs wo u ld su gge st th at maximizin g p ro d u ctio n
e fficie n cy is th e mo st imp o rtan t re q u ire me n t o f a p ro ce ss
au to matio n so lu tio n . To th at e n d , o u r in d u strial b u sin e ss
u n its are co n stan tly d e ve lo p in g ap p licatio n s th at allo w
p lan ts o r e q u ip me n t to ru n at maximu m o u tp u t, co n siste n tly
p ro d u cin g h igh -q u ality p ro d u cts. Ou r In d u strial
IT
so lu tio n s
in te grate e n gin e e rin g, o p e ratio n s an d main te n an ce activi-
tie s o n a co mmo n te ch n o lo gy p latfo rm, th u s imp ro vin g
o ve rall p lan t e fficie n cy an d safe ty. Ou r Asse t Man age me n t
an d Pe rfo rman ce Se rvice so lu tio n s min imize d o wn time an d
h e lp to re d u ce variab le co sts su ch as lab o r, main te n an ce
an d co n su mab le s. In th is e ra o f re co rd e n e rgy co n su mp -
tio n , o u r so lu tio n s fo r e n e rgy man age me n t h e lp p lan t o p e r-
ato rs to re d u ce b o th co st an d e n viro n me n tal imp act.
ABB cu sto me rs e xp e ct a h igh re tu rn o n th e ir au to matio n
in ve stme n ts, an d we o ffe r man y ways o f imp ro vin g th e
p ro d u ctivity o f cap ital. Ou r e arly in vo lve me n t in p ro je cts
h e lp s to o p timize e n gin e e rin g an d d e sign cycle s, th u s
lo we rin g p ro je ct co sts wh ile me e tin g o r e xce e d in g d e sign
go als. Ove rall p ro cu re me n t an d co mmissio n in g co sts are
fu rth e r lo we re d b y cu sto me rs wh o se le ct ABB as th e ir main
e le ctrical, au to matio n , an alytic o r in stru me n tatio n p artn e r.
To e n su re b o th p e rfo rman ce an d lo n ge vity fo r th e se in ve st-
me n ts, we o ffe r in d u strys mo st co mp re h e n sive life cycle
man age me n t p ro gram.
Risk is a majo r ch aracte ristic o f an y p ro ce ss au to matio n
p ro je ct. Pro je ct in e fficie n cy o r p o o r p ro d u ct q u ality can
ad d co st, d e lay sch e d u le s, o r in cre ase p ro je ct h azard s.
To re d u ce th e se risks, o u r Ce n te rs o f Exce lle n ce d e ve lo p
te ste d , ce rtifie d an d re u sab le in d u strial ap p licatio n s fo r
re p e atab le p e rfo rman ce , sh o rte r p ro je ct sch e d u le s an d
smo o th e r start-u p s. Th ro u gh o u r glo b al acco u n t p ro gram,
we also d e ve lo p cu sto me r-sp e cific b e st p ractice s to
e n su re co n siste n t p ro je ct d e live ry re gard le ss o f size , co m-
p le xity, sco p e o r ge o grap h ic lo catio n .
Like ABB, mo st co mp an ie s to d ay are e mb racin g a re n e we d
co mmitme n t to so cial re sp o n sib ility. Cu sto me r in ve stme n ts
in o u r in te grate d safe ty an d co n tro l syste ms h e lp e n su re
safe an d se cu re wo rkin g co n d itio n s fo r e mp lo ye e s, p ro te c-
tio n o f th e e n viro n me n t, an d th e re -u se o f in stalle d asse ts.
Th is ap p ro ach h e lp s cu sto me rs p ro te ct th e ir re p u tatio n an d
lice n se to o p e rate , wh ile me e tin g e ve r mo re d e man d in g
re gu lato ry an d co mp lian ce re q u ire me n ts. ABBs co mmit-
me n t to so cial re sp o n sib ility re fle cts we ll o n cu sto me rs
wh o sh are o u r h igh stan d ard s fo r b u sin e ss e th ics, h e alth
an d safe ty, an d co mmu n ity sp irit.
Vie we d co lle ctive ly, th e b u sin e ss n e e d s o f o u r cu sto me rs
are co mp le x. Vie we d in d ivid u ally, e ach o n e is ye t an o th e r
o p p o rtu n ity to d e live r p ro ve n so lu tio n s fo r p o we r, p ro -
d u ctivity an d su stain ab ility th at h e lp make th e wo rld a
b e tte r p lace . Man y o f th e p ro d u cts, ap p licatio n s an d se rvic-
e s th at fu lfill th e se b u sin e ss n e e d s are sh o wcase d in th is
ABB Re vie w Sp e cial Re p o rt. I h o p e yo u fin d th e co lle ctio n
o f article s in fo rmative an d in te re stin g. Mo st imp o rtan tly,
I in vite yo u to e xp lo re th e wo rld o f ABB Pro ce ss Au to -
matio n , an d to le arn o f th e man y p ro d u cts, se rvice s an d
so lu tio n s o n o ffe r to h e lp imp ro ve yo u r p ro d u ctivity.
Ve li-Matti Re in ikkala
Pro ce ss Au to matio n Divisio n He ad
Me mb e r o f th e Exe cu tive Co mmitte e
ABB Ltd
ABB Process Automation
Focusing on customer needs
ABB Review
4
5
ABB Review
ABB introduced its Industrial
IT
concept in 2000, the goal of which was to
expand the role of industrial automation beyond that of a traditional DCS
system. This was to be accomplished by integrating the domain of traditional
process control with the domain of IT technologies and applications. The
combination of industrial focus and IT infrastructure would deliver a unified
information system for control, engineering, maintenance, planning and more.
ABB Ind ustrial
IT

Providing the business value proposition for automation
Larry OBrien, ARC Advisory Group
5 Special Report Automation Systems
ABB Review
Automation Systems
ABB Review
syste m. A p o we rfu l o b je ct-o rie n te d
te ch n o lo gy calle d Asp e ct Ob je cts
u n d e rlie s all o f th e In d u strial
IT
o ffe r-
in gs an d re sid e s at th e co re o f Syste m
800xA. Simp ly p u t, Asp e ct Ob je cts
allo w u se rs to vie w an y asp e ct o f th e
au to matio n sch e me , fro m a p u mp o r a
valve to a p ro ce ss u n it o r p re ssu re
tran smitte r, as a so ftware o b je ct. Each
o b je ct in th e syste m h as a n u mb e r o f
attach e d asp e cts
Factbox
th at can ran ge
fro m in te gratio n to co mp u te rize d
main te n an ce man age me n t syste ms
(CMMS) an d En te rp rise Asse t Man age -
me n t (EAM) syste ms to sch e matic
d rawin gs an d tre n d in g in fo rmatio n .
Asp e ct Ob je cts p ro vid e s th e ke y re al-
time lin kage b e twe e n e q u ip me n t an d
ap p licatio n s.
800xA supports ARCs Collaborative
Automation vision
A ke y asp e ct o f ARCs visio n fo r Co l-
lab o rative Pro ce ss Au to matio n Syste ms
(CPAS) in clu d e s a sin gle , u n ifie d e n vi-
ro n me n t fo r th e p re se n tatio n o f in fo r-
matio n to th e o p e rato r, as we ll as th e
ab ility to p re se n t in fo rmatio n in co n -
te xt to th e righ t p e o p le at th e righ t
time fro m an y p o in t with in th e syste m.
Syste m 800xA p ro vid e s th e se fu n c-
tio n s with a sin gle win d o w e n viro n -
me n t fo r in fo rmatio n acce ss an d co n -
te xt se n sitive d e cisio n an d actio n
to o ls, an d b u ild s o n a co mmo n e n vi-
ro n me n t fo r e n gin e e rin g, o p e ratio n s,
in fo rmatio n man age me n t, an d asse t
o p timizatio n . Syste m 800xA also p ro -
vid e s a co mmo n o p e rato r e n viro n -
me n t fo r ABBs e n tire p o rtfo lio o f
safe ty an d p ro ce ss co n tro l syste ms,
p ro vid in g acce ss to in fo rmatio n acro ss
th e e n te rp rise as we ll as co n te xt se n -
sitive d e cisio n an d actio n to o ls th at
allo w th e righ t u se rs acce ss to th e
righ t in fo rmatio n at th e righ t time
fro m an y p o in t with in th e syste m.
Capital deployment is
reduced through planned
upgrades for installed
systems and the use
of Overall Equipment
Effectiveness tools.
In th e n e xt p h ase o f th e ir e vo lu tio n
p ro ce ss au to matio n syste ms will b e
co n sid e re d th e se n tin e l o f p lan t p e r-
fo rman ce . Th e y will co n tin u e to facili-
tate p ro ce ss co n tro l b u t will also b e -
co me th e p rimary so u rce o f man u fac-
tu rin g d ata an d in fo rmatio n fo r Co l-
lab o rative Man u factu rin g Man age me n t
(CMM) ap p licatio n s all with in a ro b u st
e n viro n me n t. Similarly, a ke y stre n gth
o f Syste m 800xA is its ab ility to e x-
te n d its re ach b e yo n d th e trad itio n al
fu n ctio n s o f th e Distrib u te d Co n tro l
Syste m (DCS) to in clu d e fu n ctio n s
N
o wad ays, e n d u se rs are fin d in g
th at te ch n o lo gy alo n e is n o lo n -
ge r su fficie n t to ju stify au to matio n
p u rch ase s. In ste ad au to matio n mu st
p ro vid e so lid b u sin e ss valu e b e n e fits
b ase d o n a co mb in atio n o f me trics,
su ch as e n h an ce d asse t availab ility,
re tu rn o n asse ts, re d u ce d life cycle
co st, an d man y o th e r strate gic an d
fin an cial o b je ctive s
1
. In d u strial
IT
p ro -
vid e s th is valu e p ro p o sitio n with an
o p e n te ch n o lo gy p latfo rm th at p ro -
vid e s se amle ss acce ss to d ata fro m all
are as o f th e p lan t an d th e e n te rp rise .
Th e re fo re , ABBs go al to d ay is to
sh o w th e b o tto m lin e e co n o mic im-
p act an d imp ro ve d b u sin e ss p e rfo r-
man ce th at can b e o b tain e d th ro u gh
imp le me n tatio n o f In d u strial
IT
so lu -
tio n s.
Th e fo llo win g article is an e xe cu tive
su mmary o f an ARC Ad viso ry Gro u p
re p o rt
1)
o n ABBs In d u strial
IT
arch ite c-
tu ral co n ce p t.
800xA is core of the Industrial
IT

offering
At th e co re o f all In d u strial
IT
so lu tio n s
is th e Syste m 800xA Exte n d e d Au to -
matio n co n tro l syste m
2)
. Exte n d in g th e
co re o f Syste m 800xA h ard ware an d
ap p licatio n s are ABB an d th ird p arty
p ro d u cts th at h ave b e e n te ste d an d
ce rtifie d (In d u strial
IT
En ab le d
3)
) to ve r-
ify p ro p e r o p e ratio n with an 800xA
1
Core business values
2
Empowering the knowledge worker
Automation Systems
ABB Industrial
IT
Footnotes
1)
The full, 32 page art icle can be found on www.abb.com/ indust rialit
2)
www.abb.com/ product / us/ 9AAC115756.aspx?count ry=US (Oct ober 2006)
3)
This symbol on product s from ABB and it s st rat egic part ners means a product has been t est ed and cert ified for compliance wit h Indust rial
IT
st andards for informat ion,
int egrat ion, and archit ect ure.
ABB Review
su ch as p ro d u ctio n man age me n t, safe -
ty an d critical co n tro l, ad van ce d co n -
tro l, in fo rmatio n man age me n t, smart
in stru me n tatio n , smart d rive s an d
mo to r co n tro l ce n te rs, asse t man age -
me n t, an d d o cu me n tatio n man age -
me n t cap ab ilitie s.
Over US$ 20 billion or
almost 5 percent of
production in the process
industries is lost to
unscheduled downtime.
Reduced total cost of ownership and
enhanced asset utilization
Th e th re e co re are as wh e re In d u strial
IT

p ro vid e s b u sin e ss valu e are :
In cre ase d p ro d u ctivity
Re d u ce d to tal co st o f o wn e rsh ip
En h an ce d safe ty th ro u gh re d u cin g
risk an d p ro vid in g a h igh le ve l o f
se cu rity.
Th e valu e p ro p o sitio n o f an au to ma-
tio n syste m re sts in its ab ility to p ro -
vid e e n h an ce d asse t u tilizatio n an d
re d u ce d to tal co st o f o wn e rsh ip
(TCO). Co mp an ie s are in b u sin e ss to
make mo n e y th ro u gh ad d in g valu e .
Th e amo u n t o f p ro fit re su ltin g fro m
th is e n d e avo r is d ire ctly re late d to th e
asse t u tilizatio n rate . A re ce n t ARC
su rve y co n d u cte d with 107 o p e ratio n s
an d man age me n t p e rso n n e l 86 p e r-
ce n t o f wh ich came fro m th e p ro ce ss
an d h yb rid in d u strie s , sh o we d a d e fi-
n ite sh ift to ward makin g re tu rn o n
asse ts (ROA) th e p rimary crite rio n in
ju stifyin g p ro ce ss au to matio n .
ABB o ffe rs a p ath to re d u ce d TCO
th ro u gh re d u ce d e n gin e e rin g an d
d e sign co sts fro m in te grate d fro n t e n d
e n gin e e rin g to o ls, stan d ard ize d wo rk-
flo w p ro ce sse s aro u n d th e ISA 95
stan d ard an d stan d ard ERP/ CMMS
co n n e cto rs. Cap ital d e p lo yme n t is
re d u ce d th ro u gh p lan n e d u p grad e s
fo r in stalle d syste ms an d th e u se o f
Ove rall Eq u ip me n t Effe ctive n e ss
(OEE) to o ls. Main te n an ce co sts can b e
re d u ce d b y in te gratin g o p e ratio n s an d
main te n an ce d ata, th ro u gh th e in te -
gratio n o f co n tro l syste ms with ERP
syste ms, an d b y e mb e d d in g o p e rato r
kn o wle d ge ab o u t main te n an ce in to
th e p ro ce ss au to matio n syste m. Daily
o p e ratin g e xp e n se s can b e re d u ce d b y
o ffe rin g co n te xtu al d ata acce ss, re d u c-
in g cycle time s, an d co n so lid atin g
mu ltip le d ata so u rce s.
Increased productivity not just about
cutting costs
In mo st case s, man u factu rin g asse ts
are cap ab le o f p e rfo rmin g to d e sign
3
Extended automation
The following extract has been taken from
The ABCs of Industrial
IT
ABB Review
1/ 2002, pages 613.
Aspect Object
TM
technology associates
information with the plant and business
entities (the objects) it belongs to, by orga-
nizing these objects to mirror reality and
by providing powerful functions for naviga-
tion and searching. Expanding further, the
Industrial
IT
concept defines the collection
of information required to support each
plant component as an Aspect Object
containing all the characteristics, or As-
pects of the device. Aspect Objects can
also be things such as finished products,
raw materials, sales and manufacturing
orders. An electric motor for example
could be represented by an Aspect Object
containing all the real- time information
connected with it. This might include
design drawings, control diagrams, main-
tenance information, location, quality infor-
mation and configuration information. It is
important to realize that an Aspect is not
just the real- time information connected
with a particular Aspect Object; it also
defines a set of software functions that
create, access and manipulate this infor-
mation.
Factbox
Aspect Object technology
Maintenance Operations Production Engineering
System Servers
Infrastructure Equipment
Hardware
Intelligent
Devices
ABB OCS
Controllers
3
rd
Party
Controllers
System 800xA
Controllers
Variable Speed Drives
Fieldbus Devices
Motor Control Center
Software
Applications
Process Control Energy Control
Safety Management
Infomation Management Batch Management
Production Intelligence
Alarm Management
CMMS Integration
Automation Systems
ABB Industrial
IT
ABB Review
sp e cificatio n s. Re liab ility an d u tiliza-
tio n , h o we ve r, are su ffe rin g fro m co n -
strain e d h u man p e rfo rman ce . Acco rd -
in g to ARC, o ve r US$ 20 b illio n o r
almo st 5 p e rce n t o f p ro d u ctio n in th e
p ro ce ss in d u strie s is lo st to u n sch e d -
u le d d o wn time . Up to 78 p e rce n t o f
th at is re ad ily p re ve n tab le . Hu man
e rro r, p rimarily o p e rato r e rro r, is re -
sp o n sib le fo r 40 p e rce n t. Th is can
b e ad d re sse d b y u sin g b o th th e o p e ra-
to rs an d th e au to matio n mo re e ffe c-
tive ly.
Th e b igge st ch an ge in p lan t p e rfo r-
man ce imp ro ve me n t fo r th e 21
st
ce n -
tu ry an d a ke y ve h icle fo r re d u cin g
th is u n p lan n e d d o wn time will co me
fro m th e e mp o we rme n t o f th e kn o wl-
e d ge wo rke r. Man u factu rin g will u n -
d e rgo fu n d ame n tal o rgan izatio n al
ch an ge s b e cau se o f o p e rato rs b e co m-
in g kn o wle d ge wo rke rs e mp o we re d
with in fo rmatio n
2
. Th is p ro life ratio n
o f in fo rmatio n is cau sin g o rgan izatio n -
al stru ctu re s to flatte n , p u sh in g d o wn
th e au th o rity an d re sp o n sib ility asso -
ciate d with th e d istrib u tio n o f in fo r-
matio n . A h igh e r le ve l o f co o rd in atio n
at lo we r le ve ls is also re q u ire d .
ABBs In d u strial
IT
so lu tio n s e n ab le
kn o wle d ge wo rke rs in se ve ral ke y
ways, b u t p ro b ab ly o n e o f th e mo st
imp o rtan t facto rs in clu d e p ro vid in g
in fo rmatio n in co n te xt. An o th e r im-
p o rtan t facto r in clu d e s p ro vid in g a
u n ifie d p latfo rm fo r p lan t an d asse t
main te n an ce man age me n t th at also
au to mate s th e tran sactio n s b e twe e n
th e au to matio n syste m an d co mp u te r-
ize d main te n an ce man age me n t sys-
te ms (CMMS), also kn o wn as En te r-
p rise Asse t Man age me n t (EAM) p lat-
fo rms
3
.
Main te n an ce is o n e o f th e mo st sign if-
ican t an d u n tap p e d are as o f co st sav-
in gs in p lan ts to d ay, an d also o n e o f
th e mo st o ve rlo o ke d . Acco rd in g to
Du Po n t, fo r e xamp le , main te n an ce is
th e large st sin gle co n tro llab le e xp e n -
d itu re in th e p lan t, with main te n an ce
b u d ge ts acco u n tin g fo r aro u n d two -
th ird s o f an n u al n e t p ro fit. Acco rd in g
to Do w, th e co st o f u n n e ce ssary main -
te n an ce is ab o u t th e same size as th e
to tal p lan t p ro fit. Sh e ll Glo b al So lu -
tio n s e stimate s th at ab o u t 63 p e rce n t
o f main te n an ce lab o r re su lts in n o
actio n at all.
ABBs ap p ro ach to p lan t main te n an ce
is to p ro vid e an e n viro n me n t wh e re
in fo rmatio n is tran sp are n tly acce ssib le
to u se rs in b o th th e p ro ce ss co n tro l
syste m an d th e main te n an ce syste m
e n viro n me n ts, re gard le ss o f wh e re th e
in fo rmatio n h as o rigin ate d . Th is is
co n siste n t with ARCs vie w th at in fo r-
matio n sh o u ld b e p ro vid e d in co n te xt
so th e main te n an ce p e rso n n e l h ave
acce ss to all th e in fo rmatio n th e y
n e e d wh e n th e y n e e d it, re gard le ss o f
its so u rce o r lo catio n .

Increased safety and security has direct
impact on profitability
ARC b e lie ve s th at e n d u se rs mu st
take an in te grate d ap p ro ach to p lan t
safe ty, p lan t se cu rity, an d risk re d u c-
tio n . Th ro u gh its ap p ro ach to th e
in te gratio n o f co n tro l an d safe ty sys-
te ms, ABB p ro vid e s e n h an ce d p lan t
se cu rity, an d re d u ce d risk th ro u gh an
in te grate d ap p ro ach to p ro je ct man -
age me n t wh e re it can se rve as th e
main au to matio n co n tracto r (MAC).
Un sch e d u le d d o wn time u n e xp e cte d
sto p p age s re su ltin g fro m e q u ip me n t
failu re , o p e rato r e rro r, o r n u isan ce
trip s is th e n e me sis o f all man u fac-
tu re rs. Pro vid in g a p ath to ward b e tte r
safe ty an d se cu rity also me an s p ro -
vid in g a p ath to ward in cre ase d re li-
ab ility.
Maintenance is one of
the most significant and
untapped areas of cost
savings in plants today,
and also one of the most
overlooked.

Imp le me n tatio n o f an in te grate d co n -
tro l an d safe ty syste m, su ch as th e
in te grate d critical co n tro l cap ab ilitie s
o f ABBs Syste m 800xA High In te grity
(se e n e xt p aragrap h ), allo ws u se rs to
sign ifican tly re d u ce risk an d re alize
th e b e n e fits o f an ad van ce d strate gy
fo r critical co n d itio n man age me n t
(CCM). Asid e fro m th e safe ty asp e ct,
ABB re d u ce s risk b y p ro vid in g a
sin gle p o in t o f re sp o n sib ility th ro u gh
its MAC cap ab ilitie s. On th e so ftware
sid e , th e co mp an y h as e mb e d d e d
fu n ctio n ality su ch as se cu re d e sign
p ractice s, p atch p ro grams, au d it trails,
an d ad van ce d acce ss co n tro l.
Syste m 800xA High In te grity is a
IEC 61508 an d IEC 61511 co mp lian t
Safe ty In stru me n te d Syste m (SIS) th at
sp an s th e safe ty lo o p , in clu d in g Safe ty
In te grity Le ve l (SIL) rate d co n tro lle rs,
fie ld d e vice s, I/ O mo d u le s, an d fie ld
actu ato rs. Emb e d d e d safe ty an d co n -
tro l are with in th e same arch ite ctu re
p ro vid in g a co mmo n h igh in te grity
syste m e n viro n me n t fo r p ro d u ctio n
co n tro l, safe ty su p e rvisio n , an d p ro -
d u ctio n mo n ito rin g. Th is arch ite ctu re
p ro vid e s th e o p tio n o f co mb in in g
co n tro l an d safe ty fu n ctio n s with in th e
same co n tro lle r o r ke e p in g co n tro l
an d safe ty fu n ctio n s se p arate with in
th e same syste m. With safe ty an d p ro -
ce ss ap p licatio n s e xe cu tin g with in th e
same syste m e n viro n me n t, an d e ve n
with in th e same co n tro lle r, Syste m
800xA o ffe rs safe , in stan t in te ractio n
b e twe e n ap p licatio n s.
ABBs p o sitio n in g o f In d u strial
IT

aro u n d th e th re e p rimary d o main s o f
re d u ce d co st o f o wn e rsh ip , in cre ase d
p ro d u ctivity, an d re d u ce d risk is a
go o d fit with th is in cre ase d fo cu s o n
b u sin e ss valu e . ABB also h as ad -
van ce d cap ab ilitie s in p ro d u cts, se rvic-
e s, an d ve rtical in d u strie s to h e lp e n d
u se rs re alize th e b u sin e ss valu e an d
in cre ase d p e rfo rman ce p o te n tial o f
au to matio n . In te rms o f o ffe rin g a h igh
d e gre e o f fu n ctio n ality an d a wid e
array o f ad van ce d ap p licatio n s, ABB
is ve ry stro n g an d h as a lo t to o ffe r.
Th e fu tu re su cce ss o f th e co mp an y
d e p e n d s large ly o n its ab ility to su c-
ce ssfu lly p ro vid e its cu sto me rs with
su stain e d an d me asu rab le b e n e fits
fro m au to matio n th at p ro vid e a p ath to
co n tin u o u s imp ro ve me n t fo r b u sin e ss
p e rfo rman ce an d p ro fitab ility.
Larry OBrien
Research Director, Process Automation
ARC
4)
Advisory Group,
Dedham, MA, USA
Footnote
4)
Founded in 1986, ARC Advisory Group is a
research and advisory firm in t he manufact uring and
supply chain sect or. www.arcweb.com
ABB Industrial
IT
Automation Systems
Mastering
the assets
Asset Master software improves productivity
Eric Olson
Every year, heavy industries spend
billions of dollars on maintenance;
yet, equipment failure is the principal
cause of production losses. There
is now a wide appreciation that the
development of new monitoring
technologies is critical to reducing
downtime and containing cost. Most
importantly for industrial work prac-
tice, employing asset management
will impel a shift in work culture, from
routine and reactive maintenance to
proactive maintenance.
A
s sh ip s we re to se afare rs in th e
15
th
ce n tu ry, th e co mp u te r was
to in fo rmatio n p ro ce ssin g in th e
20
th
ce n tu ry. Fro m n u mb e r cru n ch in g
to p ro b le m so lvin g, it h as b e co me an
in d isp e n sab le to o l in th e e ve r-in cre as-
in g co mp le xity o f to d ay`s wo rk e n vi-
ro n me n ts.
Th e h isto ry o f co mp u tin g is p e o p le d
with th e mo st p ictu re sq u e ch aracte rs:
Ch arle s Bab b age an d h is An alytical
En gin e ; Ad a Byro n , wh o an ticip ate d
co mp u te r p ro grammin g b y mo re th an
a ce n tu ry; Jo h n vo n Ne u man n , wh o
p ro p o se d sto rin g a p ro gram as e le c-
tro n ic d ata; an d Alan Tu rin g, wh o
b e lie ve d th at an algo rith m co u ld b e
d e ve lo p e d fo r almo st an y p ro b le m.
To d ay, large o rgan izatio n s e xp e ct to
e xamin e an d mo n ito r th e statu s o f
e ve n th e mo st re mo te o u tp o st at th e
p u sh o f a b u tto n . Ne two rks make
th is p o ssib le . It was in th e 1970s
th at ARPANET was se t u p to co n n e ct
re se arch o rgan izatio n s th ro u gh o u t th e
US. In time , th is e vo lve d in to a wo rld -
wid e n e two rk th e In te rn e t. Takin g
ad van tage o f n e two rkin g te ch n o lo -
gie s, it is n o w p o ssib le to cre ate rich e r
an d mo re p o we rfu l ap p licatio n s th at
e n ab le o rgan izatio n s to ach ie ve h igh e r
o p e ratio n al e fficie n cy.
Each p ro gre ssio n in th e e vo lu tio n
o f in fo rmatio n te ch n o lo gy h as b e e n
th e re su lt o f a time ly id e a. Th e fo cu s
to d ay is o n in te gratin g d isp arate te ch -
ABB Review
ABB Review
n o lo gie s an d syste ms to ach ie ve th e
n e xt le ve l in in d u strial au to matio n .
Creating Asset Master
a complete asset management tool
Eve ry ye ar, h e avy in d u strie s sp e n d
b illio n s o f d o llars o n main te n an ce ;
ye t, e q u ip me n t failu re is th e p rin cip al
cau se o f p ro d u ctio n lo sse s. Th e re
is n o w a wid e ap p re ciatio n th at th e
d e ve lo p me n t o f n e w mo n ito rin g
te ch n o lo gie s is critical to re d u cin g
d o wn time an d co n tain in g co st. Mo st
imp o rtan tly fo r in d u strial wo rk p rac-
tice , e mp lo yin g asse t man age me n t will
imp e l a sh ift in wo rk cu ltu re , fro m
ro u tin e an d re active main te n an ce to
p ro active main te n an ce . Co mp le te
asse t man age me n t in in d u strial p lan ts
is an e me rgin g o p p o rtu n ity an d a
p re se n t ch alle n ge , as ch an gin g cu s-
to me r n e e d s te n d to raise th e b ar in
in n o vatio n .
Th e first ste p in d e fin in g Asse t Maste r
o r mu st h ave fe atu re s was to id e n ti-
fy sp e cific in d u stry n e e d s: Th e ap p li-
catio n n e e d e d to b e cap ab le o f man -
agin g all are as o f fie ld in stru me n t
e n gin e e rin g, co mmissio n in g, an d
main te n an ce . It h ad to su p p o rt ABB
an d th ird p arty d e vice s. It n e e d e d to
p ro vid e e asy acce ss fo r o n lin e an d
o fflin e d e vice co n figu ratio n , p ara-
me te r se ttin g, o n lin e mo n ito rin g an d
tu n in g, d iagn o stic ale rts, asse t mo n i-
to rin g, calib ratio n man age me n t an d
in te gral wo rk o rd e r p ro ce ssin g. Fin al-
ly, it n e e d e d to b e scalab le . Th e ap p li-
catio n h ad to fo cu s o n sp e cific in stru -
me n tatio n n e e d s fo r d e vice man age -
me n t, wh ile su p p o rtin g d ire ct in te -
gratio n in to large scale p ro ce ss au to -
matio n syste ms su ch as 800xA. Th u s
in stru me n tatio n an d au to matio n u se rs
alike co u ld b e n e fit fro m a co mmo n
se t o f e n gin e e rin g re so u rce s an d co m-
p o n e n ts.
Today, large organizations
expect to examine and
monitor the status of
even the most remote
outpost at the push of
a button.
Mo st o f th e se d e sire d fe atu re s fo r
Asse t Maste r we re alre ad y p re se n t in
ABBs 800xA Syste m an d th u s, it p ro -
vid e d th e p e rfe ct p latfo rm fo r cre atin g
Asse t Maste r. By co n ce n tratin g o n
p ro vid in g a scale d d o wn ve rsio n o f
th is fu n ctio n ality th e p re cise n e e d s
o f in stru me n tatio n u se rs co u ld b e
ach ie ve d . A six-tie re d strate gy was
u n d e r take n fo r su p p o rtin g a n u mb e r
o f u se case s
Factbox
.
Th e tie rs p ro vid e e xte n sive sco p e ,
fro m an e le ctro n ic scre wd rive r at
o n e e xtre me to a fu ll d e vice man age -
me n t to o l in stalle d o n th e co mmo n
n e two rk u sin g a ce n tral d atab ase at
th e o th e r. Cu sto me rs can start with a
small main te n an ce b ase d ap p licatio n
an d gro w it in to a large r co n tro l sys-
te m u sin g th e same co n figu ratio n d ata
an d n avigatio n me th o d s fo r b o th .
Name d Asse t Maste r, th e so ftware
ap p licatio n fo r Tie rs 3 th ro u gh 5 is a
sin gle to o l fo r all in stru me n ts, in d e -
p e n d e n t o f th e man u factu re r o f th e
d e vice o r th e co mmu n icatio n p ro to co l
(e g, HART, PROFIBUS, o r Fo u n d atio n
Fie ld b u s).
Asset Master Architecture
Asse t Maste r is b ase d o n th e 800xA
Syste m an d make s u se o f co mmo n
fe atu re s an d co mp o n e n ts. It can b e
u p grad e d b y u sin g e xistin g 800xA
co mp o n e n ts su ch as au d it trail, cali-
b ratio n man age me n t, main te n an ce
trigge r, e tc.
1
sh o ws th e 800xA Sys-
te m arch ite ctu ral co n ce p t. Th e go al
is to re u se as man y co mp o n e n ts as
p o ssib le .
Th e fu n ctio n ality o f Asse t Maste r will
b e syn ch ro n ize d an d e xp an d e d with
e ach re le ase o f 800xA. Th e in itial re -
le ase o f Asse t Maste r, sch e d u le d fo r
e arly 2007 will ru n o n a stan d -alo n e
1
800xA software architecture concept
DTM EDD
Fieldbus
Builder
PROFIBUS/
HART
Aspect System
AIP OPC
Server
Audit Trail
Assistant
Calibration
Valve
monitoring
Aspect Integrator Platform (AIP)
Aspect
Directory
PROFIBUS
Local
Communication
Driver
HART
Local
Communication
Driver
FF
Local
Communication
Driver
DTM EDD
DTM EDD
DTM EDD
DTM EDD
other
application
aspect
systems
standalone tool basic components
DTM and EDD
additional specific DTMs or aspect systems
Tier 1: Device configuration PC
based setup tool, factory configured
devices, and local device Human-
Machine Interface (HMIs)
Tier 2: Device configuration Hand-
held configuration of ABB and third-
party devices and hand- held calibrator
Tier 3: Configuration and visualization
800xA based standalone PC
configuration and visualization tool (base
offering)
Tier 4: Calibration Device
management calibration software
(option to base offering)
Tier 5: Asset optimization Asset
monitoring and reporting (option to base
offering)
Tier 6: 800xA automation system
(upgrade from base offering + options in
Tiers 4 & 5)
Factbox
Six- tiered approach to asset
management use cases
ABB Review
PC. It will e mp lo y a n e w Asse t Maste r
wo rkp lace d e rive d fro m th e e xistin g
main te n an ce wo rkp lace .
In stru me n t co n n e ctio n s with Asse t
Maste r will b e mad e in su p p o rt o f two
p rimary u se ap p licatio n s:
p o in t-to -p o in t acce ss fo r b e n ch
wo rk co n figu ratio n (HART via
mo d e ms, PROFIBUS via ad ap te rs,
an d Fo u n d atio n Fie ld b u s via ABBs
LD800HSE)
mu ltip le xe r acce ss fo r o n lin e
n e two rk co n figu ratio n .
Th e Mo b ility h an d -h e ld calib rato r fo r
in te grate d calib ratio n is an o p tio n al
e xtra. In su p p o rt o f asse t o p timiza-
tio n , in te rface s to asse t co n d itio n
mo n ito rin g an d Co mp u te rize d Main te -
n an ce Man age me n t Syste m (CMMS)
are also availab le as o p tio n al o ffe r-
in gs.
Co n sid e rin g th e rise in tran sfe r o f
d igital in fo rmatio n o ve r ce llu lar n e t-
wo rks, an o p tio n fo r SMS me ssagin g
to ce ll p h o n e s an d p age rs will also
b e su p p o rte d . Th e 800xA in clu d e s all
o f th e se o p tio n al fe atu re s an d p ro -
vid e s th e m u n alte re d fo r u se b y Asse t
Maste r.
Every year, heavy indus-
tries spend billions of
dollars on maintenance;
yet, equipment failure
is the principal cause of
production losses.
Asset master functionality
Asse t Maste r ru n s o n Win d o ws XP
fro m a sin gle PC wo rkstatio n , an d
p ro vid e s co n cu rre n t co n n e ctio n s with
HART, PROFIBUS, an d FOUNDATION
Fie ld b u s d e vice s. So ftware in stallatio n
is straigh tfo rward , u su ally takin g le ss
th an 2 h o u rs. Su p p o rt fo r HART mo -
d e ms an d PROFIBUS ad ap te rs go e s
b e yo n d e arlie r o n lin e 800xA cap ab ili-
tie s to p ro vid e o fflin e b e n ch co n figu -
ratio n o f th e co n n e cte d fie ld b u s d e -
vice s. A se arch fu n ctio n simp lifie s
e ffo rts in id e n tifyin g all fie ld b u s
d e vice s co n n e cte d to th e mo d e m,
ad ap te r, o r lin kin g d e vice .
Th e Asse t Maste r Wo rkp lace d isp lay
e n viro n me n t fo cu se s o n main te n an ce
n e e d s an d is co mp rise d o f an alarm
b an d th at id e n tifie s asse t co n d itio n
e ve n ts o rgan ize d b y asse t typ e (p re s-
su re , flo w, e tc.), a b ro wse r fo r o rga-
n izin g an d se le ctin g asse ts an d th e ir
d isp lays o r d ata fu n ctio n s, an d a
vie win g are a to se e th e se le cte d d is-
p lay o r d ata
2
.
Th is wo rkp lace re d u ce s th e time it
take s to co mp re h e n d th e state o f all
p lan t asse ts. Asse t mo n ito rs are p ro -
vid e d to id e n tify n o t o n ly th e fau lt,
b u t also th e p ro b ab le cau se an d th e
su gge ste d co rre ctive actio n . Asse t co n -
d itio n s can trigge r a ce ll p h o n e me s-
sage to d e sign ate d p e rso n n e l. Grap h i-
cal b ase d DTMs mo n ito r an d co n fig-
u re HART an d PROFIBUS d e vice s to
2
Asset Master maintenance workplace
ABB Review
imp ro ve p lan t o p e ratio n an d p ro d u c-
tio n . FOUNDATION Fie ld b u s d e vice
an d n e two rk co n figu ratio n is in te grat-
e d with th e LD800HSE lin kin g d e vice
fo r se ttin g u p an d mo n ito rin g th e Lin k
Active Sch e d u le r an d fu n ctio n b lo ck
ap p licatio n s. De vice calib ratio n n o tic-
e s an d asse t co n d itio n s can b e u se d
to trigge r a wo rk o rd e r su b mittal to a
Co mp u te rize d Main te n an ce Man age -
me n t Syste m (CMMS) su ch as MRO
Maximo o r SAP / PM th at can th e n b e
tracke d th ro u gh co mp le tio n fro m th e
Asse t Maste r wo rkp lace .
Be cau se Asse t Maste r u se s a stre am-
lin e d ve rsio n o f 800xA, it can e asily
in te grate in to large r 800xA syste ms.
Th is allo ws a site to start small with
Asse t Maste r an d gro w o ve r time in to
a large r 800xA syste m.
Key benefits
In th e are a o f Fie ld b u s De vice Man -
age me n t, Asse t Maste r p ro vid e s sign if-
ican t b e n e fits. Primarily, it o ffe rs a
sin gle to o l to co n figu re an d d iagn o se
mu lti-ve n d o r d e vice s, th u s re d u cin g
cap ital e xp e n d itu re o n to o ls an d train -
in g an d re mo vin g th e u se rs b u rd e n
o f se le ctio n .
Th e fu ll valu e o f in te llige n t fie ld d e -
vice s, th at p ro vid e critical in fo rmatio n
o n th e ir o wn h e alth an d th e h e alth
o f p ro ce sse s an d e q u ip me n t aro u n d
th e m, can b e re alize d o n ly wh e n u se d
in co mb in atio n with asse t o p timiza-
tio n so ftware . Asse t Maste r o ffe rs im-
p ro ve d p ro d u ctivity th ro u gh ch o ice o f
d e vice s th at b e st fit th e ap p licatio n ,
in d e p e n d e n t o f fie ld b u s-typ e .
Asse t Maste r re d u ce s co n figu ratio n
time b y u sin g p re -co n figu re d fie ld
d e vice o b je cts with e xte n d e d fu n c-
tio n ality to acce ss d e vice d ata, asse t
in fo rmatio n an d d o cu me n tatio n .
It also e n ab le s faste r co mmissio n in g
th ro u gh ce rtifie d d e vice s an d ap -
p ro ve d fie ld d e vice lib rarie s.
It is in th e are a o f Asse t Op timizatio n
th at Asse t Maste r p ro vid e s tan gib le
e co n o mic b e n e fits b y re d u cin g main -
te n an ce co sts o ve r a p lan ts life cycle
an d th u s b o o stin g th e b o tto m lin e .
In d e p e n d e n t o f asse t typ e , Asse t Mas-
te r p ro vid e s a sin gle in te rface fo r e n -
gin e e rin g, n o tificatio n o f p lan t main te -
n an ce an d asse t o p timizatio n in fo rma-
tio n . Re al-time mo n ito rin g an d alarm-
in g o f asse t Ke y Pe rfo rman ce In d ica-
to rs (KPI) facilitate fast, re liab le im-
p le me n tatio n o f co rre ctive actio n s.
Asse t Maste r co lle cts, aggre gate s an d
an alyze s re al-time p lan t asse t in fo r-
matio n to p ro vid e ad van ce d warn in g
o f d e grad in g p e rfo rman ce an d / o r im-
p e n d in g failu re . Asse t Maste rs re p o rt-
in g fe atu re s p ro vid e visu alizatio n o f
cu rre n t h e alth co n d itio n s, wh ile its
an alysis fe atu re s p ro vid e th e ab ility to
d rill d o wn to th e ro o t cau se o f failu re .
In te gratio n o f d isp arate CMMS, DMS
an d Fie ld b u s e n gin e e rin g to o ls p ro -
vid e s u se rs with a sin gle vie w, le ad in g
to q u ick an d e fficie n t asse ssme n t o f
main te n an ce n e e d s.
Customers can start with
a small maintenance
based application and
develop it into a larger
control system using the
same configuration data
and navigation methods
for both.
In clu d e d stan d ard with ABB man u fac-
tu re d in stru me n tatio n are h igh ly in te -
grate d an d co mp re h e n sive asse t mo n i-
to rs th at e n ab le Asse t Maste r to n o t
o n ly id e n tify fau lts b u t to sh o w p ro b a-
b le cau se an d su gge ste d co rre ctive
actio n s. Th is can re d u ce th e me an
time to tro u b le sh o o t an d / o r re p air
th e fau lt le ad in g to imp ro ve d p ro d u c-
tivity.
In h is b o o k o n p re d ictive main te -
n an ce , Ke ith Mo b le y [1] p o in ts o u t
th at in th e US alo n e , e ve ry ye ar, u p -
ward s o f $ 200 b illio n is sp e n t o n
p lan t e q u ip me n t an d facilitie s main te -
n an ce . Eve ry ye ar, in e ffe ctive main te -
n an ce man age me n t re su lts in a lo ss o f
mo re th an $ 60 b illio n . Th u s, main te -
n an ce can re p re se n t 15 to 60 p e rce n t
o f th e co st o f go o d s p ro d u ce d , d e -
p e n d in g o n th e sp e cific in d u stry. In
an o il re fin e ry, fo r e xamp le , th e fail-
u re o f a sin gle valve d u rin g p e ak
h o u rs can re su lt in a lo ss o f h u n d re d s
o f th o u san d s o f d o llars. A o n e p e r
ce n t d e cre ase in p ro d u ctivity can re -
d u ce o u tp u t b y h u n d re d s o f b arre ls a
d ay. Th e re fo re , imp le me n tin g Asse t
Maste r cre ate s a su b stan tial savin gs
p o te n tial.
Asse t Maste r can p ro vid e an o th e r sig-
n ifican t b e n e fit b y e n su rin g in d u stry
co mp lian ce . Fo r in stan ce , p h armace u -
tical u n its, su b je ct to rigo ro u s Fo o d
an d Dru g Ad min istratio n (FDA) re gu -
latio n s, re ly o n th e tru stwo rth in e ss o f
e le ctro n ic re co rd s ge n e rate d / man age d
b y critical syste ms. A re ce n t FDA re g-
u latio n , 21 CFR Part 11, co ve rs e le c-
tro n ic re co rd s an d sign atu re s th at
affe ct p ro d u ctio n , q u ality an d d istrib u -
tio n o f d ru gs in p h armace u tical u n its.
With in te gratio n o f Mo b ility De vice
Man age me n t Syste m (DMS), Asse t
Maste r can p ro vid e u se rs with FDA
re gu latio n 21 CFR Part 11 e n ab le d
calib ratio n so lu tio n s. In an in d u stry
wh e re d ata in te grity is critical to
p ro d u ct q u ality an d / o r p u b lic safe ty,
syste ms mu st b e o ve rall co mp lian t
with FDA re gu latio n s. In te gratin g DMS
in th e co n tro l syste m o ffe rs ve rsatile
p lan t life cycle man age me n t an d o rga-
n izatio n allo win g th e u se r to d e rive
maximu m valu e fro m p lan t asse ts.
Re u sin g se ve ral 800xA award -win n in g
fe atu re s re su lte d in re d u ce d d e ve lo p -
me n t time fo r Asse t Maste r an d an
e n d -to -e n d Asse t Man age me n t To o l
th at assu re s co mp lian ce with in d u stry
re gu latio n s. Eve n n o w, th e co mb in a-
tio n o f in te llige n t fie ld d e vice s an d
asse t man age me n t so ftware is se ttin g
n e w stan d ard s fo r wh at can b e e x-
p e cte d an d acco mp lish e d fro m th e
co n tro l ro o m. Th is gro win g tre n d in
u sin g Asse t Op timizatio n will mo st
like ly acce le rate in th e fu tu re , fu e le d
b y th e n e e d fo r o u tp u t imp ro ve me n t
an d co st re d u ctio n .
Eric Olson
ABB Inc.
Warminster, PA USA
eric.olson@us.abb.com
References
R. Keith Mobley: An Int roduct ion t o Predict ive
Maint enance. But t erwort h- Heinemann, 2002.
Emerging technologies is a term probably heard most
often in the world of research and development, and is
usually associated with new products. In general, such a
term does not tend to appear in the same sentence with
after sales service and support.
Yet for companies like ABB with a huge client installed
base, advances in technology are changing the way
firms approach the subject of support. In addition, these
same advances are directly helping clients improve their
return on assets:
Remote servic es
High tech means high service performance
Gordon Cheever, John Schroeder
ABB Review
13
ABB Review
W
ith an in stalle d b ase o f mo re
th an $100 b illio n wo rth o f au to -
matio n p ro d u cts an d syste ms wo rld -
wid e , ABB is co n stan tly wo rkin g o n
ways to imp ro ve th e way th e se sys-
te ms are su p p o rte d . Re mo te se rvice s
u se e xistin g an d cu ttin g e d ge te ch n o l-
o gie s to su p p o rt fie ld e n gin e e rs, irre -
sp e ctive o f lo catio n , in ways o n ly
d re ame d o f five ye ars ago . Th e In te r-
n e t, to ge th e r with ad van ce s in co m-
mu n icatio n s an d e n cryp tio n te ch -
n iq u e s, h as co n trib u te d e n o rmo u sly
to th is. Re mo te se rvice d e ve lo p me n ts
are a d ire ct re su lt o f clie n ts ch an gin g
n e e d s. ABB h as b e e n to ld cle arly in
almo st e ve ry in d u stry it se rve s, th at it
mu st co n tin u e to imp ro ve th e re tu rn
o n asse ts o f th e syste ms it d e live rs.
Th is d o e s n o t me an cu sto me rs wan t
le ss su p p o rt, b u t rath e r mo re su p p o rt
at lo we r co sts. Re mo te se rvice s are
d e sign e d to maximize kn o wle d ge b as-
e s in th e mo st co st-e ffe ctive man n e r.
Th e re su lt sh o u ld e n su re th at th e b e st
kn o wle d ge is in th e righ t p lace , at th e
righ t time , to su p p o rt th e clie n ts as-
se ts. With a large n u mb e r o f d iffe re n t
typ e s o f p ro d u cts, th is can b e a co m-
p le x u n d e rtakin g.
Remote service benefits
A well-executed remote service offering
can reduce unnecessary maintenance
and downtime, imp rove p roduction effi-
ciency, track causes of failures, p rovide
root cause data and fault diagnosis and
recommend actions. It can p rovide p re-
dictive notification of imp ending fail-
ures allowing p roactive instead of reac-
tive corrective actions. Finally, it can
allow remote sp ecialists to ap p ly their
exp ertise to any factory in the world
24 hours p er day, 7 days p er week.
ABBs Re mo te Se rvice b u sin e ss p ro -
vid e s p re d ictive an d d iagn o stic cap a-
b ilitie s se rvin g all asp e cts o f a p lan t
au to matio n , e q u ip me n t p e r fo rman ce ,
e q u ip me n t h e alth , me ch an ics, e le ctri-
ficatio n , e le ctro n ics, an d p ro d u ctio n
to p ro vid e a co mp le te so lu tio n .
Th re e le ve ls o f re mo te mo n ito rin g
se rvice are availab le to align with cu s-
to me r n e e d s:
Remote troubleshooting
Re mo te tro u b le sh o o tin g p ro vid e s
e xp e rt o n -d e man d , d iagn o stic re mo te
su p p o rt assistan ce in th e e ve n t o f a
sp e cific p ro b le m o r failu re . A d e -
man d -d rive n co n n e ctio n to th e d rive
e q u ip me n t is in itiate d to b e gin th e
tro u b le sh o o tin g p ro ce ss.
Periodic maintenance
Pe rio d ic main te n an ce p ro vid e s a man -
age d mo n ito rin g se rvice fo r co lle ctio n
o f e q u ip me n t h e alth in fo rmatio n fo u r
time s p e r ye ar. Skille d su p p o rt sp e cial-
ists p ro vid e e xp e rt d ata an alysis b ase d
o n e stab lish e d e q u ip me n t b e n ch marks.
Continuous monitoring
Co n tin u o u s mo n ito rin g p ro vid e s co n -
tin u o u s mo n ito rin g o f ke y p arame te rs.
It au to matically se n d s a me ssage to
an ABB mo n ito rin g ce n te r wh e n p ara-
me te rs e xce e d limits. ABB sp e cialists
an alyze th e alarm an d re mo te ly acce ss
th e d e vice to fu rth e r d iagn o se th e
issu e . Co rre ctive actio n re co mme n d a-
tio n s are p ro vid e d to th e cu sto me r if
re q u ire d .
Remote services use existing and cutting- edge technologies to support on- site and field engineers, thereby ensuring the best knowledge
is in the right place, at the right time to support the clients assets.
Field engineer
Propulsion
predictive
maintenance
Asset
optimization
Web- based
maintenance
management
software
On- line
parts
Remote
drive
monitoring
Remote
robot
services
Marine Industrial
IT
enabled
products and systems
Control systems Instruments and
low- voltage
products
Drives and motors Robotics
Call center
Analysis & feedback layer
Communication layer
Connection layer
Internet, modem, direct line, etc
Remote services
ABB Review
Two typ e s o f alarms are ge n e rate d :
Pre d ictive alarms: De vice h as n o t
ye t faile d b u t ke y p arame te rs
in d icate th at a p ro b le m may o ccu r.
Re active alarms: A p ro b le m h as
o ccu rre d an d n e e d s to b e
d iagn o se d .

Asset Optimizer as a key
component
Th e Asse t Op timize r, fro m ABBs In -
d u strial
IT
p ro d u ct p o rtfo lio , take s re -
mo te se rvice s a ste p fu rth e r. Th e asse t
mo n ito rin g so ftware acq u ire s an d an a-
lyze s asse t statu s an d co n d itio n in fo r-
matio n . Po we rfu l an alysis algo rith ms
d e ve lo p e d fro m ABBs d e e p p ro ce ss
an d main te n an ce kn o wle d ge , p ro vid e
p re d ictive an d p ro active in fo rmatio n
an d alarmin g fu n ctio n s. On ce an
alarm is ge n e rate d , ABBs re mo te
mo n ito rin g e n gin e e rs are n o tifie d . In
ad d itio n to th e alarm, th e Asse t Op ti-
mize r also p ro vid e s imp o rtan t d ata
re late d to th e issu e fo r ABBs re mo te
e xp e rt to an alyze an d d e te rmin e s th e
ro o t cau se o f th e p ro b le m. On -site
o p e rato rs an d main te n an ce p e rso n n e l
can also b e n o tifie d wh e n an ab n o r-
mal co n d itio n h as o ccu rre d th at
re q u ire s so me fo rm o f main te n an ce
actio n .
Advances in technology
are changing the way
firms approach the
support of installed
equipment, as well as
helping clients improve
their return on assets.
In ad d itio n , th e Asse t Op timize r can
b e d ire ctly lin ke d to mo st co mp u te r-
ize d main te n an ce man age me n t so ft-
ware syste ms fo r au to matic wo rk o r-
d e r ge n e ratio n . Th is fe atu re p ro vid e s
a p o we rfu l, in te grate d so lu tio n co n -
n e ctin g site man age me n t, o p e ratio n s,
main te n an ce , an d ABBs re mo te se r-
vice e n gin e e rs allo win g se amle ss
co mmu n icatio n an d fast, e fficie n t
actio n s.
Remote services at work
Th e fo llo win g e xamp le s illu strate h o w
re mo te se rvice s in u se to d ay are giv-
in g cu sto me rs mo re valu e at le ss co st:
Remote paper plant support
ABB p ro vid e s re mo te se rvice s to a
No rth Ame rican p ap e r man u factu re r
th at p ro d u ce s h igh p e rfo rman ce lin e r-
b o ard . Th e re mo te se rvice in clu d e s
mo n ito rin g Co n tro l Lo o p an d Qu ality
Co n tro l Syste m (QCS) p e rfo rman ce .
ABBs QCS so lu tio n is d e sign e d sp e -
cifically fo r th e p u lp an d p ap e r in d u s-
try an d is d e sign e d to me asu re an d
co n tro l th e we igh t, mo istu re an d cali-
p e r (th ickn e ss) o f th e lin e rb o ard .
Th e re mo te se rvice p ro vid e s mo n ito r-
in g o f th e h e alth o f QCS Syste ms
scan n e rs an d se n so rs, th e PID co n tro l
lo o p s, as we ll as th e q u ality o f th e
p ro d u ct. If p o te n tial p ro b le ms are
in d icate d (b y mo n ito r trip s), ABBs
re mo te mo n ito rin g ce n te r is ale rte d .
Th e se alarms o fte n o ccu r b e fo re a fail-
u re h as e ve n take n p lace .
Th e re mo te se rvice h as p ro vid e d sig-
n ifican t valu e to th is cu sto me r. Th e
re mo te mo n ito rs re ce n tly se n se d ab -
n o rmal ch an ge s in a d e vice th at was
n o t sch e d u le d fo r imme d iate main te -
n an ce . Th e d e vice was re p lace d d u r-
in g a sch e d u le d p ro d u ctio n sto p .
Wh e n th e p ro ce ss came b ack u p , all
sign als we re n o rmal. Th is p ap e r p lan t
was ab le to save ap p ro ximate ly te n
h o u rs o f u n sch e d u le d d o wn time b y
p re d ictin g wh e n th e d e vice was ab o u t
to fail, an d ch an gin g it at th e mo st
co st-e ffe ctive time b e fo re an u n -
p lan n e d sto p p age co stin g te n s o f
th o u san d s o f d o llars in lo sse s co u ld
o ccu r.
Remote robot support
Wh e n an issu e arise s co n ce rn in g an
in stalle d ro b o t, th e o n -site p lan t e n gi-
n e e r calls ABBs glo b al ro b o tic e xp e rt
ce n te r. Th e p lan t e n gin e e r th e n cre -
ate s a d ire ct lin k b e twe e n th e ce n te r
an d th e in stalle d e q u ip me n t, b u t o n ly
afte r e n su rin g all lo cal safe ty re q u ire -
me n ts are in p lace . Off-site e xp e rts
re vie w th e e q u ip me n t, d iagn o se th e
p ro b le m an d e ith e r take d ire ct actio n
o r p ro vid e in stru ctio n s to th e site e n -
gin e e r, wh o can th e n so lve th e p ro b -
le m.
Th e ro b o t can also d iagn o se th e p ro b -
le m itse lf, an d th e n call ABBs glo b al
Ro b o tic Exp e rt Ce n te r fo r su p p o rt.
Ho we ve r, th is raise s safe ty co n ce rn s at
th e site . A b alan ce d co mp ro mise is
re ach e d with a co mb in atio n o f au to -
matic an d man u al p ro ce sse s.
Remote power utility support
A majo r p o we r u tility p ro d u ce r in th e
Un ite d State s re ce n tly e xp e rie n ce d an
issu e th at was p re ve n tin g a startu p .
Usin g th e ir su p p o rt lin e su b scrip tio n ,
th e y calle d ABB fo r te ch n ical su p p o rt
late o n a Frid ay n igh t. Th e calle r
fe are d h e wo u ld n o t ge t re su lts at th at
h o u r, an d wh e n h e was to ld so me o n e
wo u ld re tu rn h is call sh o rtly, h e fe lt
ce rtain h is fe ars wo u ld b e re alize d .
ABB holds the view that
technology for technolo-
gys sake is not always
the best solution.
Imagin e h is d e ligh t wh e n an ABB Se r-
vice En gin e e r (SE) re tu rn e d h is call
with in 30 min u te s. Th e SE imme d iate -
ly p ro ce e d e d to so lve th e p ro b le m.
Th e re was n o waitin g u n til th e n e xt
b u sin e ss d ay n o waitin g fo r an e n gi-
n e e r to fly to th e site !
Th is ABB cu sto me r h ad b e e n re se ttin g
se ve ral mo d u le s. On e h ad co n tin u e d
to re p o rt an e rro r. By u tilizin g co n tin -
u o u s mo n ito rin g, th e se rvice e n gin e e r
d e te rmin e d th at th e mo d u le h ad to b e
re lo ad e d , wh ich h e d id re mo te ly.
Th e se rvice e n gin e e r u tilize d ABBs
Re mo te Diagn o stic Se rvice s (RDS)
te ch n o lo gy to o p timize th e p o we r
u tility p ro d u ce rs asse ts in re al-time .
Th e mo d u le was su cce ssfu lly re se t.
De lays an d u n co n tro lle d main te n an ce
co sts we re avo id e d , wh ile th e startu p
staye d o n sch e d u le .
Remote condition monitoring
ABB holds the vie w that te chnology
for te chnologys sake is not always the
be st solution. Whe n it come s to vibra-
tion analysis in condition monitoring,
for e xamp le , the comp any balance s its
se rvice s to p rovide a cost- e ffe ctive ,
tie re d ap p roach. This me ans that an
ap p rop riate te chnical solution is de te r-
mine d base d on the conse que nce s of
the asse t failing and/ or its cost. In the
following, the case is conside re d of a
simp le low-cost motor in a non-critical
ap p lication that is be st sup p orte d
Remote services
ABB Review
whe n data is gathe re d manually. Vibra-
tion data is colle cte d using small hand-
he ld de vice s. This data is the n loade d
onto a PC whe re a software ap p lica-
tion de cide s whe the r the vibration
data is within sp e cification. If not, the
syste m will automatically up load the
data to global ABB condition monitor-
ing e xp e rts whe re anothe r more in-
de p th software ap p lication scre e ns it
for re comme ndations. It the n p asse s
the final data and p re -analysis to de di-
cate d vibration e xp e rts. A final re vie w
is done , and re comme ndations or work
orde rs are se nt back to the local site .
In ge ne ral, the le ve l of automation for
this p roce ss is base d on asse t costs
ve rsus human inte rve ntion costs at the
clie nts site . The syste ms for high-cost
critical asse ts automatically and contin-
uously monitor vibration data and p ro-
vide sp e cific analysis and work inte r-
ve ntion 24 hours a day.
Remote power plant support
Ke n tu ckys p rimary e n e rgy se rvice s
p ro vid e r is We ste rn Ke n tu cky En e rgy,
o r WKE. In a re ce n t p ilo t p ro gram,
WKEs Gre e n Statio n in Se b re e , Ke n -
tu cky, (USA), u tilize d asse t o p timiza-
tio n to p ro vid e d iagn o stic se rvice fo r
th e ir Harmo n y p ro ce ss co n tro l syste m
(Harmo n y Co n tin u o u s Mo n ito rin g).
Asse t mo n ito rs in stalle d o n -site se n t
critical asse t d ata to th e ABB mo n ito r-
in g ce n te r aro u n d th e clo ck.
Re mo te d iagn o stics re ce n tly d e te cte d
a faile d b acku p co mmu n icatio n mo d -
u le b e fo re it b e came a co stly issu e .
Had th e p rimary co mmu n icatio n mo d -
u le faile d , th e re d u n d an t mo d u le
wo u ld h ave b e e n u n availab le an d
p ro d u ctio n wo u ld h ave ce ase d .
ABB must continue to
improve the return on
assets of the systems it
delivers. This doesn t
mean customers want
less support, but rather
more support at lower
cost.
In ste ad , WKE was n o tifie d in a time ly
man n e r, was ab le to sch e d u le main te -
n an ce o n th e faile d re d u n d an t u n it
d u rin g ro u tin e main te n an ce , an d a
co stly sto p p age was avo id e d co m-
p le te ly. Pro d u ctio n cap acity was
e n su re d an d main te n an ce co sts ke p t
lo w th ro u gh re mo te co n tin u o u s mo n i-
to rin g.
Re mo te site asse t mo n ito rin g e n ab le s
o p timize d co n tro l syste m p e rfo rman ce
th ro u gh co n tin u o u s re trie val an d e val-
u atio n o f syste m p e rfo rman ce in d ica-
to rs again st e stab lish e d n o rms. If th e re
are o n -go in g issu e s, re mo te d iagn o s-
tics will catch th e m. Co u p le d with
au to mate d in cid e n t re p o rtin g, re mo te
mo n ito rin g p ro vid e s re d u ce d main te -
n an ce co st, e n h an ce d p ro d u ctio n
q u ality, imp ro ve d main te n an ce p lan -
n in g, an d in cre ase d u p time .
Conclusion
ABBs Re mo te Se rvice b u sin e ss p ro -
vid e s p re d ictive an d d iagn o stic cap a-
b ilitie s se rvin g all asp e cts o f a p lan t
au to matio n , e q u ip me n t p e rfo rman ce ,
e q u ip me n t h e alth , me ch an ics, e le ctri-
ficatio n , e le ctro n ics, p ro d u ctio n , an d
q u ality to p ro vid e a co mp le te so lu tio n
fo r o u r clie n ts n e e d s.
The p rimary be ne fits of Re mote Se rvic-
e s are that the y incre ase asse t availabil-
ity and imp rove p roduction e fficie ncy.
In addition, the y maximize op e rations
and mainte nance e ffe ctive ne ss.
Re mo te Se rvice s can gre atly co n trib u te
to th e o p e ratio n al e xce lle n ce an d
fin an cial p e rfo rman ce o f a cu sto me r
p lan t. Th e co mb in atio n o f p o we rfu l
p re d ictive an d d iagn o stic an alysis
alo n g with e xp e rts availab le 24 h o u rs
p e r d ay, 7 d ays p e r we e k can p ro vid e
a h igh ly e ffe ctive me an s to re main
co mp e titive in th e marke tp lace .
Gordon Cheever
ABB Automation Technologies
Wickliffe, OH, USA
gordon.r.cheever@us.abb.com
John Schroeder
ABB Automation Technologies
Westerville, OH, USA
john.schroeder@us.abb.com
Remote services
In continuous manufacturing 90
percent of all potential failures are
likely to be caused by just 10 per cent
of the installed equipment. When
planning preventive maintenance, it
therefore makes good business sense
to focus on this high-risk group. Risk
Based Inspection (RBI) enable people
to do exactly that. Recent experience
has shown that ABB customers can
benefit from a dramatic saving in time
and cost by using this tool.
Winning the b attle
with d owntime
Tony Musgrave
ABB Review
ABB Review
P
lan t e n gin e e rs figh t a co n tin u o u s
b attle with d o wn time . Alth o u gh
ke y co n trib u to rs, main te n an ce an d
re p airs are n o t, h o we ve r, th e o n ly
cau se fo r co n ce rn ; in cre asin gly, it is
th e th re at o f b u sin e ss in te rru p tio n ,
with its e ffe ct o n o u tp u t an d p ro fit-
ab ility. Th e viab ility o f a p ro ce ss,
e ve n th e b u sin e ss itse lf, may b e o n
th e lin e as a re su lt.
ABB Eu te ch
1)
h as d e ve lo p e d a Risk
Base d In sp e ctio n (RBI) me th o d th at
e n ab le s co mp an ie s to su b stan tially
in cre ase p lan t re liab ility, re d u ce th e
n u mb e r o f p lan t failu re s an d cu t th e
time re -q u ire d fo r re gu lar in sp e ctio n /
main te n an ce .
Re ce n t re su lts with fo u r cu sto me rs in
th e ch e mical an d p e tro ch e mical in d u s-
try p ro vid e co mp e llin g e vid e n ce o f
majo r savin gs. Th e to tal co st o f in -
sp e ctio n , fo r e xamp le , co u ld b e re -
d u ce d b y 49 to 80 p e rce n t. Ave rage
in sp e ctio n in te rvals we re in cre ase d b y
b e twe e n 35 an d 57 p e rce n t, with an
ave rage in cre ase o f 44 p e rce n t. An d
mo re th an h alf th e p lan t e q u ip me n t
co u ld b e re mo ve d fro m th e in vasive
in sp e ctio n p ro grams.
Th e b o tto m lin e is th at RBI re d u ce s
d o wn time , p lan n e d o r u n p lan n e d , fo r
a savin g in main te n an ce co sts. Th e
time an d cap acity/ availab ility th at is
re le ase d as a re su lt h as a d ire ct, p o si-
tive e ffe ct o n a p lan ts o u tp u t.
The principles of RBI
RBI is a kn o wle d ge -b ase d me th o d th at
u se s risk as a b asis fo r p rio ritizin g an d
man agin g an in sp e ctio n p ro gram. In
th is d e fin itio n , risk is se e n as th e
re su lt o f th e p ro b ab ility o f fu tu re fail-
u re an d th e like ly co n se q u e n ce o f th at
failu re .
Ge n e rally sp e akin g, th e le ve l o f risk
asso ciate d with th e d iffe re n t p ie ce s o f
e q u ip me n t th at make u p a p lan t is
variab le . Ho we ve r, th is fact is se ld o m
re fle cte d in th e in sp e ctio n ro u tin e s
ap p lie d acro ss th e in ve n to ry o f e q u ip -
me n t. Risk-b ase d in sp e ctio n s fo cu s
th e in sp e ctio n an d main te n an ce e ffo rt
o n th o se are as wh e re th e risk an d its
p o te n tial e ffe cts are gre ate st.
Th e p rime o b je ctive s o f an RBI p ro -
gram are to :
Fo cu s e ffo rt o n id e n tifyin g an d re -
d u cin g th e safe ty an d b u sin e ss risks.
Ach ie ve in cre ase d p lan t availab ility
b y e n su rin g th at o u tage s o n ly take
p lace fo r e sse n tial in sp e ctio n s.
Re d u ce th e main te n an ce co sts
asso ciate d with u n n e ce ssary o r
e xce ssive d isman tlin g an d
p re p aratio n .
Imp ro ve safe ty b y ge ttin g rid o f
h azard s asso ciate d with p re p arin g
fo r in sp e ctio n s.
RBI is b e co min g th e p re fe rre d to o l b y
wh ich go o d e n gin e e rin g p ractice is
me asu re d . Its p re d ictive ap p ro ach is
d e sign e d to e limin ate e xce ss an d in -
ad e q u acy b y co n ce n tratin g in sp e ctio n
e ffo rt o n re al risks
1
. Use o f RBI h as
sh o wn to b e e ffe ctive in re d u cin g th e
n u mb e r o f u n fo re se e n b re akd o wn s.
The ABB approach to RBI
ABBs RBI p ro ce ss is b u ilt aro u n d an
asse t care strate gy th at is d e sign e d to
mo n ito r th e p lan t th ro u gh o u t its life -
cycle . Th is in vo lve s th e acq u isitio n o f
d e taile d kn o wle d ge an d re q u ire s a
go o d u n d e rstan d in g o f th e b e h avio r
o f e ve ry co mp o n e n t in th e p lan t u n -
d e r its cu rre n t d u ty co n d itio n s. Mu lti-
d iscip lin ary in its ap p ro ach , it lo o ks at
p arame te rs su ch as th e d e sign / co n -
stru ctio n q u ality, in sp e ctio n / main te -
n an ce h isto ry, an d th e se rvice co n d i-
tio n s, in clu d in g n o rmal an d ab n o rmal
e xcu rsio n s. Th e re vie w id e n tifie s all
failu re me ch an isms an d asso ciate d
risks.
Th is accu mu late d kn o wle d ge an d e x-
p e rie n ce h e lp s e n gin e e rs to d e cid e
wh at e q u ip me n t n e e d s to b e in sp e ct-
e d an d wh e n , as we ll as to e stab lish
wh e re failu re wo u ld b e le ast acce p t-
ab le an d cau se th e mo st p ro b le ms.
Th is make s it e asie r to se e wh e re
e ffo rt h as to b e fo cu se d in o rd e r to
maximize th e re tu rn . It facilitate s th e
o p timizatio n o f e xamin atio n in te rvals
wh ilst at th e same time id e n tifyin g
e q u ip me n t fo r wh ich n o n -in vasive e x-
amin atio n s wo u ld b e e q u ally e ffe ctive .
Average inspection inter-
vals were increased by
between 35 and 57 per-
cent, with an average
increase of 44 percent.
Up u n til n o w, ABBs e xp e rie n ce h as
b e e n main ly with p re ssu re ve sse ls.
Ho we ve r, e xactly th e same ap p ro ach
is ad o p te d wh e n asse ssin g risks fo r
ro tatin g e q u ip me n t, critical in stru me n -
tatio n an d stru ctu re s.
Th e co mp an ys RBI ap p ro ach re lie s
o n h arn e ssin g co mp an y an d co n su l-
tan ts e xp e rtise as we ll as th e u se o f
so p h isticate d so ftware to o ls.
ABB h as re fin e d its p ro ve n RBI ap -
p ro ach in to an e fficie n t, stre amlin e d
so lu tio n calle d Risk Base d In sp e c-
tio n
+

2
. Th e re su lt o f e xp e rie n ce
gain e d th ro u gh h u n d re d s o f p ro je cts,
it fo cu se s o n d e live rin g tan gib le
re su lts b y:
1
RBI risk matrix: moving the operating risk
envelope to a safer region

L
i
k
e
l
i
h
o
o
d
Consequence
Post RBI
a
b c
d
a
No special care required
b
Hazard study
c
Periodic inspection
d
Full registration procedure
Factbox
Typical recent results
Study A B C D
Average inspection interval
before/ after RBI study (months) 31 / 44 No data 54 / 85 48 / 65
Vessels moved to
non- invasive inspection 16 out of 26 76 out of 157 90 out of 179 41 out of 82
Reduction in inspection costs 58 % 49 % 61 % 81 %
ABB Review
Accu mu latin g co mp re h e n sive
kn o wle d ge o f th e risks asso ciate d
with sp e cific p lan t asse ts.
Sign ifican tly re d u cin g th e to tal co st
o f in sp e ctio n s.
Ach ie vin g lo n ge r in te rvals b e twe e n
in sp e ctio n / main te n an ce tu rn aro u n d s
an d re d u cin g th e time n e e d e d fo r
th e m.
En su rin g mu ch imp ro ve d e q u ip me n t
availab ility an d re liab ility, an d min i-
mizin g u n fo re se e n b re akd o wn s,
re su ltin g in mo re u p time .
Bu ild in g gre ate r co n fid e n ce in
e q u ip me n t in te grity.
Pro vid in g an e stab lish e d p ath to all
n e ce ssary re gu lato ry ap p ro vals.
An o u tstan d in g e xamp le o f th e su c-
ce ss o f Risk Base d In sp e ctio n + imp le -
me n te d in clo se p artn e rsh ip with a
cu sto me r is a p ro je ct ABB u n d e rto o k
re ce n tly fo r Victre x p lc, a UK p o lyme r
p ro d u ce r.
RBI delivers for Victrex
Victre x man u factu re s PEEK p o lyme r,
a h igh -p e rfo rman ce th e rmo p lastic
with e xce p tio n al ch e mical, we ar, e le c-
trical an d te mp e ratu re re sistan ce . It is
u se d in critical ap p licatio n s in th e in -
d u strial, au to mo tive , e le ctro n ics, me d -
ical, ae ro sp ace an d fo o d in d u strie s
aro u n d th e wo rld .
Th e co mp an y is active ly e xp an d in g
its marke ts fo r PEEK p o lyme r th ro u gh
in te n sive marke tin g, cu sto me r-fo cu se d
se rvice an d a co mmitme n t to p ro d u ct
q u ality. Victre x is in th e fo rtu n ate p o -
sitio n o f e n jo yin g ve ry h igh d e man d
fo r its p ro d u ct. Its majo r ch alle n ge is
to in cre ase p ro d u ctio n wh ile co n tro l-
lin g o ve rh e ad an d in ve stme n t co sts.
Wo rkin g with ABB, Victre x e n gin e e rs
we re aimin g to b re ak o u t o f th e
vicio u s lo o p th at h ad always lin ke d
h igh e r o u tp u t to in ve stme n t in n e w
p lan t. Th e ge n e ral ru le was th at an
an n u al in cre ase o f 100 to n s in o u tp u t
always re q u ire d an in ve stme n t o f
$ 1.5 millio n .
In re ce n t ye ars o u tp u t h as b e e n raise d
fro m 1000 to n s p e r ye ar to 2000 to n s
in two ju mp s o f 500 to n s, first in 1996
an d th e n again in 2000. In e ach case
almo st $ 10 millio n was in ve ste d in
n e w p lan t
3
.
Saving time, saving cost
Th e in sp e ctio n an d main te n an ce
ro u tin e s we re a p rime targe t fo r clo se
e xamin atio n . It was se e n th at time
an d co st savin gs co u ld make a vast
d iffe re n ce to o u tp u t, e fficie n cy an d
p ro fitab ility o f th e p lan t.
Be fo re RBI th e in sp e ctio n re gime was
p re scrip tive ly in vasive o n all ite ms,
re gard le ss o f th e risks asso ciate d with
th e m. It is a fact th at, ve ry o fte n ,
e xte n sive in sp e ctio n d u rin g th e sh u t-
d o wn p e rio d s re ve als n o d e te rio ra-
tio n . Ho we ve r, th e re are o ccasio n s
wh e n u n e xp e cte d p ro b le ms are
fo u n d , an d th e se can le ad to u n -
p lan n e d re p airs th at in cre ase th e o u t-
age time .
All in sp e ctio n an d main te n an ce wo rk
o n th e main p re ssu re ve sse ls mu st
co mp ly with Pre ssu re Syste ms Safe ty
Re gu latio n s 2000. Th e se lo o k main ly
at h o w th e safe ty p e rfo rman ce an d
co n d itio n o f th e ve sse ls re d u ce wo rk-
p lace risks as far as is re aso n ab ly
p ractical.
As a Victre x e n gin e e r p u ts it, Th e
to tal co st o f in sp e ctio n in clu d e s d e -
co mmissio n in g, d e co n tamin atio n an d
p re p aratio n fo r in te rn al in sp e ctio n .
All th is time an d e ffo rt ju st to fin d
th at, mo re o fte n th an n o t, e ve ryth in g
is OK! Th is le d u s to q u e stio n o u r
ap p ro ach .
It was th is q u e stio n in g th at ste e re d
th e co mp an y to ward a kn o wle d ge -
b ase d ap p ro ach to u n d e rstan d in g th e
b e h avio r o f th e p lan t.

Th e RBI o b je ctive was to raise p lan t
availab ility fro m 80 to 85 p e r ce n t
fro m 290 d ays to 310 d ays p e r ye ar
wh ich is th e wo rld -class stan d ard fo r
similar b atch sp e cialty ch e mical p ro -
ce sse s.
New assets
Registration
assessment
Existing assets
Auditing
Training
Defect
assessment
Fitness
for purpose
assessment
Independent
design review
Asset life
planning
ABB RBI+
ABB inspection service
Registration Support Inspection life cycle database
Materials/ NDT
expertise
Design
expertise
Inspection
technology
Maintenance
expertise
Operational
knowledge
Data
collection &
analysis
Repairs &
modifications
Execution of
inspection
Risk
analysis
Reduction
of
actions
Develop
inspection
plans
Identify
dete rioration
mechanisms
2
Inspection life cycle database
ABB Review
It was co n clu d e d th at th e
main co n trib u tio n to in cre as-
in g p lan t availab ility wo u ld
co me fro m a re d u ctio n in th e
an n u al sh u td o wn time . Th is
wo u ld n e e d to b e cu t fro m
35 d ays to 21 d ays.
Th e p o te n tial fin an cial b e n e -
fit o f savin g a large amo u n t
o f d o wn time was e stimate d
to b e almo st $ 10 millio n .
Su ch an amo u n t wo u ld re su lt
fro m an imp ro ve d gro ss mar-
gin an d re d u ce d sh o rt-te rm
in ve stme n t n e e d s.
No n e o f th is me an s th at
fu tu re p lan t e xp an sio n is
ru le d o u t, b u t Victre x imme d iate p ri-
o rity was to ge t th e mo st re tu rn fro m
its e xistin g facility b e fo re e mb arkin g
o n fu rth e r majo r in ve stme n t.
Fo r b o th ABB an d Victre x th e re we re
so me e sse n tial ste p s in e n su rin g th at
RBI d e live re d th e d e sire d b e n e fits.
Ab o ve all e lse th e re was th e n e e d to
h arn e ss all e xistin g in -h o u se kn o wl-
e d ge an d e xp e rie n ce an d lin k it to
ABB e xp e rtise . As a startin g p o in t, th e
in -h o u se te am me mb e rs we re to p o o l
all th e ir kn o wle d ge an d e xp e rie n ce .
Th is d ata, b o th q u alitative an d q u an ti-
tative , to ge th e r with h isto rical re co rd s
o f p re vio u s in sp e ctio n s an d a th o r-
o u gh an alysis o f th e cau se s o f lo st
o u tp u t in th e last 12 mo n th s, p ro vid e d
th e b asis fo r th e kn o wle d ge b ase o n
wh ich th e RBI p lan wo u ld b e d e ve l-
o p e d .
For Victrex, a UK polymer
producer, the potential
financial benefit of reduc-
ing downtime through RBI
was estimated to be
almost $ 10 million.
A fu ll u n d e rstan d in g o f th e re su lts o f
p ast in sp e ctio n s o f p re ssu re ve sse ls
d u rin g sh u td o wn s was vital, sin ce p re -
p arin g fo r an d carryin g o u t in vasive
in sp e ctio n s acco u n ts fo r mu ch o f th e
time an d e ffo rt in vo lve d in a sh u t-
d o wn . Kn o win g an d u n d e rstan d in g
th e failu re me ch an isms e ach ite m is
su sce p tib le to , an d wh e re to lo o k fo r
th e m, h e lp e d th e te am d e cid e o n th e
ad e q u acy o f n o n -in vasive in sp e ctio n .
Th is p ro ve d to b e a majo r b e n e fit.
Th o ro u gh ly gath e rin g an d asse ssin g
salie n t h isto rical d ata, p lu s th e u se o f
ABB ad van ce d so ftware to o ls, e n ab le d
th e te am to d e ve lo p an in sp e ctio n
ro u tin e th at p rio ritize s an d re sp o n d s
to risks an d fo re se e n failu re sce n ario s.
It also min imize s th e risk o f u n e xp e ct-
e d failu re .
Havin g carrie d o u t th e fu ll re vie w an d
cre ate d an RBI p ro gram, th e re su lts
h ave p ro ve d imme d iate an d imp re s-
sive . Th e first sh u td o wn to b e affe ct-
e d , in Octo b e r 2001, re q u ire d o n ly
n in e d ays. Th e n e ce ssary e n -
gin e e rin g an d main te n an ce
wo rk was co mp le te d in fo u r
d ays. Th e to tal co st o f th e
e xe rcise was h alf th e amo u n t
b u d ge te d .
Th e n e xt sh u td o wn p e rio d ,
a little le ss th an a ye ar late r,
was cu t fro m 35 d ays to
20 d ays. Th e te am e xp e cts
sh u td o wn s to b e ke p t to th is
le ve l in fu tu re ye ars as so me
o f th e e q u ip me n t ge ts o ld e r
an d we ar an d te ar in cre ase s.
Be sid e s th e we lco me time
savin g it p ro vid e s, RBI h as
me t an d e xce e d e d e xp e cta-
tio n s. Du rin g a re ce n t p e rio d o f h igh
d e man d , th e gro ss margin h as b e e n
imp ro ve d b y mo re th an $ 9 millio n
o ve r e igh te e n mo n th s o f o p e ratio n
an d o th e r savin gs o n cap ital in ve st-
me n t an d asso ciate d d e p re ciatio n e x-
ce e d $ 3 millio n . Ye ar o n ye ar sh u t-
d o wn savin gs are ru n n in g at almo st
$ 100,000. Victre x e n gin e e rs ad mit th at
th e ir in itial d e sire to ap p ly RBI was an
act o f faith . Th e y saw th e o p p o rtu n ity
an d b e lie ve d th at th e go als wo u ld b e
ach ie ve d , b u t th e y h ad n o p re vio u s
e xp e rie n ce to re fe r to . As An d re w
An d e rso n , En gin e e rin g Man age r o f
Victre x says, Th e p ast e xp e rie n ce ,
p ro fe ssio n alism an d e xp e rtise o f ABB
we re vital e le me n ts in ste e rin g th e
wo rk fo rward an d in p ro vid in g th e
co n fid e n ce in th e ach ie vab ility o f o u r
o b je ctive s.
Th e Victre x e xp e rie n ce sh o ws q u ite
cle arly th at Risk Base d In sp e ctio n s
can p ro vid e th e b e n e fits b u sin e sse s
n e e d to save o n p re ve n tive main te -
n an ce wh ile min imizin g th e risks o f
failu re .
Tony Musgrave
ABB Eutech Limited
Warrington, UK
tony.musgrave@gb.abb.com
Footnote
1)
ABB Eut ech is t he process solut ions cent er of
excellence wit hin ABBs pet roleum, chemical, life
science and consumer goods indust ries business
area.
3
The Victrex plant
What equipment should be inspected?
Where would failure be unacceptable?
Where should effort be focused?
Which techniques should be used?
How can the examination intervals be
optimized?
Benefits
Increased knowledge of the risk of
operating assets
Significant reduction in the total cost of
inspection
Longer turnaround intervals, and
reduced turnaround durations
Improved equipment availability and
reliability, helping to maximize uptime
Increased confidence in equipment
integrity
Established path to regulatory approval
Factbox
ABB Risk Based Inspection
+

in brief
Good products offer more to customers when they are combined with comprehensive
support and maintenance programs. Optimal performance and minimal maintenance
costs (which drive increased operational profitability) can be achieved through service
agreements over the lifetime of a product, but effective lifecycle management requires
continuous tracking of asset history operation, wear, damage, and maintenance. Care-
ful monitoring of the condition and performance of assets allows the implementation of
predictive maintenance programs that significantly reduce maintenance costs and the
risk of asset failure. Without this information, performance suffers and maintenance
costs rise.
ABB Medium Voltage (MV) drives in cooperation with ABB Corporate Research has de-
veloped a new customer support system The DriveMonitor software and hardware
that allows an operator to monitor the performance of an MV drive system, collect data
and store the drives history, all from a remote computer. Drive performance monitoring
provides also deep insight into the process status useful extension in analyzing the
Operational profitability.
Drive monitor
Embedded product intelligence that enhances lifecycle
management and process performance in drive systems
Maciej Wnek, Michal Orkisz, Jaroslaw Nowak, Stefano Legnani
ABB Review
21
ABB Review
R
e al p lan t syste ms co mp rise a wid e
varie ty o f asse ts. So me are
straigh tfo rward , simp listic e ve n , wh ile
o th e rs are in te llige n t, cap ab le o f
se lf-d iagn o sis o r e ve n se lf-co rre ctio n .
All o f th e se asse ts n e e d care fu l mo n i-
to rin g. Large an d critical asse ts o fte n
co me with th e ir o wn su p e rviso ry co n -
tro l syste ms, b u t all o f th e asse ts in a
p ro ce ss ch ain are in fo rmatio n p ro vid -
e rs e ith e r d ire ctly, via in -b u ilt se n -
so rs, o r in d ire ctly, b y re p o rtin g o n
o th e r asse ts in th e ch ain .
Cost-effective data collection
and processing
An e fficie n t life cycle man age me n t
syste m re q u ire s scalab le to o ls th at can
b e ad ap te d to th e n atu re o f an asse t,
its valu e , statu s, an d ge n e ral main te -
n an ce p o licy. Th e first asp e ct to b e
co n sid e re d is th e co mp re h e n sive n e ss
o f th e syste m: wh e th e r it b e a sin gle
asse t (e g, a d rive ), o r a wh o le p ro d u c-
tio n lin e , wh ich co n tain s man y asse ts.
Th e se co n d asp e ct is th e availab ility
o f d ata: fro m wh ats alre ad y th e re
to d e d icate d me asu rin g syste ms th at
d e te ct vib ratio n s, cu rre n t, co rro sio n
e tc. Th e th ird asp e ct re late s to in -
cre asin g le ve ls o f kn o wle d ge co n te n t
an d d iagn o stic fu n ctio n s: at o n e e x-
tre me h avin g a simp le limit th re sh o ld ,
at th e o th e r, h avin g ad van ce d life time
p re d ictio n algo rith ms.
An efficient lifecycle
management system
requires scalable tools
that can be adapted to
the nature of an asset, its
value, status, and general
maintenance policy.
To targe t lo w to o l co sts o n e h as to
co n ce n trate o n scalab ility an d co n fig-
u ratio n fle xib ility. Similar asse ts
sh o u ld b e tre ate d similarly, b u t with
in d ivid u al atte n tio n d e p e n d e n t o n
th e ir co n te xt in th e syste m. Fo r e xam-
p le , two e le ctric mo to rs migh t b e
id e n tical, b u t if o n e is ru n n in g a ve n ti-
latio n fan o f lo w imp o rtan ce an d th e
o th e r a critical fu me -e xh au st fan , th e ir
main te n an ce p ro grams wo u ld b e simi-
lar, b u t th e le ve l o f in ve stme n t in e ach
wo u ld d iffe r acco rd in g to th e ir imp o r-
tan ce .
A scalab le syste m is n o t th e same
th in g as a co mb in atio n o f d iffe re n t
ap p ro ach e s th at ad d re ss d iffe re n t
asp e cts o f life cycle man age me n t.
To b e e fficie n t, a to o l mu st gu aran te e
fu ll d ata in te ro p e rab ility, sin gle d ata
e n try p o in ts, an d u n ifie d in te rfacin g,
u sage an d re p o rtin g. Mu ltip le syste ms
can b e co mb in e d in an IT in te gratio n
p ro je ct, b u t o n ly a scalab le to o l can
p ro vid e tru e main te n an ce o p timiza-
tio n .
In sh o rt, in d ivid u al asse ts mu st b e
asse sse d to d e te rmin e th e le ve l o f
in ve stme n t th at can b e ju stifie d b y
th e ir in d ivid u al ro le s in a p ro ce ss.
A go o d co n d itio n asse ssme n t syste m
is:
e xp an d ab le , to acco mmo d ate sin gle
o r mu ltip le asse t o b je cts
ab le to ap p ly ru le s o f vario u s co m-
p le xity to th e asse ts vib ratio n -
b ase d , te mp e ratu re -b ase d , e le ctrical
te st-b ase d , o p e ratio n d ata-b ase d ,
statistics- an d h isto ry-b ase d e tc.
ab le to acq u ire d ata fro m vario u s
so u rce s, e g, d rive syste ms, co n tro l
syste ms, vib ratio n me asu rin g to o ls,
man u al e n trie s, an d th e asse t itse lf.
ABB h as u se d th is me th o d o lo gy in
th e d e ve lo p me n t o f its Asse t Op ti-
1
MV drive an asset with a broad technology
span and a rich information source
Java/ .Net
Si Cu
Assembler
2
The DriveMonitor
TM
design principles
DriveMonitor Unit
Industrial PC
VPN
Router
Firewall
Ethernet
TCP/ IP
Optical Fibers
ACS drivers
1 ........... 5
NDBU 95
3
DriveMonitor Analyzing the systems heartbeat. Drive information can be utilized on various
diagnostic levels from the converter unit to the process section
Drive monitor
ABB Review
mizatio n / Asse t Mo n ito rs co n ce p ts
an d Drive Mo n ito r is a p art o f th is
tru ly scalab le so lu tio n
1
.
ABB Drives assets as knowledge
containers.
ABB MV Drive s fo cu se s atte n tio n o n
p ro d u ct d e sign an d d e ve lo p me n t, b u t
also o n co n figu ratio n an d o p timiza-
tio n in re latio n to cu sto me r ap p lica-
tio n s. A q u ick lo o k u n d e r th e h o o d
o f a d rive u n it will imme d iate ly sh o w
th at th e te ch n o lo gical co mp le xity o f
th is to rq u e d e live ry p lan t ran ge s
fro m co p p e r b ars to e le ctro n ic circu it
b o ard s. Its so ftware ran ge s fro m as-
se mb le r co d e to th e n e we st h igh -le ve l
lan gu age s. To o b tain th e h igh e st p o s-
sib le p e rfo rman ce fro m su ch a d e vice
o ve r its e n tire life time re q u ire s so me
atte n tio n . Ho we ve r, d rive u n its, su ch
as th e MV Drive fro m ABB, are h u ge
b an ks o f d ata, re co rd in g in fo rmatio n
re latin g n o t o n ly to th e d rive co n ve rt-
e r p e rfo rman ce , b u t also to th e d rive n
e q u ip me n t, an d e ve n to th e wh o le
d o wn stre am p ro d u ctio n p ro ce ss. Effi-
cie n t u se o f th e se d rive d ata is th e
first ste p to ward s th e life cycle man -
age me n t at first fo r th e co n ve rte r
itse lf, u ltimate ly fo r th e wh o le d rive -
p o we re d p ro ce ss.
Efficient lifecycle management
A p ragmatic ap p ro ach to life cycle
man age me n t issu e s sh o u ld an swe r th e
fo llo win g q u e stio n s:
Wh at sh o u ld b e d o n e to th e asse t in
o rd e r to main tain th e h igh e st p e r-
fo rman ce an d th e lo we st co sts.
Wh e n sh o u ld th is actio n b e take n ?
Id e ally th e asse t sh o u ld b e in te llige n t
e n o u gh to p ro vid e th is in fo rmatio n to
th e o p e rato r. Alte rn ative ly, th e in te lli-
ge n ce can b e e mb e d d e d as th e asse t
e xte n sio n in te llige n ce th at u tilize s
fu lly th e amo u n t o f d ata p ro ce sse d in
th e d rive .
In order to keep tool
costs down, maintenance
systems should be flexible
and able to accommodate
a wide range of asset
types.
Th e Drive Mo n ito r syste m is d e sign e d
to me e t th e se re q u ire me n ts. On th e
o n e h an d it p ro vid e s co n tin u o u s mo n -
ito rin g an d an alysis o f th e d rive state
an d o p e ratio n , su p p o rts ro o t-cau se
an alysis (RCA) an d h e lp s to fo llo w
p re d ictive main te n an ce p ath s. On th e
o th e r, it p ro vid e s a p latfo rm u p o n
wh ich to o ffe r th e cu sto me r u n iq u e
e xte n sio n fe atu re s th at, b y u tilizin g
d rive sign als, allo w th e o p e rato r to
visu alize th e wh o le sh aft state alo n g
with p ro ce ss-re late d KPIs, e tc.
DriveMonitor: embedded intelligence,
scaleable and secure
Th e Drive Mo n ito r syste m co n sists o f a
h ard ware - an d a so ftware laye r
2
. Th e
h ard ware laye r is a p ro p e rly in te r-
face d in d u strial PC th at is facto ry in -
stalle d in th e mo st p o we rfu l n e w ABB
MV Drive s (it can also b e o ffe re d as
an u p grad e to e xistin g mo d e ls). Th e
so ftware laye r au to matically co lle cts
an d an alyse s se le cte d d rive sign als
an d p arame te rs. Th e Drive Mo n ito r
h ard ware is b ase d o n an in d u strial PC
p latfo rm to p ro vid e th e e xp e cte d lo n -
ge vity an d re mo te acce ssib ility. Virtu al
Private Ne two rk (VPN) so lu tio n s are
u se d fo r re mo te acce ss to e n su re h igh
se cu rity.
Scalability the biggest challenge
Th e Drive Mo n ito r so ftware laye r is
e xtre me ly fle xib le with re sp e ct to th e
co n figu ratio n o f d iagn o stic ru le s, th e
ran ge o f th e asse ts with wh ich it can
b e u se d , its alarm an d re p o rtin g fu n c-
tio n s, an d its d ata in take so u rce s.
Be in g co mp atib le with ABBs Asse t
Mo n ito r family, Drive Mo n ito r o p e n s
th e d o o r to th e wh o le ABB Asse t Man -
age me n t p o rtfo lio , with Asse t Op ti-
mize r an d o th e r Asse t Mo n ito rs as
o p tio n al e xte n sio n s. Drive Mo n ito r can
b e e asily in te grate d in to au to matio n
syste ms u sin g th e ABB 800xA p latfo rm
(o th e r syste ms can b e co n n e cte d
th ro u gh OPC
1)
se rve rs). Th e Drive -
Mo n ito r is d e sign e d to b e u se d with a
sin gle d rive , an d with large syste ms.
Th e re are p o ssib ilitie s fo r e xp an sio n
to in clu d e o th e r me asu re me n ts su ch
as co rro sio n , vib ratio n s, ad d itio n al
te mp e ratu re se n so rs, e tc. It p ro vid e s
millise co n d -b ase d samp lin g rate s with
ye ar-b ase d sch e d u lin g, e ve n t-d rive n
actio n s an d alarms, an d mo re . Th e
vario u s Drive Mo n ito r co mp o n e n ts can
b e d istrib u te d to d iffe re n t co mp u te rs.
Fo r in stan ce , se ve ral Drive Mo n ito r
u n its can b e co n figu re d in p aralle l to
co ve r large r in stallatio n s an d th e re -
su lts can b e b ro u gh t to a ce n tral co n -
tro l ro o m PC fo r o p e rato r co n ve -
n ie n ce .
Application area
Th e b asic fu n ctio n o f th e Drive Mo n i-
to r is to watch th e co n ve rte r p art o f
Extended support information facilitating root- cause analysis
Footnote
1)
OPC- OLE for Process Cont rol
Drive monitor
ABB Review
a d rive sh aft syste m
3
. It co n tin u o u sly
mo n ito rs th e d rive statu s an d re sp o n d s
wh e n th at statu s ch an ge s. Ch an ge s in
d rive statu s can b e cau se d b y d rive
fau lts (u n e xp e cte d d rive sto p p age s),
alarms (sign als cro ssin g th re sh o ld val-
u e s), u se r-d e fin e d p arame te r ch an ge s,
an d h igh e r le ve l, Drive Mo n ito r-ge n e r-
ate d ap p licatio n -sp e cific alarms.
ABB MV Drives focuses
attention on product
design and development,
but also on configuration
and optimization in relation
to customer applications.
With e xtra d iagn o stic p ackage s, Drive -
Mo n ito r can fo llo w o th e r sh aft train
co mp o n e n ts su ch as th e main circu it
b re ake r, th e tran sfo rme r, an d th e d riv-
e n mach in e . At th e h igh e st le ve l, sp e -
cialist p ackage s d ire ctly re late d to
sp e cific ap p licatio n are as (su ch as
ro llin g mills, wate r p u mp s, an d co m-
p re sso rs) can b e in te grate d in to th e
syste m. Th is kin d o f e xp an sio n can b e
d o n e at an y p o in t in time d e p e n d in g
o n th e cu sto me rs n e e d s. It is also
p o ssib le to in co rp o rate e xtra me asu re -
me n ts th at go b e yo n d th e d rive sig-
n als. Drive Mo n ito r-b ase d d iagn o stic
ro u tin e s are valu ab le e xte n sio n s to
p lan t-le ve l Asse t Man age me n t p ro -
gram su ch as ABB Asse t Op timizatio n
so lu tio n . Th e Drive Mo n ito r b lo ck is an
e asy fit to alre ad y in stalle d ABB co n -
tro l p latfo rms an d o n th e o th e r h an d
can b e a go o d start fo r p lan t Asse t
Man age me n t so lu tio n .
Oil and gas Ras Laffan pumping
station
Th e p u mp in g statio n co n sists o f 27
p u mp u n its u sin g, in to tal, mo re th an
19 MW o f p o we r d e live re d b y ABB
e le ctrical mo to rs an d ACS6000 d rive s.
All d rive s are su p e rvise d b y th e mo n i-
to rin g p ackage , b u t as an e xte n sio n ,
th e d ata fro m th e ABB AC800M co n -
tro lle rs th at co n tro l th e p u mp lin e
o p e ratio n are p ro ce sse d b y th e d iag-
n o stic p ackage . With o u t re q u irin g
ad d itio n al in ve stme n t in h ard ware o r
me asu rin g d e vice s, th e syste m watch -
e s th e statu s o f th e mo to rs an d th e
p u mp s te mp e ratu re s, o p e ratin g co n -
d itio n s an d vib ratio n le ve ls p ro ce sse d
fo r th e co n tro llin g p u rp o se b y AC800M
u n its. In th is way, a h igh ad d e d valu e
is o b tain e d at lo w in ve stme n t co st. All
re su lts are in te grate d in to th e 800xA
Wo rkp lace p an e l givin g th e o p e rato r
visu ally co mp atib le statu s in fo rmatio n
n o t n e e d to le arn ye t an o th e r p lat-
fo rm fo r co n d itio n mo n ito rin g as it is
typ ically th e situ atio n in in d u strial
p lan ts.
DriveMonitor
TM
continu-
ously monitors the drive
status and responds
when that status changes.
Rolling mills Seeing the process
heartbeat
ABB Drive s are ve ry p o we rfu l an d
co n figu rab le u n its in a p ro ce ss. Th e ir
statu s is n o t o n ly co n ve rte r-re late d ,
b u t re fle cts se ve ral p arame te rs th at
re fle ct th e p ro ce ss statu s. Th e se p ara-
me te rs in clu d e sh aft to rq u e , p h ase
cu rre n t an d p h ase vo ltage s. Th e se
d ata as p ro vid e d b y th e d rive u n it
an d an alyze d b y th e Drive Mo n ito r
can re tu rn valu ab le p ro ce ss statu s in -
fo rmatio n re gard in g p ro ce ss o u tlie rs,
p ro ce ss d rift an d ch an ge s. Again , at
n o h ard ware in ve stme n t, d rive d ata is
map p e d again st trad itio n al p ro ce ss in -
fo rmatio n fro m th e co n tro l p latfo rm
an d all th is is e n ab le d b y syste matic
an d co o rd in ate d d e ve lo p me n t o f th e
ABB Asse t Man age me n t p latfo rm
b o th fro m th e p ro d u ct an d th e syste m
sid e s.
Concluding remarks
ABB p ro ce ss au to matio n o ffe rs co m-
p le te syste ms fo r th e p lan t asse t man -
age me n t th at are in all re sp e cts co m-
p atib le with ABBs p ro d u ct p o rtfo lio
ge n e ratin g h igh le ve l b e n e fits at lo w
in ve stme n t co sts. 1+1 can e q u al 3 o r
e ve n 5 in th is case .
Maciej Wnek
Michal Orkisz
Jaroslaw Nowak
ABB Corporate Research
Krakow, Poland
maciej.wnek@pl.abb.com
michal.orkisz@pl.abb.com
jaroslaw.nowak@pl.abb.com
Stefano Legnani
ABB Medium Voltage Drives
Turgi, Switzerland
stefano.legnani@ch.abb.com
Drive monitor
DriveMonitor shaft- line overview
Plant Personnel
Pager
e- mail
Cell Phone
SCALABLE
Asset
Monitors
Drive Monitor
Control loops are a vital part of the
process industry and are especially
important when it comes to quality,
economy and safety. In fact, a
significant portion of incorrectly tuned
automatic control loops can actually
decrease production performance
rather than improve it.
Control loop s
p leasure or p lague?
A plant floor view within the process industry
Alexander Horch
The availability and effectiveness of a
control system is essential for
operating the process safely and at
maximum performance, ensuring
quality of production and its
profitability. Supervision and
improvement of controller
performance is therefore vital and
important.
Performance monitoring of closed
loops or Control Loop Condition
Monitoring (CLCM) as it is also known
is used to automatically assess
controller performance. In this article,
ABBs control loop condition
monitoring technology is reviewed.
ABB Review
25
ABB Review
C
o n tro l lo o p s are an in trin sic p art
o f an y au to matio n syste m. It h as
b e e n e stimate d th at co n tro l lo o p s h ave
an asse t valu e o f $ 25,000, with a co st
d istrib u tio n as sh o wn in
1
. Acco rd in g
to a re ce n t e d ito rial fro m th e Hyd ro -
carb o n Pro ce ssin g Jo u rn al [1], With -
o u t p ro p e rly tu n e d co n tro l lo o p s to
min imize variab ility, an d u p d ate d p ro -
ce ss mo d e ls u se d b y th e ad van ce d
co n tro ls to re fle ct re al co n strain ts an d
b u sin e ss o b je ctive s, su b stan tial b e n e -
fits are lo st. In o th e r wo rd s, in clu d e
co n tro l lo o p s in asse t man age me n t.
Au to mate d CLCM is h igh ly attractive
in mo st p lan ts b e cau se th e re are sim-
p ly to o man y co n tro l lo o p s to b e
main tain e d b y o n e se rvice e n gin e e r
o n a re gu lar b asis, ie , at le ast e ve ry
six mo n th s. An o th e r re aso n wh y man y
in d u strie s are in te re ste d in CLCM is its
in h e re n t n o n -in vasive n e ss.
CLCM wo rks like a d o cto rs ste th o -
sco p e : it o b tain s a d iagn o sis b y p as-
sive ly liste n in g to th e p ro ce ss. Typ i-
cally, n o mo re in fo rmatio n th an stan -
d ard DCS tags se tp o in t (SP), p ro ce ss
variab le (PV), co n tro lle r o u tp u t (CO)
e tc. is re q u ire d . In a typ ical p ro d u c-
tio n p lan t in th e p ro ce ss in d u stry, fo r
e xamp le , th e re may b e u p to se ve ral
th o u san d co n tro l lo o p s.
2
sh o ws a
typ ical an d imp o rtan t lo o p p e rfo r-
man ce ran kin g re su lt, in clu d in g typ i-
cal d ata fo r e ach cate go ry.
The need for CLCM?
Asse ssme n t o f co n tro l lo o p b e h avio r
is as o ld as co n tro lle r d e sign . In th e
d e sign p h ase , th e d e sign e r u su ally
cre ate s a co n tro lle r th at satisfie s so me
give n p e rfo rman ce sp e cificatio n s.
Un fo rtu n ate ly, th e se p e rfo rman ce
sp e cificatio n s o fte n can n o t b e e valu at-
e d u sin g me asu re me n t d ata o b tain e d
fro m n o rmal p lan t o p e ratio n .
In h e lp in g to re so lve th is issu e co n -
sid e rab le re se arch h as b e e n carrie d
o u t to d e ve lo p a h o listic an d n o n -in -
vasive me th o d o lo gy th at can au to mati-
cally asse ss co n tro lle r p e rfo rman ce .
An o ve rvie w o f o n go in g re se arch is
p re se n te d in [3].
Automated CLCM is
highly attractive in most
plants because there are
simply too many control
loops to be maintained by
one service engineer on a
regular basis, ie, at least
every six months.
Th e mo st o b vio u s an d se rio u s co n tro l
lo o p p ro b le m is a p e rsistin g o scilla-
tio n . Re aso n s are man ifo ld : b ad co n -
tro lle r se ttin gs; e xte rn al p ro b le ms;
valve frictio n ; e q u ip me n t failu re ; o r
p ro ce ss-re late d re aso n s. Irre gu lar d e -
viatio n s fro m targe ts are mo re d ifficu lt
to an alyse . Lu ckily n o wad ays, o scilla-
tio n s an d p o o r p e rfo rman ce can b e
au to matically d e te cte d with h e lp , fo r
e xamp le , fro m wh at is kn o wn as th e
Harris In d e x [2]. Ho we ve r, th e main
ch alle n ge o f d iagn o sin g b ad p e rfo r-
man ce re main s.
CLCM typ ically fo cu se s o n b asic co n -
tro l lo o p s th at are vital in ach ie vin g
th e targe te d p ro d u ct q u ality an d p lan t
p e rfo rman ce . Ho we ve r, in situ atio n s
wh e re h igh ly ad van ce d co n tro l lo o p s
are u se d , mo re ad van ce d su p e rvisio n
fu n ctio n ality is n e e d e d . Ad van ce d
co n tro l (e g, a mo d e l-p re d ictive co n -
tro lle r) re lie s h e avily o n th e assu mp -
tio n th at th e u n d e rlyin g b asic co n tro l
lo o p s p e rfo rm satisfacto rily. CLCM
e n su re s th is re q u ire me n t.
CLCM in industry
Th e ch e mical, p e tro -ch e mical an d
p u lp an d p ap e r in d u strie s we re th e
first to ap p ly CLCM me th o d s an d
h ave , o ve r th e ye ars, b u ilt u p co n sid -
e rab le e xp e rie n ce . Mo re re ce n tly,
10 %
1
Cost distribution of a control loop.
Sensor
Control valve
Commissioning
Share of DCS
Installation
Engineering
Maintenance
26 %
8 % 24 %
12 %
8 %
12 %
2
Loop ranking overview for a typical plant in
the process industry.
Good Fair
Poo Open- loop
Excellent
S
P
,

P
V
O
P
S
P
,

P
V
O
P
S
P
,

P
V
O
P
S
P
,

P
V
O
P
S
P
,

P
V
O
P
16 %
32 %
18 %
6 %
28 %
Control loop s p leasure or p lague?
ABB Review
th e re h ave b e e n su cce ssfu l ap p lica-
tio n s in p o we r p lan ts. Th e in cre asin g
n u mb e r o f acad e mic re se arch gro u p s
an d th e in cre asin g in te re st fro m d iffe r-
e n t au to matio n syste m ve n d o rs is an -
o th e r in d icatio n o f th e u se fu ln e ss o f
CLCM.
CLCM includes single-
loop analysis (bottom-up)
as well as plant-wide
analyses (top-down).
ABB is first to offer this
superior combination.
Th is in te re st is also an e ffe ct o f th e
mo re ge n e ral tre n d s affe ctin g asse t
man age me n t. Th e se tre n d s h ave
b e e n re ce n tly p u b lish e d b y th e ARC
gro u p [4]:
De live r re co mme n d atio n s, n o t o n ly
p u re in fo rmatio n .
Exte n d th e u sage o f cu rre n t asse ts
( n o tre n d to re p lace cu rre n t
e q u ip me n t).
Pro vid e tigh t in te gratio n with th e IT
e n viro n me n t.
Re d u ce p lan t staff an d in cre ase
co mp e titive n e ss b y cre atin g a n e w
main te n an ce p arad igm.
Mo d e rn CLCM to o ls strive to su p p o rt
th e se tre n d s. In fact ARC re co mme n d s
th e co mb in atio n o f co n tro l lo o p co n -
d itio n mo n ito rin g with a co n tro lle r
tu n in g to o l.
ABB h as ad o p te d th is id e a an d in te -
grate d b o th fu n ctio n alitie s in to wh at it
calls th e Op timize
IT
Lo o p Pe rfo rman ce
Man age r (LPM) to o l [5].
Whats on offer from ABB
ABB o ffe rs CLCM fu n ctio n ality o n d if-
fe re n t le ve ls o f its In d u strial
IT
au to ma-
tio n p ale tte
3
.
Optimize
IT
Loop Performance Manager
(LPM)
ABBs Op timize
IT
Lo o p Pe rfo rman ce
Man age r (LPM) is a ge n e ral an d p o w-
e rfu l to o l fo r co n tro lle r p e rfo rman ce
co n d itio n mo n ito rin g. It co mb in e s
b o th co n tro l lo o p asse ssme n t an d
co n tro lle r tu n in g fu n ctio n ality, an d
ru n s with an y au to matio n arch ite ctu re
via OPC d ata co n n e ctivity
4
. Th e lat-
e st ve rsio n also in clu d e s a Plan t-wid e
Distu rb an ce An alysis mo d u le wh ich
h as p ro ve n to b e ab le to lo cate p lan t-
wid e d istu rb an ce ro o t cau se s ve ry
su cce ssfu lly.
LPMs co n tro l lo o p au d itin g n o t o n ly
in d icate s th e b e st an d wo rst p e rfo rm-
in g lo o p s in a p lan t se ctio n , b u t it also
give s d e taile d an alyse s o n h o w to re -
mo ve id e n tifie d p ro b le ms. Th e se
p ro b le ms in clu d e d iscre p an cie s in th e
fin al co n tro l e le me n t, e xte rn al d istu r-
b an ce s, an d co n tro lle r tu n in g.
Controller hardware: Control
IT
AC800M
On th e fie ld d e vice le ve l, so me b asic
fu n ctio n ality e xists fo r co n tro l lo o p
co n d itio n mo n ito rin g. Fo r e xamp le ,
o scillatio n s d u e to valve stick-slip b e -
h avio r are ve ry co mmo n . Th e se o scil-
latio n s can b e au to matically d e te cte d
b y ABBs AC800M co n tro lle r. No t o n ly
th is b u t th e AC800M co n tro lle r can
o ve rco me th e stickin g valve mo ve -
me n t b y ad d in g p u lse s to th e man ip u -
late d variab le so th e valve mo ve s to
th e d e sire d p o sitio n [6].
5
sh o ws a
typ ical me asu re me n t sign al (PV) in a
co n tro l lo o p e xh ib itin g stick-slip an d
th e co rre sp o n d in g AC800M fu n ctio n al-
ity.
Th e co n tro lle r can d e te ct stickin g
valve s an d ap p ly a stictio n co mp e n sa-
to r algo rith m to gu aran te e b e st p o ssi-
b le co n tro lle r actio n u n til th e n e xt
valve main te n an ce .
CLCM is able to detect
loop performance
deficiencies and can
contribute to substantial
gains once the appropri-
ate maintenance actions
have been taken.
System 800xA: Asset Optimization and
control loop asset monitoring
ABBs 800xA Asse t Op timizatio n Sys-
te m in clu d e s fu lly au to matic lo o p
mo n ito rin g fu n ctio n ality via a so
calle d Co n tro l Lo o p Asse t Mo n ito r.
By th at th e d e te ctio n an d d iagn o sis o f
co n tro l lo o p p ro b le ms is fe d in to th e
asse t o p timizatio n d ata h an d lin g o f
th e 800xA syste m [7]. Me ssagin g, co n -
4
ABB Loop Performance Manager (LPM): loop auditing window.
3
Automation architecture indicating controller condition monitoring
functionality (red arrows).
Plant network
Optimize
IT
Loop
Performance Manager
Plant
Information
Management
System (PIMS)
800xA System
=
800xA Asset
Optimization
ABB Review
n e ctio n to th e co mp u te rize d main te -
n an ce man age me n t syste m (CMMS),
an d acce ss to h isto rical d ata an d o th e r
re al-time p lan t in fo rmatio n h e lp s th e
u se r trace p ro b le ms an d in itiate co r-
re ctive actio n s.
Industrial applications
With o u t an y d o u b t, in d u strie s e xp e ri-
e n ce vario u s co n tro l-lo o p re late d
p ro b le ms. Th e se p ro b le ms may vary
d e p e n d in g o n th e in d u stry in q u e s-
tio n .
According to a recent
editorial from the Hydro-
carbon Processing Jour-
nal, Without properly
tuned control loops to
minimize variability, and
updated process models
used by the advanced
controls to reflect real
constraints and business
objectives, substantial
benefits are lost .
A simp le e xamp le is to co mp are th e
h igh -p re cisio n p o sitio n co n tro lle r in a
d isc d rive with a su rge tan k le ve l co n -
tro lle r in a p ap e r mill. Ob vio u sly,
b o th co n tro lle rs sh are th e same task
b u t th e ir re sp e ctive b e n ch marks
sh o u ld b e se t o n two d iffe re n t
scale s.
Co n se q u e n tly, so me o f th e
co n tro l p e rfo rman ce mo n ito r-
in g me th o d o lo gy wo u ld fit
th e first ap p licatio n , so me o f
it th e o th e r. Sin ce co n tro l p e r-
fo rman ce mo n ito rin g trad i-
tio n ally o rigin ate s fro m th e
p ro ce ss in d u stry, mo st e stab -
lish e d me th o d s fo cu s o n th e
p ro b le ms th at are typ ically
e n co u n te re d in th is in d u stry.
Diagnosis of controllers in the
(petro-) chemical and pulp and
paper industry
6
sh o ws a su b se t o f d ata b e -
fo re an d afte r a p e rfo rman ce
imp ro ve me n t in itiative in a
p u lp mill. CLCM me th o d s
d e te cte d o scillato ry co n tro l
lo o p s, an d e xp e rime n ts ve rifie d th e
d iagn o se s. Th e su b se q u e n t imp ro ve -
me n ts are o b vio u s fro m th e d ata co l-
le cte d late r.
Diagnosis of controllers
in power plants
CLCM-re late d p ro b le ms in p o we r
p lan ts are ve ry similar to th o se in o th -
e r in d u strie s. So me asp e cts, h o we ve r,
d o d iffe r, su ch as th e to tal n u mb e r o f
co n tro l lo o p s is so me wh at lo we r th an
in th e ch e mical in d u stry. Th is allo ws
gre ate r so p h isticatio n wh e n it co me s
to th e co n figu ratio n an d tu n in g o f
e ach o f th e lo o p s. Cascad e s, fe e d fo r-
ward an d mo re ad van ce d co n tro l lo g-
ics are also mo re co mmo n an d CLCM
n e e d s to take su ch co n figu ratio n s in to
acco u n t.
One imp ortant p oint is the ability to
classify CLCM results by the current
load situation in the p ower p lant. Con-
troller behavior is typ ically a function
of the load (eg, high, low, start-up ,
load change) or of other p rop erties like
raw material typ e etc. Modern CLCM
methods do consider such conditions.
Diagnosis of control-relevant
disturbances in cold rolling mills
In th e ro llin g mill in d u stry,
a fe w h igh ly so p h isticate d
co n tro l lo o p s are n e e d e d
fo r te n sio n an d th ickn e ss
co n tro l. Ho we ve r, th e ap p li-
catio n o f stan d ard CLCM
me th o d s in th e ro llin g mill
in d u stry is p e rh ap s n o t as
straigh tfo rward as in th e
ch e mical in d u stry, as re ce n t
ap p licatio n s o f th e se me th -
o d s h ave p ro d u ce d re su lts
th at are d ifficu lt to in te rp re t.
On th e o th e r h an d , wh e re
CLCM fu n ctio n ality h as b e e n
sp e cially d e sign e d fo r ro llin g
mill ap p licatio n s, th e re su lts
h ave b e e n ve ry e n co u ragin g.
To b e mo re sp e cific, CLCM
fu n ctio n ality h as b e e n su c-
ce ssfu lly d e sign e d to d iag-
n o se an d re mo ve p e rio d ic
5
Oscillation detection and stiction compensation function overview in the 800M controller.
The process value exhibits typical stiction behavior.
Setpoint
Process value
Advanced PID controller module
Enable
Output
Output if
oscillations
sluggish control
are detected
Stiction
compensator
Process valve at
risk of stiction
AO
PID Algorithm
Oscillation
detector
Sluggishness
detector
!
6
Improvement of controller performance after application of CLCM
with subsequent maintenance.
before after
20
16
12
8
4
0
T
a
g

n
u
m
b
e
r
Samples (s)
0 500 1000 1500 2000
ABBs CLCM has caught
the attention of various
industries, and many are
starting to apply such
techniques.
ABB Review
References
[1] Kane, L. A., Include cont rol loops in asset management , Edit orial of Hydrocarbon Processing, June 2003, p. 128, 2003.
[2] Harris, T. Assessment of cont rol loop performance , In The Canadian Journal of Chemical Engineering , Vol 67, pp. 856861 (1989).
[3] Horch, A., Dumont, G., Int ernat ional Journal of Adapt ive Cont rol and Signal Processing, Special Issue on Cont rol Performance Monit oring, Eds., Vol. 17, No. 79,
Sept ember- November 2003.
[4] ARC Advisory Group, Real- t ime Performance Monit oring St rat egies for Asset Opt imizat ion , ARC St rat egies, July 2004 (www.ARCweb.com)
[5] ABB (2005). Opt imize
IT
Loop Performance Manager Version 2.0. Users Guide. ABB Advanced Cont rol Solut ions, www.abb.com Product s & Services Syst ems
and Indust ry Solut ions Chemicals Advanced Cont rol LPM.
[6] Hgglund, T. (1997). St ict ion compensat ion in cont rol valves. In European Cont rol Conference, Brussels, Belgium.
[7] ABB (2005). Syst em 800xA Asset Opt imizat ion, www.abb.com Product s & Services ABB Product Guide Cont rol Syst ems 800xA Asset Opt imizat ion
[8] ABB (2005). Syst em 800xA Informat ion Management , www.abb.com Product s & Services ABB Product Guide Cont rol Syst ems 800xA Informat ion
Management
[9] ABB (2005), Advise
IT
for Cold Rolling Mills , Brochure, Ref. No. DEPI/ BM_0105_EN., www.abb.com/ met als
[10] ABB (2005). ABB Service Guide . www.abb.com Product s & Services ABB Service Guide
[11] Horch, A., Hegre, V., Hilmen, K., Melb, H., Benabbas, L., Pistikopoulos, S., Thornhill, N., Bonavita, N., Root Cause . ABB Review 2/ 2005.
Additional reading
ARC Advisory Group, Applying OpX t o Cont rol Loops increases ROI , ARC Insight s, Oct ober 2002 (www.ARCweb.com).
7
ABB Operate
IT
screen for the diagnosis of periodic disturbances.
d istu rb an ce s wh ich are p re d o min an t in
ro llin g mills [9], an d a typ ical au to mat-
e d d iagn o sis scre e n sh o t is sh o wn in
7
.
Beyond single-loop controller condition
monitoring
CLCM is ab le to d e te ct lo o p p e rfo r-
man ce d e ficie n cie s an d can co n trib u te
to su b stan tial gain s o n ce th e ap p ro p ri-
ate main te n an ce actio n s h ave b e e n
take n . Ho we ve r, th e re are case s
wh e re th e p lan t is n o t p ro p e rly o p ti-
mize d e ve n th o u gh th e co n tro lle rs
are p e rfo rmin g we ll. In su ch case s, it
is h igh ly p ro b ab le th at th e cu rre n t
co n tro lle r stru ctu re is n o t su fficie n t.
A syste matic an d fast way o f asse ssin g
th e co n tro lle r lan d scap e an d th e p re -
vailin g au to matio n in frastru ctu re is b y
u sin g a b e n ch markin g se rvice p ro vid -
e d b y ABB [10].
Conclusions
CLCM is in h e re n tly a p assive an d au to -
matic te ch n iq u e wh ich h as cau gh t th e
atte n tio n o f man y in d u strie s. Th e b e n -
e fits gain e d b y re mo vin g co n tro l p e r-
fo rman ce b o ttle n e cks an d p e rfo r-
man ce d e grad atio n s d u e to b ad co n -
tro l are su b stan tial. So mu ch so th at
mo re an d mo re in d u strie s an d co mp a-
n ie s are startin g to ap p ly su ch te ch -
n iq u e s.
ABBs re se arch an d p ro d u ct varie ty
h as e n ab le d a fle xib le ap p licatio n o f
CLCM acro ss man y d iffe re n t in d u s-
trie s. Th e se ap p licatio n s h ave b e e n
ad ap te d so th at th e e xistin g h ard ware
at a cu sto me r site is u se d . CLCM can
b e ap p lie d to an y p ro ce ss arch ite ctu re
re gard le ss o f wh e th e r ABBs 800xA
Syste m o r a th ird -p arty DCS is in -
stalle d .
Alexander Horch
ABB Corporate Research,
Ladenburg, Germany
alexander.horch@de.abb.com
The benefits gained by
removing control perfor-
mance bottlenecks and
performance degrada-
tions due to bad control
are substantial.
Energy is vital for industries to operate. Many of ABBs energy-intensive cus-
tomers require a reliable and stable energy supply for the motors that drive
compressors, pumps, fans and machines. Some operate in areas where the
public electricity supply is unreliable or non existent meaning they must rely
heavily on their own generation capabilities. An unscheduled trip in, for exam-
ple, a refinery or a liquefied natural gas (LNG) plant due to a total loss of pow-
er could result in several days of lost production. When translated, this repre-
sents a value exceeding $-10 million.
Because of this dependence on electricity and the volatility of energy costs,
combined with a growing environmental consciousness and more stringent
legislation, efficient energy management is becoming ever more important.
ABBs Industrial
IT
Power Management System (PMS) is a family of unique
solutions that ensure reliable and stable energy supply for energy-intensive
industries. The PMS balances energy demands with the available energy
supply, thus preventing disturbances or even blackouts in operations.
Furthermore, it enables a company to control its energy costs, to enhance
safety, and to mitigate environmental and health impacts.
Not on my watc h
How ABBs Power Management System prevents multi million dollar shutdowns
Otto van der Wal, Per Erik Holsten
T
h e situ atio n in n e arly an y b lack-
o u t is almo st always th e same :
o n e p art o f a syste m fails fo rcin g
n e arb y e q u ip me n t to ab so rb its lo ad .
Th is e q u ip me n t is th e n p u sh e d in to
an o ve rlo ad mo d e cau sin g it in tu rn to
fail. Th e se mu ltip le failu re s sn o wb all
an d a large are a e n d s u p in th e d ark
with p o te n tial d ire co n se q u e n ce s
in clu d in g p o te n tial lo ss o f life , lo ss o f
p ro d u ctio n an d d amage d e q u ip me n t.
It is imp e rative th at p ro ce ss u p se ts
an d sh u td o wn s are avo id e d as th e y
will h ave a n e gative e ffe ct o n th e fi-
n an cial, e n viro n me n tal an d so cial p e r-
fo rman ce o f a co mp an y. Po we r su p -
p ly re liab ility an d p o we r q u ality affe ct
b o th th ro u gh p u t an d safe ty; th e re fo re
avo id in g b lack-o u ts an d p o we r d istu r-
b an ce s are o f su b stan tial valu e to an y
p ro ce ss p lan t. Eq u ip me n t mu st b e
mo n ito re d co n tin u o u sly to e n su re o p -
timal p e rfo rman ce an d stab ility o ve r
time . Th e e xtre me ly fast d yn amic
p ro p e rtie s o f th e e le ctrical p ro ce ss re -
q u ire q u ick re sp o n se time s o f th e
ABB Review
ABB Review
[1, 2], which is de signe d to monitor,
control and p rote ct all se ctions of a
p roce ss p lant. This common Industrial
IT

p latform p rovide s control functions,
and a fle xible and we ll organize d sin-
gle -window inte rface that allows op e r-
ators to work e fficie ntly. In addition,
advance d functions such as inte llige nt
alarm filte ring, consiste ncy analysis
and op e rator guidance he lp re duce the
ne e d for op e rator inte rve ntion and,
more imp ortantly, the se functions can
p re ve nt incorre ct inte rve ntions.
Th e imp o rtan ce o f syste matic o p e rato r
train in g in a re alistic se ttin g is in cre as-
in gly ackn o wle d ge d as a p re re q u isite
to re ach o p e ratio n al b e st in class tar-
ge ts. Th e In d u strial
IT
Train in g simu la-
to r can b e in te grate d with a mu ltitu d e
o f p ro ce ss an d e le ctrical simu lato rs.
Be cau se it ru n s o n th e In d u strial
IT

p latfo rm, th e PMS can b e co n ve n ie n tly
d e p lo ye d in th e in te grate d Train in g
Simu lato r, wh e re co n tro l strate gie s
su ch as lo ad sh e d d in g p rio ritie s an d
wh at-if simu latio n s can b e te ste d
p rio r to d e p lo yme n t
1
.
PMS main functions
Th e PMS p ro vid e s an in te grate d se t o f
co n tro l, su p e rvisio n an d man age me n t
fu n ctio n s fo r p o we r ge n e ratio n , d istri-
b u tio n an d su p p ly in in d u strial p lan ts.
Su ch b ro ad fu n ctio n ality is p artially
re p re se n te d b y mo d u le s co mmo n ly
u se d b y th e in d u stry u n d e r d iffe re n t
n ame s
1)
.
By checking the open/
close positions of critical
circuit breakers in the
electrical network and
using its internal knowl-
edge of the electrical
network topology, the
Network Determination
function can determine
network contingencies.
In ad d itio n to th e trad itio n al fu n ctio n s
o f su p e rviso ry co n tro l an d d ata acq u i-
sitio n (SCADA), th e syste m o ffe rs:
SCADA e le ctrical fu n ctio n s:
Generator control in clu d in g in te -
gratio n with th e go ve rn o r an d
e xcitatio n co n tro lle r.
Circuit breaker control in clu d in g
in te gratio n with p ro te ctio n re lays,
e ve n t mo n ito rin g, time syn ch ro n i-
zatio n with 1ms re so lu tio n . Syn -
ch ro n izatio n b e twe e n two e le ctri-
cal islan d s mu st b e p e rfo rme d an d
ch e cke d b y th e PMS b e fo re a cir-
cu it b re ake r is clo se d . Th e ge n e r-
ato rs u se d fo r syn ch ro n izatio n can
b e se le cte d man u ally o r au to mati-
cally. Th is is p e rfo rme d b y th e
synchroniz ation fu n ctio n .
Transformer and tapchanger
control: th e mo d e co n tro l fu n c-
tio n ch an ge s th e co n tro l mo d e
o f tap -ch an ge rs, go ve rn o rs an d
e xcitatio n syste ms acco rd in g to
th e statu s o f th e e le ctrical n e t-
wo rk
2
.
Motor control in clu d in g in te gra-
tio n with mo to r co n tro l ce n te rs,
time syn ch ro n izatio n , au to matic
se q u e n tial re -start an d re -acce le ra-
tio n re le ase afte r lo ad sh e d d in g o r
u n d e r-vo ltage .
Network Determination: Th is an d
th e mo d e co n tro l fu n ctio n are
imp o rtan t su p p o rtin g fu n ctio n s fo r
th e Po we r Co n tro l, Lo ad Sh e d d in g
an d Syn ch ro n izatio n fe atu re s. Se e
Factbox
.
The Network Determination function is an
important supporting function for the Power
Control, Load Shedding and Synchronization
functions.
By checking the open/ close positions of
critical circuit breakers in the electrical
network and using its internal knowledge of
the electrical network topology, the Network
Determination function can determine
network contingencies.
The PMS uses sophisticated matrix
calculations to determine electrical network
contingencies. Network contingencies must
be calculated in a matter of milliseconds after
a circuit breaker position has changed and
are therefore determined by complex logics.
To give an idea of the complexity and size of
the necessary logic, an electrical network
with one grid connection and eight
generators has 2(1+8) 1 possible network
contingencies.
Factbox
Network Determination
The electrical network matrix is a square
matrix with same number of columns and
rows. Each column and row represents a
(main) bus bar in the electrical network. The
cells in the matrix represent circuit breaker
positions which are the connections between
the (main) bus bars.
The Network Determination function
calculates the electrical network contingen-
cies from this matrix it calculates a re-
duced network matrix. The number of rows
in this reduced network matrix is equal to the
number of sub networks (or network islands)
in the electrical network. The reduced net-
work matrix is used by: Power Control to
calculate imported and generated power and
balance loads in sub networks; Load Shed-
ding to calculate imbalances between avail-
able and required power; Synchronization to
check which power sources (grid and gener-
ators) are available to achieve synchroniza-
tion.
o rd e r millise co n d s to p re ve n t p ro -
te ctio n re lays fro m issu in g trip co m-
man d s le ad in g to a d o min o e ffe ct in
te rms o f e q u ip me n t o ve rlo ad .
In e fficie n cy isn t ju st co stly in te rms
o f e xce ssive fu e l co n su mp tio n ; h igh
e missio n s can rack u p th e co st still
fu rth e r. So lu tio n s th at h e lp lo we r o p -
e ratin g co sts wh ile re d u cin g e n viro n -
me n tal imp act are so re ly n e e d e d b y
in d u stry.
On e su ch so lu tio n , ABBs In d u strial
IT

Po we r Man age me n t Syste m (PMS),
h e lp s ach ie ve stab le o p e ratio n wh e re -
b y th e e le ctrical p lan t as a wh o le can
with stan d large r d istu rb an ce s fro m
with in o r fro m o u tsid e th e p lan t. Th is
ap p licatio n p ackage co n tain s n o t o n ly
th e trad itio n al SCADA fu n ctio n ality
b u t also a fu ll co mp le me n t o f e le ctri-
cal so lu tio n s in clu d in g Po we r Co n tro l
an d Lo ad Sh e d d in g, two majo r fu n c-
tio n s th at are d e scrib e d in d e tails in
th is article .
A common platform for process control,
safety, power generation and utility
control
The PMS is base d on ABBs Industrial
IT Exte nde d Automation Syste m 800xA
Not on my watch
ABB Review
Power Control in clu d in g tie -lin e
co n tro l, p e ak sh avin g an d lo ad sh ar-
in g.
Load Shedding in clu d in g b o th fast,
slo w an d fre q u e n cy b ase d .
Bo th Po we r Co n tro l an d Lo ad Sh e d -
d in g are d e scrib e d in gre ate r d e tail in
th e fo llo win g p aragrap h s.
Power Control
Th e o b je ctive o f th e Po we r Co n tro l
fu n ctio n is to main tain stab le o p e ra-
tio n . It d o e s th is b y sh arin g active an d
re active p o we r d e man d amo n g d iffe r-
e n t ge n e rato rs an d tie -lin e s in su ch a
way th at th e wo rkin g p o in ts o f th e
ge n e rato r se ts are as far as p o ssib le
fro m th e b o rd e r o f th e in d ivid u al
PQ-cap ab ility d iagrams so th e p lan t
can with stan d b igge r d istu rb an ce s
3
.
The importance of sys-
tematic operator training
in a realistic setting is in-
creasingly acknowledged
as a prerequisite to reach
operational best in class
targets.
In th e fo llo win g p aragrap h s, th e co n -
tro l strate gie s co n tain e d with in th e
o ve rall Po we r Co n tro l p ackage are
d e scrib e d .
Tie-line control
Th e Tie -lin e co n tro l fu n ctio n , wh ich
is p art o f Po we r Co n tro l, o p timize s
th e p o we r e xch an ge with th e Pu b lic
Po we r Co mp an y (PPC) to an ad ju st-
ab le se tp o in t b ase d o n co n tractu al
o b ligatio n s, su ch as th e maximu m 15
min u te s p e ak valu e u se d in Eu ro p e .
It wo rks as fo llo ws: th e PMS me asu re s
th e imp o rte d (o r e xp o rte d ) p o we r, o r
th e tran smitte d p o we r b e twe e n d iffe r-
e n t lo catio n s, b y co u n tin g p u lse s fro m
e n e rgy me te rs. Fro m th e se me asu re -
me n ts, a slid in g 15 min u te s p o we r
d e man d fo re cast is calcu late d . Wh e n
p o we r d e man d te n d s to e xce e d co n -
tracte d e le ctricity imp o rt limits o r a
se tp o in t sp e cifie d b y an o p e rato r, th e
PMS will in itially try to in cre ase in -
p lan t ge n e ratio n to avo id e xce e d in g
th e co n tractu al o b ligatio n s. If th is is
n o t p o ssib le , th e Tie -lin e co n tro l fu n c-
tio n will in te rface with th e Lo ad sh e d -
d in g fu n ctio n (se e Pe ak Sh avin g b e -
lo w) to sh e d su fficie n t n o n -critical
lo ad s.
Active Power Control
As p art o f Po we r Co n tro l, th e Active
Po we r Co n tro l mo d u le p e rfo rms fre -
q u e n cy co n tro l an d active p o we r flo w
co n tro l at an e xch an ge p o in t with th e
grid . It mo n ito rs th e actu al n e two rk
co n figu ratio n an d se n d s an active
p o we r se tp o in t to th e p articip atin g
ge n e rato rs to :
Main tain th e b u s b ar fre q u e n cy at a
p re -d e fin e d valu e if th at p articu lar
n e two rk is iso late d .
Or main tain an active p o we r flo w
b e twe e n a p articu lar n e two rk co n -
n e cte d to th e grid .
Active Po we r Co n tro l Asp e ct d e cid e s
if fre q u e n cy co n tro l o r p o we r flo w
co n tro l is ap p licab le . Th is d e cisio n
d e p e n d s o n th e actu al n e two rk co n -
figu ratio n . Th is me an s n o o p e rato r in -
te ractio n is re q u ire d afte r a n e two rk
co n figu ratio n ch an ge .
Th e active p o we r se tp o in ts are se n t to
th e p articip atin g ge n e rato rs, ie , th e
ge n e rato rs th at act in Go ve rn o r Au to -
mo d e .
Power mismatch
In th e case o f fre q u e n cy/ vo ltage co n -
tro l, th e wo rkin g p o in t, take n fro m
th e b u s b ar, is su b tracte d fro m th e se t-
p o in t. In case o f active p o we r co n tro l,
th e d iffe re n ce in [Hz] is co n ve rte d in to
an active p o we r u n it [MW].
In case o f p o we r flo w co n tro l, th e
p o we r wo rkin g p o in t at th e e xch an ge
p o in t is su b tracte d fro m th e p o we r
se tp o in t.
PI control
Th e in p u t to th e PI co n tro l e le me n t is
p o we r mismatch . Th e o u tp u t o f th e
co n tro l e le me n t in cre ase s/ d e cre ase s
as lo n g as th e re is a mismatch at th e
in p u t o f th e PI co n tro l e le me n t.
Participating factor
Th e o p e rato r can assign a p articip at-
in g facto r to e ach ge n e rato r. Th is d e -
te rmin e s to wh at e xte n t th e ge n e rato r
will p articip ate in p o we r co n tro l. To
d e cid e o n th e mo st su itab le p articip at-
in g facto r, th e o p e rato r can lo o k at
calcu late d facto rs b ase d o n th e avail-
ab le co n tro l margin s. Th e re are p artic-
ip atin g facto rs fo r active p o we r co n -
tro l an d re active p o we r co n tro l.
Power setpoint per generator
A p o we r se tp o in t can b e se t to ke e p
th e ge n e rato r at a d e sire d sp o t in th e
ge n e rato r cap ab ility cu rve with o u t
affe ctin g th e fre q u e n cy/ vo ltage o r
active / re active p o we r flo w co n tro l.
Reactive power control
Th e Re active Po we r Co n tro l mo d u le is
th e Ob je ct Co n tro l Asp e ct fo r vo ltage
co n tro l an d re active p o we r flo w co n -
tro l at an e xch an ge p o in t with th e
1 What is needed for an efficiently operating plant.
U
s
e
r
s
I
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s
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i
a
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I
T
P
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t
...
Power
Control
Mode
Control
Synchr.
Load
Shedding
Re-acc.
Re-start
Visualization, Interaction
Object monitoring, control and protection
Utility Operator Process Operator Maintenance Manager
Power Generation
and distribution
Inventory,
Shipment
Production
Process
Not on my watch
ABB Review
grid . It mo n ito rs th e actu al n e two rk
co n figu ratio n an d se n d s an re active
p o we r se tp o in t to th e p articip atio n
ge n e rato rs an d / o r tran sfo rme r to :
Main tain th e b u s b ar vo ltage at a
p re -d e fin e d valu e . Main tain a re ac-
tive p o we r flo w b e twe e n a p articu -
lar n e two rk an d th e grid , o r an o th e r
n e two rk.
Main tain th e p o we rfacto r at th e
e xch an ge p o in t.
Th e Re active Po we r Co n tro l Asp e ct
d e cid e s if vo ltage co n tro l o r re active
p o we r flo w co n tro l is ap p licab le d e -
p e n d in g o n th e actu al n e two rk co n fig-
u ratio n . Th is me an s th at n o o p e rato r
in te ractio n is re q u ire d afte r a n e two rk
co n figu ratio n ch an ge .
Th e re active p o we r se tp o in ts are se n t
to th e p articip atin g ge n e rato rs an d
tran sfo rme r.
Also a re active p o we r se tp o in t can b e
se t to ke e p th e ge n e rato r at a d e sire d
sp o t in th e ge n e rato r cap ab ility cu rve
with o u t affe ctin g th e vo ltage an d / o r
re active p o we r flo w co n tro l.
Reactive power control in cooperation
with transformer control
A tran sfo rme r is u se d fo r main co n tro l
wh e n it p articip ate s in vo ltage co n tro l
o r re active p o we r flo w co n tro l. Tran s-
fo rme r co n tro l main tain s th e vo ltage
o r re active p o we r flo w at a d e sire d
se tp o in t an d th e re main in g mismatch
b e twe e n se tp o in t an d wo rkin g p o in t
(me asu re d valu e ) is min imize d b y th e
AVR co n tro l o f th e p articip atin g ge n e r-
ato rs. Co n tro l p arame te rs as gain an d
time in te gratio n are ad ju ste d in su ch
a way th at th e tran sfo rme r co n tro l
p re vails.
Load Shedding
Th e PMS Lo ad Sh e d d in g fu n ctio n
e n su re s th e availab ility o f e le ctrical
p o we r to all critical an d e sse n tial
lo ad s in th e p lan t at all time s. Lo ad
sh e d d in g is ach ie ve d b y switch in g o ff
n o n -e sse n tial lo ad s wh e n th e re is a
sh o rtage o f p o we r ge n e ratio n cap acity
in th e e le ctrical n e two rk o f th e p lan t.
Th e re are fo u r d iffe re n t typ e s o f lo ad
sh e d d in g:
Fast Load Shedding is b ase d o n
e le ctrical e n e rgy b alan ce
calcu latio n s. As so o n as o n e o r
mo re e le ctrical islan d s are d e te cte d
(u sin g n e two rk d e te rmin atio n
so ftware ), th e syste m calcu late s if
th e re is e n o u gh e le ctrical p o we r
availab le in e ve ry in d ivid u al islan d
to p o we r th e lo ad s. If n o t, an y
e xistin g d e man d su rp lu s is sh e d .
Th e sh e d d in g p ro ce ss is d ictate d b y
p rio rity tab le s, wh ich are b ase d o n
th e o p e ratio n al co n d itio n s o f th e
p ro ce ss.
Frequency Load Shedding (o r b ack-
u p lo ad sh e d d in g) u se s a fre q u e n cy
d ro p as an in p u t to activate lo ad
sh e d d in g. Activatio n o f an actu al
sh e d co mman d can b e b ase d o n a
fre q u e n cy d e cay o r b y p assin g a fre -
q u e n cy th re sh o ld . Fre q u e n cy Lo ad
Sh e d d in g is u su ally u se d as an in d e -
p e n d e n t b ack-u p syste m fo r fast
lo ad sh e d d in g
Slow Load Shedding is u se d wh e n
an o ve rlo ad h as o ccu rre d . Fo r e x-
amp le if a tran sfo rme r is lo ad e d at
120 p e rce n t, switch in g o ff so me
lo ad s to b rin g th e tran sfo rme r b ack
to its n o min al lo ad is b y far th e b e st
so lu tio n . Th e syste m ad vise s th e
o p e rato r wh ich n o n -critical lo ad s h e
can switch o ff. Th is man u al e ffo rt
mu st b e d o n e with in a sp e cifie d
p e rio d o f time o th e rwise th e syste m
will d o it au to matically.
Pe ak Sh avin g is an o th e r typ e o f
slo w lo ad sh e d d in g an d o ccu rs
wh e n th e fo llo win g situ atio n aris-
e s: if in -h o u se ge n e ratio n is maxi-
mize d b u t it se e ms h igh ly p ro b a-
b le th e 15 min u te s slid in g maxi-
mu m p o we r d e man d will e xce e d
th e co n tracte d maximu m valu e ,
th e n so me o f th e lo w p rio rity
lo ad s are sh e d . Manual Load
Shedding is main ly u se d wh e n
o n e o f th e afo re -me n tio n e d co n d i-
tio n s fo r Slo w Lo ad Sh e d d in g
o ccu rre d b u t o p e ratio n s d id n o t
allo w th e syste m to sh e d au to -
matically.
How much to shed?
Th e ABB syste m is fast b e cau se it
d o e sn t wait fo r a d e cre ase in fre q u e n -
cy b e fo re it starts to sh e d lo ad s. In -
ste ad , its d e cisio n to sh e d as we ll as
h o w mu ch sh o u ld b e sh e d d e p e n d s
2 Generator Capability diagram with working point and mode selections.
Not on my watch
ABB Review
o n th e b alan ce b e twe e n th e amo u n t
o f p o we r ge n e rate d an d co n su me d in
e ve ry islan d . To e xe cu te lo ad sh e d -
d in g with in 100250 ms o f a d istu r-
b an ce , h o we ve r, man y calcu latio n s
mu st b e d o n e in ad van ce .
De cid in g h o w mu ch p o we r sh o u ld b e
sh e d d e p e n d s o n th e n u mb e r o f p rio r-
itie s u se d , th e size , in MW, o f th e lo ad
sh e d gro u p s, an d th e availab ility o f
syste m me asu re me n ts.
ABBs load she dding se t-up is ve ry
fle xible be cause an op e rator can adap t
(online ) the p riority of the various
p lant loads to the p roce ss op e rating
conditions and the electrical network
4
.
Also at the mome nt the syste m de te r-
mine s the she dding orde r, it conside rs
how much sp inning re se rve is avail-
able . To utilize this re se rve , the syste m
can, and will if ne ce ssary, change the
op e rating mode of a ge ne rator.
The coordination between load shed-
ding and re-acceleration is also imp or-
tant. Re-acceleration is disabled when a
load shedding action is required, and is
immediately restarted once the condi-
tions for load shedding have vanished.
Summary
Th e PMS b e n e fits are cle arly visib le
d u rin g:
The plant definition p h ase : th e im-
p ro ve d syste m stab ility allo ws tigh t-
e r d ime n sio n in g an d th u s re d u ce d
co sts.
Plant start up: th e PMS will e n su re
th e p o we r syste m cap acity is n o t
vio late d at an y time b y h o ld in g lo ad
start co mman d s u n til th e syste m can
p ro vid e th e p o we r re q u ire d to start
a p articu lar lo ad . Th is h e lp s ge t th e
p lan t safe ly o n stre am as q u ickly as
p o ssib le .
All phases of plant operation: th e
PMS will co n tro l ge n e rato rs an d
tran sfo rme r tap -ch an ge rs to e n su re
stab le p o we r syste m o p e ratio n , as
we ll as mo n ito rin g an d co n tro llin g
active an d re active p o we r e xch an ge
with th e p u b lic grid . Th e ge n e ral
wo rklo ad an d n u mb e r o f in te r-
ve n tio n s fro m th e o p e rato rs are
re d u ce d .
Maintenance planning:
co mp re h e n sive d ata are re co rd e d
an d aggre gate d o n th e co n d itio n o f
th e e le ctrical asse ts. Th e ap p ro p riate
ABB In d u strial IT Asse t Mo n ito rs
can mo n ito r th is d ata au to matically,
an d th e re sp o n sib le p e o p le are
n o tifie d wh e n actio n s mu st b e
take n . Th e ABB In d u strial IT Asse t
Op timize r wo rkp lace p ro vid e s th e
o ve rvie w o f e q u ip me n t h e alth an d
th e b ase in fo rmatio n n e e d e d to p lan
main te n an ce camp aign s.
Th e PMS can also b e p art o f a b ro ad e r
e le ctrical syste m d e live ry fro m ABB.
In ce rtain in d u strie s su ch as ch e mical,
p e tro ch e mical, ce me n t an d ste e l, e n -
e rgy co sts re p re se n t ap p ro ximate ly
30 to 50 p e rce n t o f th e to tal p ro d u c-
tio n co st. ABBs PMS can p ay fo r itse lf
in a sh o rt sp ace o f time ju st b y e n su r-
in g gre ate r e fficie n cy o f p o we r ge n e r-
atio n , imp o rt an d u sage u n d e r varyin g
o p e ratin g co n d itio n s.
Th e in ve stme n t can e asily b e ju stifie d
in b o th gre e n an d b ro wn fie ld p lan ts,
an d se ve ral e xamp le s o f re ce n t in stal-
latio n s e xist aro u n d th e glo b e . Th e
same syste m is u se d fo r b o th e le ctrical
an d p ro ce ss co n tro l allo win g co st re -
d u ctio n in train in g, sp are p arts an d
main te n an ce .
Otto van der Wal
ABB A.S. Norway
otto.wal@nl.abb.com
Per Erik Holsten
ABB A.S. Norway
per-erik.holsten@no.abb.com
References
[1] Taft, Mike W., Indust rial
IT
Syst em 800xA, Ext end-
ing t he reach of aut omat ion t o achieve cont inuous
product ivit y improvement s , ABB Review 1/ 2004,
pp 3237.
[2] www.abb.com/ aut omat ion
Footnotes
1)
Elect rical Cont rol Syst em (ECS).
2)
Elect rical Int egrat ed Cont rol Syst em (ELICS).
3)
Int egrat ed Prot ect ion and Cont rol Syst em (IPCS).
4)
Power Dist ribut ion Cont rol Syst em (PDCS).
5)
Load Management Syst em (LMS).
6)
Elect rical Net work Monit oring & Cont rol Syst em
(ENMCS).
3 Single Line Diagram indicating that four motors have been shed after
a generator trip.
4 Graphical presentation of the accumulated effect of shedding the
loads assigned to the 20 load shedding priorities.
Not on my watch
The 125 year old Mondi Packaging Frantschach mill sits in the Lavant Valley
amid the breathtaking beauty of the southern Austrian Alps. Three paper
machines produce approximately 250,000 tons of sack and kraft paper per
year. Frantschachs high quality pulp and paper are used to produce high
quality end products. Producing pulp for the Melitta coffee group as well as
luxury paper bags based on its kraft paper, the mills overall export rate is
more than 80 percent of production. Quality is the key factor and to maintain
such high quality, the companys strategy is to modernize continuously to
ensure it has the most up-to-date technology. And helping Frantschach in this
task is one of its many long-term partners, ABB.
Exp erienc e c ounts
Mondi Packaging Frantschach can rely on ABB
Marja-Liisa Parkkinen
T
h e Mo n d i Packagin g Fran tsch ach
1

Factbox
mill h as th re e p ap e r
mach in e s, th e PM 6, 7 an d 8, th at p ro -
d u ce ap p ro ximate ly 250,000 to n s o f
sack an d kraft p ap e r p e r ye ar. Th e
wire wid th o f th e PM 6 is 490 mm
an d th e sack p ap e r p ro d u ce d co ve rs
60-125 grams p e r m
2
. With a sp e e d o f
920 me te rs p e r min u te , th e PM 6 is
o n e o f th e faste st sack p ap e r
mach in e s in th e wo rld . Th e PM 8 also
p ro d u ce s sack p ap e r an d h as a wire
wid th o f 510 mm an d a sp e e d o f
830 me te rs p e r min u te , wh ile PM 7
p ro d u ce s kraft p ap e r o f 30150 grams
p e r m
2
with a sp e e d o f 350 me te rs p e r
min u te . Th e Fran tsch ach mill also
p ro d u ce s ap p ro ximate ly 50,000 to n s
o f u n b le ach e d marke t p u lp p e r ye ar,
an d u se s sp ru ce an d p in e wo o d as
th e raw mate rials. Fran z Maisch b e rge r
2
is He ad o f th e Pro je ct De p artme n t
re sp o n sib le fo r Ele ctrical, Pro ce ss
Co n tro l an d Pro ce ss IT. He h as b e e n
wo rkin g at th e mill fo r 29 ye ars; h is
p assio n fo r stab le state -o f-th e -art te ch -
n o lo gy is o n e o f th e re aso n s fo r Fran t-
sch ach mills p o sitio n as a te ch n o lo gi-
cal fo re ru n n e r. Mr Maisch b e rge r says
th at th e mills stre n gth s lie in : q u ality;
Re se arch an d De ve lo p me n t; e mp lo ye e
skill; two h igh ly e fficie n t sack p ap e r
mach in e s; an d ju st-in -time d e live ry.
Its o u tstan d in g ap p ro ach to sack
p ap e r p ro d u ctio n se ts th e stan d ard fo r
man y o th e r Mo n d i sack p ap e r mills.
End products
Fran tsch ach s sack an d kraft p ap e r
go e s u n d e r th e b ran d n ame o f
ADVANTAGE . Sack p ap e r n e e d s to
b e o f th e ve ry h igh e st q u ality wh e n
o n e co n sid e rs th at so me cu sto me rs fill
th e m with 25 o r 50 kilo s o f ce me n t,
p ro d u cin g so me 4,000 sacks p e r h o u r!
ABB Review
ABB Review
b e rge r, We wo rk alo n gsid e cu sto me rs
wo rld wid e to ach ie ve wo rld grad e
q u ality. We wan t to b e o u r cu sto me rs
p re fe rre d , lo n g-te rm p artn e r. Th e
same attitu d e e me rge s wh e n Mr. Mais-
ch b e rge r re fe rs to su p p lie rs. He p re -
fe rs majo r, glo b al su p p lie rs wh o , in
th e lo n g ru n , p ro vid e h igh q u ality.
Quality is a key factor
to maintain such high
quality, the companys
strategy is to modernize
continuously to ensure it
has the most up to date
technology.
Basis for high quality
Se ve ral facto rs h ave co n trib u te d to
th e mills re p u tatio n as a h igh q u ality
p u lp an d p ap e r p ro d u ce r. First o f all,
th e co mp an ys strate gy is to co n tin u -
o u sly mo d e rn ize to e n su re it h as th e
mo st u p -to -d ate te ch n o lo gy. Th is is
h e lp e d b y th e fact th at it h as re liab le
lo n g-te rm p artn e rsh ip s with majo r
P&P in d u stry mach in e , an d e q u ip me n t
an d syste m su p p lie rs. Th e Fran tsch ach
mill is cu rre n tly re co n stru ctin g its
wo o d yard an d raw mate rial mixin g
at a co st o f ap p ro ximate ly 20 millio n
e u ro s.
Se co n d ly, th e co mp an y id e n tifie s b e st
p ractice s in its p ro d u ctio n p ro ce sse s
an d is co n stan tly accu mu latin g e xp e ri-
e n ce th ro u gh its Kn o wle d ge fo r Pro -
d u ctio n co n tin u o u s le arn in g syste m.
Each sh ift wo rke r lo gs in fo rmatio n o n
an y in cid e n ts o r p ro b le ms, as we ll as
th e re late d actio n s an d so lu tio n s. Th is
me an s th at all e xp e rie n ce s re late d to
th e p ro ce ss are availab le o n lin e
aro u n d th e clo ck.
Th e th ird facto r co n ce rn s h e alth an d
safe ty. Mr. Maisch b e rge r says th at
safe ty, h e alth , e n viro n me n tal frie n d -
lin e ss an d a ze ro rate o f accid e n ts
are o u r wo rkin g e n viro n me n t go als.
Th is is a q u e stio n o f attitu d e s rath e r
th an te ch n iq u e s, h e co n tin u e s. As a
re su lt o f th is amb itio u s p ro gram, safe -
ty p e rfo rman ce h as d e ve lo p e d sign ifi-
can tly o ve r th e last fe w ye ars.
ABB a long-term partner
Eq u ip me n t an d PCs b e arin g th e ABB
lo go can b e fo u n d all o ve r th e mill.
Th e se co n d ge n e ratio n o f Man u factu r-
in g Exe cu tio n Syste ms (MES) so lu tio n s
th e e q u ivale n t o f Co llab o rative Pro -
d u ctio n Man age me n t (CPM) h ave
b e e n d e p lo ye d in p ro d u ctio n p lan n in g
an d o p timizatio n , p ro d u ctio n trackin g
an d q u ality man age me n t
3
. Th re e
q u ality co n tro l syste ms d e live re d b y
ABB p e rfo rm o n lin e q u ality co n tro l o n
The Mondi Packaging Frantschach is
member of the Mondi Packaging Group, a
leading European paper and packaging
(P&P) company. It is active in the bag and
flexibles business and has more than 100
production facilities worldwide.
The Mondi Group is owned by the Anglo
American Group. Mondi operates worldwide
and is principally involved in producing paper,
packaging solutions, coating and business
paper. In 2005, it employed 16,278 people
with sales totaling 3,092 billion euros.
Mondi Packaging Frantschach GmbH is
located in the Lavant Valley in Austria and
was founded in 1881. It is responsible for all
R&D within the Mondi Packaging Paper
Division. The mill employs more than 500
people and in October 2006, it celebrated its
125th anniversary.
Factbox
Mondi Packaging
Mondi Packaging Frantschach mill has won
several awards in recent years because of its
attention to quality and innovation. In partic-
ular it has won countrywide environmental
improvement and innovation awards.
Taking care of the environment
The nearby town of Frantschach- St. Ger-
traud has some 3,000 inhabitants, and the
area is renowned for skiing in winter and its
hiking and biking routes in the summer. Envi-
ronmental issues are therefore of great im-
portance to Mondi Packaging Frantschach
and due to solid technology improvements,
waste water figures have dropped to an
1,500 Inhabitants Equal Value, while SO
2

emissions have tumbled from 1,800 mg/ m
3

to 40 mg/ m
3
. In 1998 the mill was certified
according to the Environmental Management
System ISO 14001.
1
The 125 year old Mondi Packaging
Frantschach mill sits in the Lavant Valley
amid the southern Austrian Alps
2
Franz Maischberger is Head of the Project
Department responsible for Electrical,
Process Control and Process IT
Fran tsch ach e n ab le s cu sto me rs to
ach ie ve th is b y p ayin g sp e cial atte n -
tio n to facto rs su ch as p rin tab ility,
stre n gth , e n e rgy ab so rp tio n an d p o -
ro sity
1)
. Ve ry fe w sack p ap e r p ro d u c-
e rs are ab le to me e t su ch q u ality
re q u ire me n ts. Th e wo rld -re n o wn e d
co ffe e filte r b ran d , Me litta, acq u ire s
Fran tsch ach s u n b le ach e d p u lp . Oth e r
sp e cial p u lp grad e s p ro d u ce d b y th e
mill are u se d in th e p ro d u ctio n o f
iso latio n mate rial fo r tran sfo rme rs.
Me an wh ile th e lu xu ry p ap e r b ags
u se d in man y sh o p s are b ase d o n
Fran tsch ach s kraft p ap e r.
Qu ality is th e ke y facto r th at e mb race s
e n d p ro d u cts, th e p ap e r p ro d u ctio n
p ro ce ss, th e p u lp mill p ro ce ss, th e
wo o d yard p ro ce ss as we ll as th e staffs
kn o w-h o w. Acco rd in g to Mr. Maisch -
Exp erience counts
ABB Review
PM 6, 7, 8 an d th e flash d rye r
4
, wh ile
ABBs Au to matio n Syste m, wh ich
alre ad y co ve rs th e p ap e r mach in e s,
th e p u lp mill an d th e p o we r p lan t, h as
ju st b e e n u p grad e d an d e xte n d e d to
n o w co ve r th e wo o d yard .
CPM
Ap p ro ximate ly 10 ye ars ago , ABB
d e live re d an MES syste m to th e Fran t-
sch ach p ap e r mill. So me ye ars late r it
was d e cid e d to in stall a n e w syste m
b e cau se (a) th e o rigin al MES syste m
was n e arin g th e e n d o f its life cycle
an d (b ) Fran tsch ach mills co rp o rate
stru ctu re ch an ge d wh e n it b e came a
me mb e r o f th e glo b al Mo n d i Packag-
in g Gro u p . Fo r th e se re aso n s, th e mill
d e cid e d to acq u ire n e w p ro d u ctio n
p lan n in g, p ro d u ctio n trackin g an d
q u ality man age me n t syste ms fro m
ABB in 2002 to co ve r th e p ro d u ctio n
sch e d u lin g o f th e flash d rye r, p ap e r
mach in e s, win d e rs an d re win d e rs as
we ll as ware h o u sin g an d lo gistics.
Acco rd in g Mr. Maisch b e rge r, Ou r
e xp e rie n ce o f ABBs e arlie r syste ms
was d e cisive in o u r d e cisio n to p u r-
ch ase an o th e r CPM so lu tio n fro m
th e m, as we ll as th e fin an cial asp e ct.
Th e ap p licatio n s we re d e sign e d as
mu lti-mill so lu tio n s, p o ssib ly co ve rin g
similar mills b e lo n gin g to Mo n d i Pack-
agin g in th e fu tu re .
The company identifies
best practices in its pro-
duction processes and is
constantly accumulating
experience through its
Knowledge for Produc-
tion continuous learning
system.
A te mp late so lu tio n , a p ro to syste m
b ase d o n ABBs In d u strial
IT
CPM so lu -
tio n , was cre ate d as a first ste p . IT
sp e cialists fro m th e Fran tsch ach mill
an d ABBs He lsin ki b ase wo rke d to -
ge th e r to in stall th e n e w syste m. Eve n
th o u gh it was b ase d o n a stan d ard
CPM so lu tio n , man y cu sto mize d fe a-
tu re s we re in co rp o rate d to e n su re th at
it fitte d p e rfe ctly in to th e mills p ro -
ce sse s. A ch alle n gin g ad d itio n al as-
p e ct was th e lin kin g o f th e ABB-CPM
so lu tio n to a ce n tralize d SAP syste m
b u ilt simu ltan e o u sly. Th e syste m n o w
su p p o rts 70 co n cu rre n t u se rs.
A fu n d ame n tal n e w fe atu re o f th e
te mp late / p ro to so lu tio n is th e Cap a-
b ility to Pro mise (CTP) fe atu re , wh ich
give s a 100 p e rce n t assu ran ce o n lin e
to cu sto me rs th at Mo n d i Packagin g
Fran tsch ach is ab le to d e live r th e righ t
q u ality at th e righ t time . An o th e r
u n iq u e fe atu re , th e in te grate d p lan -
n in g fu n ctio n ality, e n ab le s p ap e r
p ro d u ce rs to fo re cast th e amo u n t o f
p u lp n e e d e d fo r p ap e r an d marke t
p u lp p ro d u ctio n an d to b alan ce th is
with th e p lan n e d p ro d u ctio n o f b u lk
p u lp .
Th e p ro je ct was calle d SPARK 2, an d
laste d th re e ye ars. Mr. Maisch b e rge r
said th at th e re aso n s u n d e rlyin g o u r
in ve stme n t d e cisio n s imp ro ve d p ro -
ce sse s, q u ality an d b e tte r cu sto me r
se rvice h ave all b e e n b o rn e o u t.
A similar syste m, b ase d o n th is Fran t-
sch ach te mp late , was su cce ssfu lly in -
stalle d at th e Mo n d i Packagin g Dyn s
mill in May 2006.
Enterprise integration the key
to success
A fu lly in te grate d mill me an s th at
e ve ry asp e ct o f th e mill can b e co n -
tro lle d . Th e wo o d yard was mo d e rn -
ize d an d is also co n tro lle d u sin g th e
co n tro l syste m d e live re d b y ABB.
Th e o rigin al p u lp mill co n tro l syste m
was d e live re d b e twe e n 1996 an d 2000
an d was u p grad e d in 2006 to in clu d e
th e late st ad van ce d fe atu re s o f th e
cu rre n t syste m. Th is syste m co mp rise s
12 ADVANT AC450 co n tro lle rs an d
16,000 in p u t/ o u tp u t p o in ts gath e rin g
in fo rmatio n o n p ro ce sse s, with ab o u t
20 o p e rato r wo rkstatio n s. Th e p ap e r
mill syste m is b ase d o n ADVANT
AC460 te ch n o lo gy wh ich o p e rate s all
th re e p ap e r mach in e s o n o n e Distrib -
u te d Co n tro l Ne two rk. Th e re fo re sit-
tin g in a co n fe re n ce ro o m, fo r e xam-
p le , an o p e rato r can co n n e ct o n lin e
to th e p u lp an d p ap e r mill p ro ce sse s
an d simu ltan e o u sly d isp lay th e co n tin -
u o u s co o kin g p ro ce ss, p ap e r mach in e
o p e ratio n an d QCS in re al time .
Acce ss righ ts are se t u p so th at e ach
u se r ge ts th e re q u ire d in fo rmatio n fo r
time ly an d in fo rme d d e cisio n -makin g.
In th e same way, o n lin e h isto ry d ata
is mad e availab le imme d iate ly. Th is
fu lly in te grate d so lu tio n is h e lp in g to
imp ro ve th e p ro d u ctivity o f th e e n tire
mill.
ABB Finland
marja-lissa parkkinen@fi.abb.com
Footnote
1)
Print abilit y, st rengt h, t ot al energy absorpt ion and
porosit y are t he most import ant qualit y feat ures
in sack paper. Frant schach has a qualit y cont rol
syst em for every paper machine; t hese ADVANT
1190 syst ems have been cont rolling basic paper
propert ies for many years.
3
The second generation of MES solutions
have been deployed in production planning
and optimization, production tracking and
quality management
4
Three ABB quality control systems perform
online quality control on PM 6, 7, 8 and the
flash dryer
Exp erience counts
For over 30 years ABB has supplied electrification solutions to green field pulp
and paper paper mills as well as to ones that have been modernized. To create
the best economical and technical solution for the customer requires superior
knowledge and extensive experience, both of which are in abundance at ABB.
This short article gives a brief overview of how the company approaches these
solutions.
Find ing the right
b alanc e
Electrification solution for the pulp
and paper industry
Marja-Liisa Parkkinen, Juha Willman
ABB Review
ABB Review
A
to tal e le ctrificatio n so lu tio n co v-
e rs b asic an d d e taile d e n gin e e r-
in g, su p p ly site man age me n t, su p e rvi-
sio n , e re ctio n an d co mmissio n in g o f
th e e n tire e le ctrical so lu tio n . ABBs
lo n g-te rm an d e xte n sive e xp e rie n ce in
su ch e le ctrificatio n p ro je cts fo r th e
p u lp an d p ap e r in d u stry e n ab le s th e
co mp an y to imp le me n t an e le ctricity
d istrib u tio n p lan fo r a co mp le te p u lp
o r p ap e r p lan t b ase d o n re lative ly lim-
ite d in itial d ata. At th e ve ry le ast th is
in itial d ata sh o u ld in clu d e lists o f co n -
su me rs an d a p lan t layo u t. Ho we ve r,
in re ality co n su me r in fo rmatio n at th e
b e gin n in g o f a p ro je ct can b e e x-
tre me ly limite d . In su ch case s ABBs
e xp e rie n ce in vario u s typ e s o f p u lp
an d p ap e r p lan ts can b e e xp lo ite d b y
co mp le me n tin g th e in itial d ata with
e xp e rime n tal d ata fro m o th e r p ro je cts
o f similar typ e s. In ad d itio n , o th e r
te ch n ical matte rs re late d to th e p ro -
ce ss in q u e stio n , in clu d in g p o we r
statio n s, sh o u ld b e co n sid e re d .
Network calculations
Go o d b asic skills acq u ire d fro m wo rk-
in g with e le ctrical syste ms, to ge th e r
with an ad van ce d n e two rk calcu latio n
p ro gram e n su re a n e two rk co n figu ra-
tio n in wh ich margin s are man age d ,
u n n e ce ssary o ve r d ime n sio n in g is
avo id e d an d so lu tio n s th at are te ch n i-
cally th e simp le st are o b tain e d . In
so me case s th e n e two rk d ime n sio n in g
is ch e cke d b y u sin g o p e ratio n al
mo d e s wh ich are ve ry d iffe re n t fro m
o n e an o th e r. Fro m th e p o in t o f vie w
o f d ime n sio n in g, situ atio n s in wh ich
th e n e two rk is at its we ake st in clu d -
in g iso late d o p e ratio n fo rm th e mo st
ch alle n gin g situ atio n s. ABB u se s th e
Neplan network calculation program
to carry o u t th e e le ctro te ch n ical
d ime n sio n in g o f a n e two rk. Th is p ro -
gram can mo d e l all th e ce n tral e le c-
tro te ch n ical p arame te rs, an d it h e lp s
e n gin e e rs fin d th e mo st re liab le
d ime n sio n in g o f an e n tire n e two rk
fo r vario u s n o rmal an d ab n o rmal situ -
atio n s.
ABBs extensive experi-
ence in electrification
projects enables it to
implement an electricity
distribution plan for a
complete pulp or paper
plant
Energy efficiency
In ad d itio n to p u rch asin g co sts, o th e r
facto rs wh ich can o p timize o ve rall
co sts sh o u ld b e co n sid e re d d u rin g th e
d e sign p h ase . En e rgy co sts an d lo sse s,
fo r e xamp le , are in cre asin g all th e
time an d in th e fu tu re th e ir sh are o f
th e to tal co sts will b e e ve n mo re sig-
n ifican t. With th is in min d , ABB h as
d e d icate d mu ch R&D to ward s imp ro v-
in g th e e fficie n cy o f vario u s ap p aratu s
an d d e cre asin g th e ir lo sse s.
To tal lo sse s are n o t o n ly p o sitive ly
affe cte d b y th e mo st co n stru ctive
so lu tio n fo r an e le ctricity d istrib u tio n
syste m, b u t also th ro u gh b asic ch o ice s
su ch as th e vo ltage le ve ls u se d . Th e
re ce n t te n d e n cy to ward s large r u n its
in p u lp an d p ap e r p lan ts is n o tice ab le
in th e p ro ce sse s th e mse lve s an d in th e
sin gle u n its o f p ro ce ss e q u ip me n t e m-
p lo ye d . Th e u se o f large r u n its h as
me an t th at o p timal vo ltage le ve ls h ave
h ad to in cre ase . Fo r e xamp le , 690 V
h as re p lace d , to a large e xte n t, th e
400 V valu e wh ich was ve ry p o p u lar
as a lo w vo ltage . Du e to its gre ate r
stiffn e ss it can also re p lace , o r at le ast
p artly, 3 kV an d 6 kV as a mo to r vo lt-
age . In e le ctricity d istrib u tio n , a vo lt-
age o f 33 kV h as o fte n re p lace d lo we r
d istrib u tio n vo ltage le ve ls.
Compatibility
As a ru le , a n e w e le ctrical syste m is
re late d to an alre ad y e xistin g syste m
b u t it h as limitatio n s o r re q u ire me n ts
imp o se d o n it b y th e o ld e r syste m.
Ho we ve r, th e n e w syste m cre ate s its
o wn p re co n d itio n s fo r fu tu re p lan t
e xte n sio n s. Fo r th is re aso n , th e mo st
p ro b ab le sce n ario s fo r fu tu re e xte n -
sio n s sh o u ld also b e take n in to co n -
sid e ratio n wh e n d e sign in g a n e w
n e two rk. In o th e r wo rd s, th e fu tu re
e xte n d ib ility o f a p lan t d e p e n d s to a
large e xte n t o n th e b asic d e cisio n s
mad e in th e cu rre n t d e sign .
To su cce ssfu lly imp le me n t large sys-
te ms, th e q u ality o f e le ctricity an d th e
co mp atib ility o f th e e q u ip me n t an d
syste ms are o f th e u tmo st imp o rtan ce .
Co mp atib ility is p artly an e q u ip me n t-
re late d facto r b u t it can also b e affe ct-
e d th ro u gh d iffe re n t co n stru ctive so lu -
tio n s o f th e syste ms to b e u se d .
As to th e co mp atib ility o f th e n e t-
wo rks in p u lp an d p ap e r p lan ts, h ar-
mo n ics fro m lo ad s an d vo ltage d ro p s
re su ltin g fro m th e startin g p ro ce ss o f
mo to rs are th e mo st imp o rtan t facto rs.
Th e se sh o u ld also b e take n in to ac-
Network analysis Harmonic spectrum
f/ fn
1.5
1.0
0.5
0.0
0 5 10 15 20 25 27
U
%
Network analysis Network impedance Z(f)
0 200 400 600 800 1000 1200
f/ Hz
1.5
1.2
0.9
0.6
0.3
0.0
Z
/
o
h
m
co u n t in n e two rk calcu latio n s in ad d i-
tio n to lo ad in g an d sh o rt-circu it cu r-
re n ts. By mo d e llin g a n e two rk accu -
rate ly, it is p o ssib le to e n su re (a) su f-
ficie n t margin s fo r d iffe re n t d e sign
p ara me te rs e ve n in th e mo st d ifficu lt
situ atio n s an d (b ) su fficie n t co mp ati-
b ility fo r d iffe re n t p arts o f th e n e t-
wo rk. Ho we ve r, sign ifican t co st d iffe r-
e n ce s may arise b e twe e n vario u s so lu -
tio n s. By o p timally p ro p o rtio n in g th e
immu n ity le ve ls o f th e e q u ip me n t an d
th e amo u n t o f in te rfe re n ce s ge n e rate d
in th e n e two rk, sign ifican t savin gs can
b e o b tain e d wh e n co mp are d to ge n e r-
o u s o ve r-d ime n sio n in g. Un n e ce ssary
o ve r-d ime n sio n in g o f th e q u ality o f
e le ctricity cau se s e xtra in ve stme n t
co sts.
Th e vo ltage d ro p s th at o ccu r d u rin g
th e startin g p ro ce ss o f a mo to r n o lo n -
ge r re p re se n t a limitin g facto r fo r th e
mo to r size b e cau se o f mo d e rn te ch -
n iq u e s. As e ffe ctive startin g me th o d s
are n o w availab le , th e u n d e r-vo ltage s
e n co u n te re d d u rin g mo to r start-u p
can always b e ad ju ste d to acce p tab le
le ve ls. Ho we ve r, th e se re q u ire me n ts
sh o u ld b e ch e cke d in all switch in g
situ atio n s wh e re start-u p is re q u ire d .
In fact, th e n o rmal o p e ratio n o f th e
mo to r ap p e ars to b e th e o n ly limitin g
facto r. Mo to r startin g is an e sp e cially
d e man d in g o p e ratio n in an iso late d
n e two rk if th e mo to r is large co m-
p are d to th e ge n e rato r. In th is situ a-
tio n th e d yn amic b e h avio u r o f th e
ge n e rato r an d th e e xcitatio n syste m
sh o u ld also b e co n sid e re d . In sh o rt,
th e o p timal ch o ice an d d ime n sio n in g
o f th e startin g arran ge me n ts o f mo to rs
h as an imp o rtan t e ffe ct o n co sts an d
availab ility.
Th e re are te ch n iq u e s availab le th at
almo st co mp le te ly e limin ate th e large
h armo n ic cu rre n ts cu rre n ts cre ate d
b y mo to rs in th e n e two rk. Ho we ve r,
th e ir e limin atio n is n o t always th e
mo st o p timal so lu tio n . In th e e n d co r-
re ct re active p o we r co mp e n satio n an d
h armo n ic filte rin g h ave th e mo st sig-
n ifican t e ffe ct o n co sts.
Implementation design
Th e ap p licatio n d e sign p ro ce ss also
u se s n e two rk mo d e llin g. It give s b asic
valu e s fo r d ime n sio n in g p arame te rs
an d d e te rmin e s d iffe re n t so lu tio n s fo r
re lay p ro te ctio n . In ad d itio n to b asic
p ro te ctio n fu n ctio n s, su ch as sh o rt-cir-
cu it an d e arth -fau lt p ro te ctio n , d iffe r-
e n t kin d s o f ad van ce d p ro te ctio n so lu -
tio n s, in clu d in g lo ad sh e d d in g an d
islan d in g, can b e mo d e lle d an d th e
o p e ratio n al valu e s can b e accu rate ly
d e te rmin e d .
Th e said o p timize d crite ria are also
in clu d e d in p ro je ct-re late d stan d ard s
an d gu id e lin e s su ch as d e sign an d
d ime n sio n in g in stru ctio n s wh ich are
cre ate d to ge th e r with th e cu sto me r.
Th e se stan d ard s an d gu id e lin e s take
in to acco u n t ABBs e xte n sive e xp e ri-
e n ce in th e p u lp an d p ap e r in d u stry,
th e ad van tage s o f mo d e rn so lu tio n s,
th e re su lts o f n e two rk mo d e llin g an d
th e cu sto me rs kn o wle d ge o f lo cal
co n d itio n s to give th e b e st p o ssib le
e n d re su lt.
Juha Willman
ABB Automation technologies
Helsinki, Finland
marja-liisa.parkkinen@fi.abb.com
juha.willman@fi.abb.com
ABB Review
Plant Network
Process Control
Fieldbus
Process Controller
Power Distribution
Control
Power
Transformers
High Current
Busbars
Medium Voltage
Switchgear
Sectional
Drives
Field Instruments
Frequency
Converters
HCC
Links
Low Voltage
Switchgear
Low Voltage Motors
Distribution
Transformers
Medium Voltage Motors
Protection
Relays
Generator/ Motor
Excitation
High Voltage
Switchgear GIS
Substation
It is no secret in the cement business as with many other indus-
tries that basic automation solutions are fast becoming a com-
modity product. However many patchwork automation systems
exist either because plant managers have had no choice but to
buy the equipment they need from various suppliers or the overall
concept was never properly considered or thought out to begin
with. In many cases, the end result is a poor unsatisfactory work-
ing solution.
This is where ABB Process Automation and its family of Industrial-
IT
System 800xA products and solutions stand out and differenti-
ate themselves. ABB uniquely identifies itself not only as an auto-
mation product supplier, but also as: a manufacturer and supplier;
an engineering, commissioning, services and support partner; and
a cement process specialist. This single point of responsibility is
what cement customers are looking for in a competent automation
partner.
Peac e
of mind
Enabling increased productivity and
profitability in the cement industry with
ABBs System 800xA
Heikki Tanskanen, Alfredo Zeta
T
h e co n stru ctio n an d mo d e rn izatio n
o f ce me n ts p lan ts is, in man y
ways, ve ry similar to o th e r in d u strie s.
Ce me n t cu sto me rs an d p ro d u ce rs aim
to p ro d u ce a h igh q u ality e n d p ro d u ct
e fficie n tly u sin g th e mo st co st e ffe ctive
me an s p o ssib le , wh ile at th e same
time min imizin g o ve rall e n viro n me n tal
imp act.
Glo b al p laye rs in th e ce me n t in d u stry
co mp rise co mp an ie s su ch as Ho lcim
(Switze rlan d ), Lafarge (Fran ce ) an d
He id e lb e rg (Ge rman y) as we ll as a
n u mb e r o f small lo cal co mp an ie s. Th e
majo rity o f ce me n t p ro je cts, in clu d in g
co mp le te n e w p lan ts as we ll as re -
vamp s an d mo d e rn izatio n s, u su ally
o ccu r in d e ve lo p in g co u n trie s an d
e me rgin g marke ts in clu d in g Asia
an d th e Mid d le East. Th is is n o su r-
p rise b e cau se b o o min g an d e me rgin g
e co n o mie s are u su ally acco mp an ie d
b y a n e e d fo r n e w b u ild in gs, b rid ge s
an d o th e r in frastru ctu re .
Challenges facing the cement customer
Each p ro je ct is u n iq u e in its co mp le xi-
ty an d is h e avily d e p e n d e n t o n lo cal
co n d itio n s. No t man y p e o p le re alize
th at th e ce me n t man u factu rin g p ro -
ce ss is in fact a ch e mical p ro ce ss
wh ich is fu lly d e p e n d e n t o n th e q u ali-
ty o f lo cal raw mate rials an d th e ir in -
h e re n t n atu ral variatio n s. Th e ce me n t
man u factu rin g p ro ce ss is also d e -
man d in g in te rms o f e n e rgy co n su mp -
tio n an d e n viro n me n tal co n sid e r-
atio n s. Ce me n t p ro d u ctio n d e man d s a
so u n d au to matio n so lu tio n wh ich can
d e al with th e se variatio n s at a mo -
me n ts n o tice , an d ad ap t to its n e w
co n d itio n s as e fficie n tly as p o ssib le .
In ad d itio n , an au to matio n so lu tio n
can o n ly b e su cce ssfu l wh e n th e cli-
e n ts au to matio n p artn e r an d su p p lie r
fu lly u n d e rstan d th e co mp le xitie s o f
th e ce me n t man u factu rin g p ro ce ss,
ABB Review
ABB Review
an d h as th e e xp e rie n ce n e ce ssary to
re alize th e se u n iq u e so lu tio n s.
Wh at is co mmo n to all ce me n t man u -
factu re rs, as we ll as to mo st in d u s-
trie s, is th e n e ce ssity fo r o p e ratio n al
e xce lle n ce , p ro d u ctivity an d p ro fit-
ab ility, min imize d e n viro n me n tal im-
p act, glo b al an d lo cal co mp e te n ce , re -
sp o n sib ility an d su p p o rt, all o f wh ich
can b e su mme d u p as risk man age -
me n t an d min imizatio n . Bu ild in g a
b ran d n e w gre e n fie ld ce me n t p lan t is
cle arly a majo r u n d e rtakin g b u t th e
mo d e rn izatio n o f an o ld p lan t to th e
late st stan d ard s, p ro d u ctio n an d e ffi-
cie n cy le ve ls wh ile it is still in o p e ra-
tio n
1)
d e man d s a wh o le d iffe re n t se t
o f skills an d co mp e te n ce s fo r th e su p -
p lie r an d p artn e r.
Th is is wh e re ABB sh in e s an d stan d s
o u t as th e le ad e r in th e fie ld . ABBs
Min e rals Bu sin e ss Un it, b ase d in Swit-
ze rlan d an d with wo rld wid e re sp o n si-
b ility fo r all ce me n t cu sto me rs an d
p ro je cts, h as cle arly e stab lish e d itse lf
as th e in d u stry le ad e r in au to matio n
so lu tio n s.
ABBs distinctive approach
ABBs ce me n t o rgan izatio n h as b e e n
se rvin g cu sto me rs sin ce th e 1960s,
an d d u rin g th is time it h as amasse d a
we alth o f e xp e rie n ce . On e o f th e
main re aso n s th e co mp an y h as always
p ro vid e d wo rld class au to matio n so lu -
tio n s to its cu sto me rs is b e cau se it is
also th e d e ve lo p e r an d man u factu re r
o f th e fu ll ran ge o f p ro d u cts th at it
su p p lie s. All au to matio n re late d h ard -
ware , so ftware , to o ls an d e n gin e e rin g
as we ll as se rvice an d su p p o rt are
p ro vid e d to its cu sto me rs b ase wo rld -
wid e via ABB with o u t th e in vo lve me n t
o f e xte rn al th ird p artie s. ABBs p ro -
ce ss kn o wle d ge , b u ilt in to stan d ard
p ackage s, lib rarie s an d au to matio n
so lu tio n s fo r th e ce me n t in d u stry, h as
b e e n co n tin u o u sly e vo lvin g sin ce th e
1960s. To d ay, th is kn o wle d ge is fu lly
imp le me n te d an d stan d ard ize d in
ABBs In d u strial
IT
(IIT) Syste m 800xA
p latfo rm.
Fo r th e ce me n t in d u stry, fo r e xamp le ,
a su ite o f re -u sab le o b je cts fo r co n tro l
an d co mmu n icatio n fo r ap p licatio n
d e ve lo p me n t with d rag-an d -d ro p facil-
itie s
1
. It p ro vid e s a co mp le te se t o f
o p e rato r fu n ctio n s, re alistic p ro ce ss
d isp lays with grap h ic e le me n ts an d
face p late s, su p e rio r tre n d in g cap ab ili-
tie s, in te llige n t alarm an d e ve n t h an -
d lin g with re mo te me ssagin g, re p o rt-
in g, as we ll as in te grate d d rawin gs
an d wirin g d iagrams.
Su ch fe atu re s give ABB th e u n iq u e
ad van tage o f b e in g ab le to h an d le
ve ry co mp le x p ro je cts, fro m tu rn ke y
n e w gre e n fie ld p lan ts to th o se th at
1
Modular automation
ERP
Business
Management
HMI
CPM
Process Optimization
Information Management
Product on Support
Interface
Sensor/
Actuator
Interface
Control
Loops
Interface
MCC
Interface
Drives
Interface
Power
Distribution
Interface
Peripheral
Control
Controller Controller Controller
2
Industrial
IT
System 800xA in the Cement and Minerals industry
Thin Clients for Process Control e- commerce clients Business/ ERP- System
Intranet or
Internet
Firewall
Router
Shared
Printer
Process Portal Clients Engineer
E0/ LM
Thin Clients
RMP
Thin Client
KM/ LIMS
Thin Clients
Client/ Server Network (TCP/ IP)
Process Portal
OPC Servers
Expert Optimiser /
RMP/
Server
Control Network (Ethernet)
MB 300
AC800M
AC400
MP200
S100 I/ O
KM Knowledge Manager /
LIMS Laboratory/
Information Management/
Server
Infrared
Scanner
Profibus/ Foundation Fieldbus/
Ethernet/ TCPIP
Advant Fieldbus 100
Profibus
S800 I/ O
S400 I/ O
S800 I/ O
Remote I/ O
AC 6
Drives
familiy
Field
Devices
Universal
Motor
Controller
Insum
MCC
Optional redundancy for any OCS component available
Process Portal
Autolab
Grinding
X- ray
AC800M
Autolab
Laser granulometer
Press
Profibus
ABB
ap p licatio n s b ase d o n fo u r d e cad e s o f
e xp e rie n ce e xists. Syste m 800xA e m-
b race s th e p rin cip le s o f o p e n , re al-
time n e two rkin g with its u n iq u e in te -
grate d o b je ct o rie n te d syste m e n viro n -
me n t fo r o p e ratio n s, co n tro l an d e n gi-
n e e rin g, an d p ro vid e s a scalab le so lu -
tio n th at sp an s an d in te grate s lo o p ,
u n it, are a, p lan t an d in te r-p lan t co n -
tro ls.
Th e Syste m 800xA Min e rals Lib rary,
fo r in stan ce , in clu d e s p re -e n gin e e re d
mo d u lar o b je cts co n tain in g co n tro l
lo gic, h u man mach in e in te rface (HMI)
Peace of mind
Infrared
Scanning
System
Footnote
1)
St ringent ly planned and minimized downt imes are
essent ial.
ABB Review
n e e d re vamp in g an d mo d e rn izin g
u n d e r se ve re time , b u d ge t an d sch e d -
u le co n strain ts
2
. Th e ad van tage fo r
th e cu sto me r is lo n g te rm su p p lie r
co mmitme n t an d th e assu ran ce th at,
as its b u sin e ss e vo lve s, its au to matio n
p artn e r, ABB, can always p ro vid e a
p ro fe ssio n al, re liab le an d co mp atib le
so lu tio n to th e e xistin g, o ld e r te ch n o l-
o gie s in stalle d in th e p lan t.
Holcim (Maroc) Settat plant
Ho lcims n e w Se ttat ce me n t p lan t (se e
title p ictu re ) is lo cate d so u th o f Casa-
b lan ca in Mo ro cco . At th e e n d o f 2004,
Ho lcim d e cid e d to e stab lish a co m-
p le te ce me n t facto ry b y ad d in g a n e w
ce me n t grin d in g p lan t an d a clin ke r
p ro d u ctio n lin e . Op e ratio n o f th e
grin d in g p lan t was sch e d u le d fo r th e
th ird q u arte r o f 2006, an d th e clin ke r
p ro d u ctio n lin e is e xp e cte d to b e in
fu ll o p e ratio n b y th e e n d o f 2007. Th e
main q u arry is lo cate d 25 km fro m th e
main p lan t an d p ro vid e s th e raw mate -
rials fo r th e p ro ce ss. A railro ad lin ks
th e two lo catio n s.
ABB e n gin e e re d , su p p lie d , in stalle d
an d co mmissio n e d th e co mp le te sys-
te m in clu d in g e le ctrical d istrib u tio n
with in th e p lan n e d b u t ve ry d e -
man d in g sh o rt co n stru ctio n sch e d u le .
Th e IIT 800xA b ase d so lu tio n was im-
p le me n te d in a ste p b y ste p fash io n ,
th an ks to its p lu g an d p lay fu n ctio n al-
ity. So ftware co mp atib ility th ro u gh o u t
th e p ro je ct was e n su re d with so lid
e n gin e e rin g fo u n d atio n s, co n siste n t
me th o d s an d th e u se o f stan d ard
lib rarie s wh ich co mp rise d ABBs ye ars
o f p ro ce ss e xp e rie n ce with similar
p ro je cts.
Ho lcim Se ttat n o t o n ly h as ABBs le ad -
in g au to matio n so lu tio n , b u t it will
also b e n e fit fro m ad van ce d e n e rgy
mo n ito rin g an d re d u ce d co n su mp tio n ,
e n viro n me n tal man age me n t an d p o w-
e r mo n ito rin g. On to p o f th is, th e
co mp an y will p ro fit fro m ABBs p ro -
d u ctio n in fo rmatio n man age me n t an d
o p timizatio n cap ab ilitie s. Fin ally, th e
o ve rall au to matio n so lu tio n will b e
co mb in e d in to o n e syste m at th e main
p lan t an d re mo te q u arry, all u sin g th e
same d e sign an d ap p licatio n p rin ci-
p le s, th u s simp lifyin g o ve rall o p e ra-
tio n an d main te n an ce .
ABB more than just automation
As a le ad in g p ro vid e r to th e ce me n t
in d u stry, ABB take s o n th e so le re -
sp o n sib ility o f p ro vid in g q u ality p ro d -
u cts, so lu tio n s an d stan d ard s, an d th e
me an s fo r in cre ase d p ro d u ctivity an d
e fficie n cy wh ile always co n sid e rin g
th e cu sto me rs To tal Co st o f Own e r-
sh ip (TCO) an d e n viro n me n tal imp act.
Be cau se o f p ro ve n me th o d s, mo d u le s,
te ch n o lo gie s an d p latfo rms, p lan n in g
an d e xp e rie n ce , ABBs au to matio n so -
lu tio n s are in a class o f th e ir o wn .
Mo re imp re ssive ly, co mp le te tu rn ke y
so lu tio n s are also p ro vid e d th at co ve r:
th e raw mate rials n e e d e d (RMP-Raw
Mate rial Pre p aratio n ); o p timizatio n
(EO-Exp e rt Op timize r); lab s (Au to -
Lab ); kn o wle d ge man age me n t (KM-
Kn o wle d ge Man age r); an d d isp atch . In
ad d itio n , e le ctrificatio n to au to matio n
to in te grate d ERP syste ms an d n o n -
ABB p ro d u cts are also co ve re d .
Pu re au to matio n , in th e trad itio n al
se n se , is gre atly e xp an d e d with IIT to
in clu d e CPM (Co llab o rative Pro d u c-
tio n Man age me n t)
3
an d ERP (En te r-
p rise Re p o rtin g Syste ms) as we ll as
acce ss an d co n tro l o f su b statio n s,
p o we r d istrib u tio n , MCCs, ge n e rato rs,
q u ality an d lab o rato ry syste ms, e xp e rt
an d o p timizatio n syste ms as we ll as
b u sin e ss syste ms in clu d in g SAP. Th is
also in clu d e s th e se amle ss in te gratio n
o f in d u stry stan d ard te ch n o lo gie s like
TCP/ IP, Fie ld b u s/ Pro fib u s an d o th e rs.
In ad d itio n , ABBs tu rn ke y so lu tio n s
can also in clu d e fu ll e le ctrificatio n ,
cab lin g, se n so rs, mo to rs an d d rive s,
ligh tin g, fire an d vid e o syste ms as
we ll as th e in stallatio n an d co mmis-
sio n in g o f all ite ms p ro vid e d .
ABB has installed automation systems
for over 500 p roduction lines, 30 in the
last three years alone. The comp anys
installed base and advanced automa-
tion solutions save customers over
1 100 million p er year on energy costs
alone. Four decades of exp erience
combined with its ability to develop
and manufacture the full range of auto-
mation p roducts it sup p lies means ABB
can take sole resp onsibility for com-
p lete automation solutions. ABB p rod-
ucts are comp lemented with the com-
p anys skills, which are in turn trans-
ferred to local teams and p artners to be
used in the industries and markets they
serve. Customers therefore have p eace
of mind in the knowledge that, as their
own businesses grow, ABBs automa-
tion solutions will grow with them.
Heikki Tanskanen
Alfredo Zeta
ABB Switzerland Ltd
heikki.tanskanen@ch.abb.com
alfredo.zeta@ch.abb.com
3
CPM solutions for the cement industry
Economic Process Optimization
Thermal Energy Electrical Energy
Performance Indicators
Production Performance
Costs
SAP
MM/ SD PP- PI PM
Expert Optimizer
Kiln Optimization
Mill Optimization
Alternative Fuels
Raw Mix Preparation
Stockpile Blending
Raw Mix Proportioning
Raw Mill Optimization
Knowledge Manager
Production Information Mngt
Production Accounting
SAP Integration
LIMS
Process Data Management
Dispatch
Automation
Solutions
AutoLab
Quality
Robotics
Process Control
Set Points
Information
Raw Data
Peace of mind
R
e ce n t in ve stme n ts in gre e n fie ld
p lan ts with state -o f-th e -art te ch -
n o lo gie s h ave p rimarily b e e n d ire cte d
to ward s facilitie s lo cate d in th e d e ve l-
o p in g wo rld . To re main co mp e titive
th e b ro wn fie ld man u factu rin g site s
o f No rth Ame rica an d Eu ro p e mu st
sign ifican tly imp ro ve th e ir ROA (re -
tu rn - o n asse ts).
Nurturing brown fields for green bucks
Th is ch alle n gin g glo b al e n viro n me n t
is d rivin g th e o wn e rs o f b ro wn fie ld
p lan ts to se arch fo r co mp e titive ad -
van tage s in th e e xte n d e d u se o f au to -
matio n . Se ve ral strate gie s can b e ad -
o p te d :
Reduce unplanned downtime. Th e
ARC Ad viso ry Gro u p h as e stimate d
th is to re p re se n t two to five p e rce n t
o f cu rre n t p ro d u ctio n .
Implement reliability centered
maintenance techniques to re d u ce
co sts an d o p timize main te n an ce
p ractice s. Th e main te n an ce b u d ge t
in a typ ical ch e mical p lan t is e sti-
mate d to b e two th ird s o f n e t p ro fit.
Acco rd in g to a US Fe d e ral En e rgy
Man age me n t Pro gram Re p o rt, sav-
in gs in th e d o u b le -d igit p e rce n tage
ran ge can b e gain e d th ro u gh im-
p ro ve d main te n an ce te ch n iq u e s in
su ch p lan ts.
Increase personnel productivity. Pro -
vid in g re al-time acce ss to re le van t
in fo rmatio n facilitate s e mp o we re d
d e cisio n -makin g an d actio n , e n -
ab lin g co st an d p ro d u ctivity ad van -
tage s, wh ich is vital to th e b u sin e ss
p ro ce ss imp ro ve me n ts n e ce ssary to
ach ie ve gre ate r ROA.
Integration failed in the past
In th e last d e cad e , b illio n s o f d o llars
we re sp e n t o n n e w ERP (e n te rp rise
re so u rce p lan n in g) syste ms. Th e in te n t
was to in te grate th e b u sin e ss wo rld
with th e man u factu rin g p ro ce ss. In
mo st case s th e b asic ERP imp le me n ta-
tio n p ro je cts o ve rwh e lme d th e o rgan i-
zatio n an d in te gratio n was n e ve r re al-
ize d . Fu rth e r b u sin e ss p ro ce ss im-
p ro ve me n ts an d th e imp le me n tatio n o f
b e st-in -class p ro ce sse s re q u ire clo se
in te gratio n o f p lan t flo o r au to matio n
with b u sin e ss syste ms. A re n e we d at-
te mp t to h arn e ss th e su b stan tial im-
p ro ve me n t availab le th ro u gh in fo rma-
tio n in te gratio n will d rive au to matio n
in ve stme n ts o ve r th e n e xt d e cad e .
Aging workforce
A massive tu rn -o ve r o f in te lle ctu al
tale n t in p ro ce ss man u factu rin g p lan ts
is p ro je cte d in th e n e xt 510 ye ars.
Th e re is an u rge n t n e e d to cap tu re
th at e xp e rie n ce an d kn o wle d ge an d
make it availab le via th e au to matio n
an d in fo rmatio n man age me n t syste ms
to th e o p e ratio n s, e n gin e e rin g, an d
main te n an ce p e rso n n e l o f th e fu tu re .
Mu ch d ata is alre ad y b e in g co lle cte d
via th e ap p licatio n s ru n n in g in th e
e xistin g au to matio n an d p e rip h e ral
syste ms o n th e p lan t flo o r. Ho we ve r,
it is n o t acce ssib le as kn o wle d ge in an
in te grate d , co n te xtu al fash io n to th o se
p e o p le wh o n e e d it, wh e n th e y n e e d
it.
Aging automation infrastructure
Mo rgan Stan le y e stimate s th e valu e o f
in stalle d au to matio n syste ms in p ro -
ce ss man u factu rin g facilitie s th at h ave
re ach e d th e e n d o f th e ir life cycle to
b e $ 65 b illio n . Plan t flo o r in stallatio n s
are a co lle ctio n o f agin g, d isp arate
an d lo o se ly o r n o n -co n n e cte d sys-
Footnote
1)
ARC DCS Worldwide Out look, Sept ember 2005
ABB Review
Naturally, ABBs first priority is to look after its installed base and provide a cohesive
evolution path to its new technology while simultaneously preserving the investment
of its clients. It is a tough balancing act to follow, and one that has never been under-
taken on such a large scale by any automation system supplier, but ARC
1)
believes that
ABB is performing this task at a level that exceeds the industry norm. says Larry
OBrien, ARCs Research Director for Process Industries, when commenting on ABBs
control system evolution strategies.
Age is no issue
Evolution of automation systems to improve return on assets
Mark W. Taft
ABB Review
b e e n a fo rmid ab le ch alle n ge , wh ich
h as le d to th e d e ve lo p me n t o f Syste m
800xA.
ABBs pledge of evolu-
tion through enhance-
ment ensures that new
advances in automation
systems technologies
strengthen, rather than
compromise prior auto-
mation investments.
Syste m 800xA e xte n d s th e re ach o f
trad itio n al au to matio n syste ms b e yo n d
p ro ce ss co n tro l, to ach ie ve th e p ro -
d u ctivity gain s n e ce ssary fo r man u fac-
tu re rs to su cce e d in to d ays b u sin e ss.
Th is sco p e is acce ssib le fro m a sin gle
u se r in te rface th at p re se n ts in fo rma-
tio n an d p ro vid e s in te ractio n in a co n -
te xt ap p ro p riate to e ach u se rs re sp o n -
sib ility. Exte n d e d Au to matio n o b je cts
cre ate d with in Syste m 800xA p ro vid e
a fo u n d atio n fo r th e e fficie n t d e ve lo p -
me n t an d co n tin u o u s imp ro ve me n t
o f p ro d u ctio n ap p licatio n s with a p re -
d ictab ility u n attain ab le b y o th e r au to -
matio n o ffe rin gs.
Th e syste ms arch ite ctu re is b u ilt u p o n
ABBs p ate n te d Asp e ct Ob je ct
TM
te ch -
n o lo gy
2)
. Asp e ct Ob je cts re late p lan t
d ata (asp e cts) su ch as I/ O d e fin itio n s,
e n gin e e rin g d rawin gs, grap h ics,
tre n d s, e tc., to sp e cific p lan t asse ts
(o b je cts). Th is u n iq u e arch ite ctu re le ts
cu sto me r-o wn e rs in te grate b e st-in -
class p ro d u cts, ap p licatio n s an d se r-
vice s fro m ABB an d In d u strial
IT
ce rti-
fie d su p p lie r-p artn e rs with e xistin g
au to matio n in stallatio n s re gard le ss
o f th e o rigin al syste ms o rigin to
cre ate an e xte n d e d au to matio n e n vi-
ro n me n t. Th e 800xA syste m su p p o rts
to tal p lan t man age me n t an d co n tro l,
re mo vin g th e b arrie rs o f trad itio n al
d istrib u te d co n tro l syste ms.
Evolutionary customer benefits
Wh e th e r a cu sto me r-o wn e rs o rigin al
syste m n ame p late says Ad van t, DCI,
Fre e lan ce , INFI 90, Maste r, Me lo d y,
MOD 300, Satt, Symp h o n y, o r th at o f
a co mp e tito r, it can an d sh o u ld b e
u se d as th e fo u n d atio n o n wh ich to
b u ild a Syste m 800xA in stallatio n
1
.
Th is e vo lu tio n ary ap p ro ach o ffe rs
man y fu n d ame n tal d e live rab le s to
ABBs cu sto me r-o wn e rs.
By co mb in in g n e w Syste m 800xA
ap p licatio n s su p p o rtin g asse t o p timi-
zatio n , in fo rmatio n an d p ro d u ctio n
man age me n t an d ERP in te gratio n with
e xistin g syste ms, n e w p ro d u ctivity
p o te n tial may b e ach ie ve d .
Th e re u se o f in te lle ctu al in ve stme n ts
in e xistin g syste ms via d ire ct re -h o st-
in g o f ap p licatio n s, o r via ap p licatio n
tran slatio n to o ls an d se rvice s re d u ce s
risk, an d sh o rte n s imp le me n tatio n
sch e d u le s an d switch -o ve r time .
En gin e e rin g e ffo rts fo cu s o n imp ro ve -
me n t rath e r th an re cre atin g fu n ctio n al-
ity th at alre ad y e xists.
1 An 800xA evolution builds on existing architecture 2 ORLEN is Central Europes largest refiner of crude oil and ethylene
te ms. Th e se clo se d syste ms are a
b arrie r to in te gratio n . Man u factu re rs
re q u ire a migratio n p lan to h e lp th e m
re main co mp e titive . At issu e is th e
massive in ve stme n t th at h as b e e n
mad e , b o th in te lle ctu al an d cap ital.
Au to matio n u se rs u n d e rstan d th e n e e d
to b alan ce th e b e n e fits o f mo d e rn iza-
tio n with th e re q u ire me n t to ach ie ve
h igh e st p o ssib le re tu rn o n e xistin g in -
ve stme n t. Man y migratio n so lu tio n s
re q u ire e xte n sive re wo rk, au to matio n
ap p licatio n re d e ve lo p me n t an d d is-
ru p tive rip an d re p lace o f e xistin g
syste m co n te n t ju st to re tu rn fu n ctio n -
ality to cu rre n t le ve ls o f p e rfo rman ce .
Th is ap p ro ach sacrifice s th e e xp e ri-
e n ce an d kn o wle d ge au to matio n o wn -
e rs h ave accu mu late d in th e ir ap p lica-
tio n s. So h o w can th e se co mp an ie s
u p grad e th e ir syste ms wh ile p re se rv-
in g th is kn o wle d ge ?
Th e an swe r is au to matio n e vo lu tio n !
Evolution vs. migration
ABBs In d u strial
IT
Syste m 800xA Ex-
te n d e d Au to matio n so ftware facilitate s
th e ad d itio n an d in te gratio n o f th e
n e w cap ab ilitie s to p rio r ge n e ratio n
au to matio n syste ms. ABBs p le d ge o f
e vo lu tio n th ro u gh e n h an ce me n t
e n su re s th at n e w ad van ce s in au to ma-
tio n syste ms te ch n o lo gie s stre n gth e n ,
rath e r th an co mp ro mise p rio r au to ma-
tio n in ve stme n ts. Au to matio n syste m
e vo lu tio n is a p ro ce ss o f simp le , grad -
u al ad van ce me n t to a h igh ly in te grat-
e d , e xte n d e d au to matio n e n viro n -
me n t. Th e task o f me rgin g d isp arate
co n tro l syste m familie s in to a co h e sive
mo d e rn au to matio n syste m, wh ile p re -
se rvin g cu sto me r in ve stme n ts, h as
Footnote
2)
See also ABB Review 1/ 2002 pages 613.
Age is no issue
ABB Review
Syste m 800xA Pro ce ss Po rtal su p p o rts
stan d ard d isp lays, face p late s an d o p -
e ratin g p h ilo so p h ie s fro m p rio r ge n e r-
atio n Op e rato r Statio n p ro d u cts to
main tain a familiar o p e ratio n s e n vi-
ro n me n t. Th e kn o wle d ge th at o p e ra-
to rs, e n gin e e rs, an d main te n an ce p e r-
so n n e l h ave gain e d th ro u gh u se o f
th e ir e xistin g syste m will p ro vid e a
fo u n d atio n fo r imp ro ve me n t. Train in g
can b e fo cu se d o n le arn in g n e w cap a-
b ilitie s o f th e syste m.
The reuse of intellectual
investments in existing
systems via direct re-
hosting of applications,
or via application trans-
lation tools and services
reduces risk, and short-
ens implementation
schedules and switch-
over time.
By e vo lvin g an au to matio n in stallatio n
in a ste p -wise fash io n s cu sto me r-o wn -
e rs ad d re ss th e ir b u sin e ss n e e d s in a
time -frame ap p ro p riate to th e ir in ve st-
me n t ap p e tite . Fo r e xamp le , th e ad d i-
tio n o f Asse t Op timizatio n cap ab ility
to an e xistin g in stallatio n p ro vid e s th e
o p p o rtu n ity to min e th e in te llige n ce
o f e xistin g HART fie ld d e vice s to im-
p le me n t asse t mo n ito rs. Th e asse t
mo n ito rs facilitate a mo ve in main te -
n an ce strate gie s to a re liab ility ce n -
te re d ap p ro ach . Th e n e w so ftware
ru n s in co n ce rt with th e e xistin g in -
stallatio n an d p ro vid e s th e fo u n d atio n
fo r th e ad d itio n o f o th e r Syste m 800xA
cap ab ilitie s.
ABBs te ste d an d p ro ve n e vo lu tio n
p ro je ct e xe cu tio n se rvice s an d p ro ce -
d u re s e n su re lo w-risk, co st-e fficie n t
an d p re d ictab le re su lts fo r e ve ry e vo -
lu tio n ste p . De taile d e vo lu tio n p lan -
n in g se rvice s p ro vid e a we ll th o u gh t
o u t e xe cu tio n p lan fo r p re d ictab le
p e rfo rman ce th ro u gh o u t th e ste p -b y-
ste p e vo lu tio n p ro gram.
ABBs p ro d u ct life -cycle su p p o rt p o li-
cy p ro vid e s p re d ictab le su p p o rt fo r
in stalle d p ro d u cts, an d a co mmitme n t
to p ro vid e fu n ctio n al re p lace me n t
p ro d u cts to ke e p th e p lan t ru n n in g.
Th is p o licy allo ws cu sto me r-o wn e rs to
e vo lve th e ir syste m in a ste p -wise
fash io n with th e co n fid e n ce th at th e
fo u n d atio n will b e su p p o rte d , an d
availab le fo r p ro d u ctio n o ve r th e
p lan n e d e vo lu tio n p e rio d .
Project briefs
Wh e n Mo lso n Bre we ry in Can ad a,
n e e d e d to e xp an d an d u p grad e th e ir
20 ye ar o ld Ne two rk 90 syste m, Eve r-
e st Au to matio n h e lp e d th e m e valu ate
all o p tio n s. Mo lso n ch o se to e xte n d
th e ir e xistin g syste m b y ad d in g Syste m
800xA Pro ce ss Po rtal b e cau se o f th e
man y b e n e fits it o ffe re d , su ch as p e r-
so n alize d wo rksp ace s an d vie ws th at
p ro vid e b e tte r visib ility in to th e ir p ro -
ce ss, re mo te d e vice co n figu ratio n ca-
p ab ility an d co n tin u e d u se o f th e ir
o rigin al syste m in ve stme n t.
Acco rd in g to syste m in te grato r Jo e
So llazzo , th is so lu tio n allo we d Mo l-
so n to se amle ssly an d e ffo rtle ssly co n -
n e ct Pro ce ss Po rtal to th e e xistin g
syste m, an d h ave o p e rato rs vie w th e
o ld syste m as we ll as th e n e w, o n o n e
co mmo n p latfo rm a ve ry re al in ve st-
me n t savin gs.
PKN ORLEN is Ce n tral Eu ro p e s large st
re fin e r o f cru d e o il an d e th yle n e .
2
ORLENs first b le n d in g co n tro l an d
o p timizatio n syste m was su cce ssfu lly
co mmissio n e d in 1998. Ad d in g n e w
co n tro lle rs an d o p e rato r statio n s to
th e e xistin g MOD 300 syste m e xte n d -
e d th e DCS. On -lin e an d o ff-lin e o p ti-
mizatio n an d p lan n in g fu n ctio n s we re
valu ab le e xte n sio n s.
By evolving an automation
installation in a step-wise
fashion customer-owners
address their business
needs in a time frame
appropriate to their invest-
ment appetite.
ABB syste ms p ro te ct o u r in ve stme n t
ve ry we ll. Th e re are man y e xamp le s
in th e co mp an y wh e re we starte d
fro m a ve ry small, sin gle n o d e an d
th e n migrate d to h u ge co n tro l sys-
te ms. Th is is a go o d e xamp le o f ste p -
b y-ste p e vo lu tio n . Th e ABB syste m is
we ll su ite d to th is ap p ro ach , said
ORLENs Man age r o f Pro ce ss Au to -
matio n , Wald e mar Nag rko . We
ach ie ve d all o u r targe ts with o u r ABB
co n tro l syste m u p grad e ; o p timal u se
o f mo re co mp o n e n ts, o p timize d co sts,
e limin atio n o f re -b le n d s, ve ry go o d
3 Tissue- making machine 4 Alunorte plant in Brazil
Age is no issue
ABB Review
p re d ictio n an d co n tro l o f mo re p ro d -
u ct p ro p e rtie s re su ltin g in re d u ce d
p ro d u ctio n co sts an d re d u ce d give -
aways.
CMPC Tissue SA is a le ad in g p artici-
p an t in th e p u lp & p ap e r marke t ac-
tive in o ve r 50 co u n trie s o n five co n ti-
n e n ts. To me e t its o n go in g go al o f
co n stan tly imp ro vin g e fficie n cy b y
u tilizin g th e mo st ad van ce d co n tro l
te ch n o lo gie s, th e co mp an y re ce n tly
u p grad e d its mo re th an te n ye ar o ld
co n tro l syste m in th e Talagan te mill
lo cate d in Ch ile .
CMPCs Talagan te mill h ad b e e n o p e r-
atin g su cce ssfu lly with an ABB Maste r
syste m. CMPC d e cid e d to re d u ce
main te n an ce co sts b y co mb in in g a
n e w mill e xp an sio n with th e e vo lu tio n
o f th e e xistin g syste m. Co st was fu r-
th e r re d u ce d b y th e re -u se o f e xistin g
ap p licatio n s. Th e mill e xp an sio n was
d ire ctly in te grate d with th e e xistin g
syste ms via e vo lu tio n to Syste m
800xA.
ABBs In ve stme n t e n h an ce me n t
th ro u gh e vo lu tio n co n tro l syste m
u p grad e strate gy gave u s th e p o ssi-
b ility o f main tain in g, o r p o rtin g-o ve r
a wh o le e n gin e e rin g p ro ce ss, rath e r
th an h avin g to start o ve r, says
Sr. Re in ald o Urib e , Pro je ct Man age r
o f CMPC Tissu e s Pu e n te Alto Mill.
We n e ve r h ave th e o p p o rtu n ity to
ch an ge e ve ryth in g at o n ce . Th e ab ility
to make in cre me n tal imp ro ve me n ts
o ve r time is ve ry imp o rtan t. Th is is
th e way yo u p ro te ct yo u r in ve stme n t
an d yo u r co mp an y. Fro m th e b e gin -
n in g, ABB h as me t all o u r re q u ire -
me n ts.
Incremental additions and
functional extensions have
delivered dramatic pro-
ductivity improvements for
ABB automation custom-
ers, while building upon
the value of the baseline
capital and intellectual
investment they made in
their original systems.
Alu n o rte , in th e Par state in Brazil,
is p re se n tly o n e o f th e five large st
alu min a re fin e rie s in th e wo rld
4
.
It b e gan its p ro d u ctio n with two lin e s
in 1995, u tilizin g ABBs Maste r te ch -
n o lo gy. Wh e n a th ird lin e was ad d e d
in 2003, th e Maste r te ch n o lo gy was
e vo lve d to fu lly in te grate with an
Ad van t co n tro l syste m fo r all lin e s.
Alu n o rte fu rth e r e n h an ce d its au to ma-
tio n b y ad d in g Syste m 800xA wh e n it
b e gan its se co n d an d late st e xp an sio n
p ro je ct. Th e Exte n d e d Au to matio n
syste m u tilize s fie ld b u s co mmu n ica-
tio n s (b o th Pro fib u s an d Fo u n d atio n
Fie ld b u s), as we ll as ABBs Re al Time
Pro d u ctio n In te llige n ce (Re al-TPI)
so ftware . Th is e xp an sio n will allo w
Alu n o rte to p ro d u ce u p to 99 p e rce n t
o f th e o p e ratio n al time , slash in g
d o wn time to ju st o n e p e rce n t makin g
th e p lan t th e large st, mo st e fficie n t
alu min a p ro d u ctio n facility in th e
wo rld wh e n in stallatio n is co mp le te d
in 2006.
Th e ABB syste m h as h e lp e d Alu n o rte
re ach p ro d u ctio n go als sin ce start-u p .
If th e DCS can give yo u go o d d ata,
yo u can ch an ge th e d ata in to in fo rma-
tio n . If yo u h ave th e p o we r o f in fo r-
matio n yo u can ch an ge e ve ryth in g,
b u t yo u n e e d th e righ t to o l to make
th e ch an ge . Alu n o rte d rive s fo r im-
p ro ve me n t an d ABB is o n e o f th e
mo st imp o rtan t p artn e rs in o u r e ffo rts
to in cre ase o f p ro d u ctio n cap acity,
said Jo rge Ald i, Pro ce ss & Syste m
De ve lo p me n t Man age r, Alu n o rte .
Conclusion
As illu strate d ab o ve , in cre me n tal ad d i-
tio n s an d fu n ctio n al e xte n sio n s h ave
d e live re d d ramatic p ro d u ctivity im-
p ro ve me n ts fo r ABB au to matio n cu s-
to me rs, wh ile b u ild in g u p o n th e valu e
o f th e b ase lin e cap ital an d in te lle ctu al
in ve stme n t th e y mad e in th e ir o rigin al
syste ms. Plan n in g is a ke y co mp o n e n t
to a su cce ssfu l ste p -wise e vo lu tio n
p ro gram
5
. Th ats wh e re a co llab o ra-
tive e ffo rt b e twe e n ABB an d cu sto m-
e r-o wn e rs to map o u t th e b e st strate -
gie s will h e lp to min imize p ro d u ctio n
lo sse s, an d maximize th e b e n e fit o f
e ach in cre me n t o f th e p ro gram. ABBs
o ve rall go al is to mitigate risk, wh ile
e xtractin g maximu m valu e fro m o u r
cu sto me r-o wn e rs au to matio n syste m
in ve stme n ts.
Mark W. Taft
Process Automation
Wickliffe, OH, USA
mark.taft@us.abb.com
Age is no issue
5 Evolution architecture.
System Servers
Workplaces
Remote Clients
Plant Network/ Intranet/ Internet
Router/ Firewall
Control Network
Harmony System
Control
800xA System
Control AC800M
Variable Speed
Drives
MCC
Fieldbus High Speed
Linking Devices
(FF HSE/ HI, PB DP/ PA)
Harmony INFI 90
Controllers
Rack I/ O
Common System Applications
Operator Workplace
Maintenance Workplace
Manager Workplace
S800 I/ O
Engineering tool integration for process industries
David Dobson, Robert Martinez
The design of a process plant is a daunting task. Numerous sensors and
actuators need to be installed and connected, cables must be laid and cabinets
wired. The instrumentation within the plant is specified and designed by
different teams. Highly complex documentation is required to keep track of all
this. It is essential that such documentation is updated as modifications are
made during the lifecycle of the plant.
What is needed is powerful software that supports the designers in this
complex process, improving flexibility and driving down costs while maintaining
high levels of data quality and traceability. This is best achieved within a
database. Rather than storing the finished documentation, for example, in the
form of diagrams, the database holds the underpinning design information that
enables the automatic generation of such documentation.
ABB Review
ABB Review
T
h e e n gin e e rin g o f a p ro ce ss p lan t
starts with a co n ce p tu al d e sign
p h ase kn o wn as FEED (Fro n t En d
En gin e e rin g an d De sign ). In th is
p h ase , th e d e scrip tio n o f th e mate rial
flo ws th ro u gh th e e q u ip me n t are
d e fin e d . Th is is typ ically p e rfo rme d
b y an EPC (En gin e e r, Pro cu re , Co n -
stru ct) Co mp an y. Th e EPC u se s d e sign
to o ls to mo d e l th e p ro ce ss layo u t in
all d ime n sio n s an d o th e r to o ls to
mo d e l th e p h ysical p ro p e rtie s o f th e
p ro ce ss, su ch as te mp e ratu re an d
p re ssu re . On ce th e o ve rall d e sign is
co mp le te th e d e tail d e sign an d p ro -
cu re me n t p ro ce sse s can b e gin .
Th e p ro je ct th e n e n te rs th e d e taile d
e n gin e e rin g p h ase wh e re th e EPC p ro -
d u ce s p ip in g an d in stru me n t d iagrams
(P&ID) u sin g 2D co mp u te r-aid e d d e -
sign so ftware . In stru me n tatio n e n gi-
n e e rs u se d e sign to o ls to sp e cify th e
d e tails o f e ach se n so r an d actu ato r o n
th e P&ID. In p aralle l, th e co n tro l e n gi-
n e e rs d e ve lo p th e co n tro l strate gy
d rawin gs wh ich sh o w h o w th e d e vic-
e s n e e d to wo rk to ge th e r in re al time
to co n tro l th e p ro ce ss. Th e safe ty
syste m u n d e rgo e s a similar p ro ce ss
re su ltin g in th e sp e cificatio n o f cau se
an d e ffe ct matrice s to d e fin e th e in te r-
lo ck lo gic.
Th e o u tp u t o f th is p h ase is th e startin g
p o in t fo r ABBs o wn te ch n ical activi-
tie s wh ich , in th e case o f au to matio n
in clu d e s h ard ware e n gin e e rin g, ap p li-
catio n so ftware , an d Hu man Mach in e
In te rface (HMI). Th e co n tro l syste m
e n gin e e rs u se th e co mp an ys o wn p ro -
grammin g an d syste m co n figu ratio n
to o ls, su ch as th o se in clu d e d with
800xA En gin e e rin g Stu d io . Th e main
p ro je ct d e live rab le s fo r d e taile d au to -
matio n an d e le ctrical e n gin e e rin g are
sh o wn o n th e righ t-h an d sid e o f
1
.
On ce d e sign s are agre e d , p ro je cts
e n te r a man u factu rin g an d te stin g
p h ase , typ ically cu lmin atin g in th e
Facto ry Acce p tan ce Te st (FAT) fo l-
lo we d b y sh ip me n t an d in stallatio n
in clu d in g a Site Acce p tan ce Te st
(SAT). Afte r acce p tan ce th e syste m is
h an d e d o ve r to th e clie n t fo r co mmis-
sio n in g le ad in g to o p e ratio n an d o n -
go in g main te n an ce .

Th e re are man y variatio n s o f th e
ab o ve p ro ce ss. Fu n ctio n s su ch as te le -
co ms, e le ctrical syste ms an d an alytics
are in cre asin gly imp o rtan t an d co u ld
b e with in ABBs sco p e o f d e live ry.
All large p ro je cts h ave a co mmo n
n e e d to man age co mp le xity. Fo r a
p lan t with te n s o f th o u san d s o f in stru -
me n ts, a h u ge vo lu me o f in te r-re late d
in fo rmatio n mu st b e man age d . Th is
in fo rmatio n o rigin ate s fro m d ive rse
so u rce s; fro m p e o p le wo rkin g in se p a-
rate te ams; in se p arate co mp an ie s, o f-
te n o n se p arate co n tin e n ts; e ach with
th e ir o wn se t o f sp e cialize d to o ls.
The engineering challenge 1:
Globalisation of engineering
Th e trad itio n al mo d e l o f th e p ro je ct
e n gin e e rin g life cycle as d e scrib e d
ab o ve is b e in g ch alle n ge d b y th e in -
te n se co mp e titive p re ssu re s o f glo b al-
izatio n .
Sh o rte r d e live ry sch e d u le s fo rce p ro j-
e ct e n gin e e rin g p artn e rs to wo rk in
n e w ways an d b re ak th e trad itio n al
lin e ar e n gin e e rin g mo d e l in o rd e r to
allo w mo re tasks to b e p e rfo rme d in
p aralle l. Co st p re ssu re s fo rce th e p ro j-
e ct e n gin e e rin g p artn e rs to o u tso u rce
mo re tasks to h igh -e fficie n cy e n gi-
n e e rin g ce n tre s. Mo re strin ge n t safe ty
an d e n viro n me n tal re gu latio n s are
fo rcin g p ro je ct e n gin e e rin g p artn e rs to
p ro d u ce mo re an d b e tte r d o cu me n ta-
tio n . Mo re d e man d in g cu sto me rs in sist
o n h an d o ve r o f a h igh -q u ality e n gi-
n e e rin g d atab ase alo n g with th e ir p ro -
ce ss p lan t in clu d in g syste ms to ke e p
th is d ata syn ch ro n ize d with p lan t
ch an ge s so th at th e d atab ase stays
as-b u ilt .
Pro gre ss in IT is allo win g p ro je ct
e n gin e e rin g p artn e rs to u p grad e th e ir
o wn to o ls an d ad d fe atu re s to co p e
with th e se n e w ch alle n ge s. A ce n tral
p re re q u isite fo r th is is th e ab ility to
e xch an ge d ata with glo b ally d istrib u t-
e d te ams, an d to man age , with fu ll
trace ab ility, th e e vo lu tio n o f th is d ata
th ro u gh o u t th e life time o f th e p ro je ct.
To su p p o rt th e se re q u ire me n ts, e n gi-
n e e rin g an d d e sign to o ls are b e co m-
in g d ata- rath e r th an d o cu me n t-o rie n t-
e d with th e d rawin g d o cu me n t with
re n d e re d fro m th is d ata. Data is also
b e in g in cre asin gly stan d ard ize d in
n e u tral fo rmats p ro mo te d b y o rgan iza-
tio n s su ch as th e IEC (In te rn atio n al
Ele ctro te ch n ical Co mmissio n ).
As th e wo rld s large st p ro ce ss au to -
matio n an d e le ctrical su p p lie r, ABB is
in ve stin g in to o ls, me th o d s an d stan -
d ard isatio n strate gie s wh ich are tran s-
fo rmin g th e sh are d d ata fro m an e n gi-
n e e rin g b u rd e n in to a h igh -valu e asse t
1
Plant engineering lifecycle phases and deliverables
HVAC Load
Calcs
Piping
Double
Lines
PDS
3D Model
Motor
Control
Schematics
Switchgear
Line- up
Loop
Diagrams
Vessel
Sketches
Process
Data
Sheets
Piping &
Instrument
Diagrams
Process
Flow
Diagrams
Cable
Schedule
Instrument
Index
BPCS
Specifications
SIS / F&G
Specifications
Equipment
Index
Piping Line
List
Electrical
Panel
Schedule
Instrument
Data
Sheets
Control System
Architecture
Diagram
Cause &
Effects
Equipment
Data
Sheets
Piping
Tie- Lines
Lighthing
Plans
Instrument
Spec
Sheets
Logic
Diagrams
Site Plot
Plan
Civil
Plans
Structural
Plans
Equipment
Plans
Piping
Plans
Area
Classification
Plans
Instrument
Location
Plans
IO
Loading
Wiring
Diagrams
MCC
Layouts
Installation
Details
Graphics
Development
Single Line
Diagrams
JB Layouts
Logic
Definition
Power
Load
Tabulation
FEED
RFQ
Fabrication
& Testing
Installation &
Commissioning
Operations &
Maintenance
Architectural
Civil
Process Systems
Piping
Rotating Equipment
Structural
Control Systems
Electrical
Detailed
Design &
Engineering
ABB Review
fo r b o th p ro je ct e n gin e e rs an d e n d -
cu sto me rs. Th e fin an cial re tu rn fro m
th is e ffo rt is h igh as au to matio n e n gi-
n e e rin g typ ically acco u n ts fo r h alf o f
th e to tal co n tro l syste m p ackage , an d
e le ctrical e n gin e e rin g fo r mo re th an
o n e th ird o f th e to tal e le ctrical p ack-
age . Effe ctive e xe cu tio n o f e n gin e e r-
in g imp acts o n th e p ro je ct sch e d u le ,
co sts an d o n ABBs p e rce ive d cap ab il-
ity to d e live r su ch p ro je cts to a gro w-
in g glo b al marke t.
Delivering the digital asset
Fo r e n d -cu sto me rs, e ffe ctive man age -
me n t o f e n gin e e rin g in fo rmatio n is
vital fo r th e safe ty an d main te n an ce
o f th e p lan t o ve r its life time . Fo r p ro -
ce ss in d u strie s, so u rce s e stimate th at
th e valu e o f we ll-man age d e le ctro n ic
e n gin e e rin g d ata is ap p ro ximate ly
two p e rce n t o f th e to tal co st o f th e
p lan t.
A large p art o f th is e n gin e e rin g in fo r-
matio n is d e sign d ata fo r te n s o f th o u -
san d s o f in stru me n ts an d th e ir in p u t/
o u tp u t (I/ O). Fo r a p ro ce ss p lan t, in -
stru me n tatio n is ab o u t 10 p e rce n t o f
th e cap ital e xp e n d itu re (CAPEX) b u t
ab o u t 20 p e rce n t o f th e o p e ratio n al
e xp e n d itu re s (OPEX). En gin e e rin g
co mp an ie s e age r to win co n tracts fo -
cu s o n re d u cin g th e fo rme r, b u t it is
OPEX wh ich mo st affe cts th e o p e ra-
to rs b o tto m lin e .
It sh o u ld th e re fo re b e n o su rp rise th at
e n d -cu sto me rs are p u sh in g fo r gre ate r
stan d ard izatio n an d imp ro ve d h an -
d lin g o f p ro ce ss e n gin e e rin g in fo rma-
tio n , as re co mme n d e d b y in d u stry
co n su ltan ts ARC in a re ce n t re p o rt
1
.
Th e call fo r gre ate r in te r-o p -
e rab ility an d fo r ve n d o r in -
d e p e n d e n ce o f e n gin e e rin g
d e sign d ata is a fre q u e n t re -
q u e st in man y are as o th e r
th an p ro ce ss d e sign . In d e -
vice co mmu n icatio n , fo r e x-
amp le , th e d ata h an d le d is
re al-time in ste ad o f d e sign
d ata, b u t th e u n d e rlyin g is-
su e s are th e same . Fo r e x-
amp le , ve n d o rs wh o acte d
e arly to e mb race o p e n fie ld -
b u s stan d ard s h ad a sale s
ad van tage As th e te ch n o lo gy
o p e n e d th e d o o r fo r a ran ge
o f n e w p ro d u cts an d se rvice s su ch as
asse t man age me n t.
Integrate automation and instrumenta-
tion design
Th e re are a n u mb e r o f in stru me n ta-
tio n d e sign so ftware p ackage s o n th e
marke t. Th e se p ackage s atte mp t to
ce n tralize p lan t in stru me n tatio n d e -
sign in fo rmatio n so th at it can b e e asi-
ly acce sse d , man ip u late d an d u p d at-
e d , th u s e n su rin g co n siste n cy acro ss
th e d iffe re n t in stru me n t tasks an d d e -
live rab le s. All su ch p ackage s ad d re ss
th e p ro je ct life cycle in fo rmatio n re -
q u ire me n ts fro m e arly co n ce p tu al d e -
sign an d e n gin e e rin g to co n stru ctio n ,
main te n an ce an d d e co mmissio n in g.
Th e co mmo n ly u se d p ackage s in clu d e
In te rgrap h s SmartPlan t
In stru me n ta-
tio n (SPI) an d In n o te cs Co mo s
PT.
Cu rre n tly SmartPlan t
In stru me n tatio n
(fo rme rly INto o ls) h as a d o min an t p o -
sitio n wo rld wid e , p articu larly with th e
majo r EPCs, wh ile Co mo s PTs marke t
is main ly Eu ro p e an , b u t gro win g.
Th e se p ackage s u se a d atab ase to
h o ld all d ata re late d to th e d e sign o f
th e in stru me n tatio n syste m fro m th e
fie ld in stru me n t (se n so r e le me n t o r
valve ) th ro u gh to th e co n n e ctio n to
th e co n tro l syste m. Th is d ata is e ith e r
o b tain e d fro m o th e r d e sign so u rce s e .
g. P&IDs, o r e n te re d d u rin g th e d e -
sign p ro ce ss. Ou tp u ts fro m th e syste m
in clu d e in stru me n t sch e d u le s; h o o k-
u p d e tails fo r p u rch asin g an d in stalla-
tio n ; p an e l d e sign s; cab lin g d e tails
an d alarm d ata. All th e se are ve ry re l-
e van t to ABBs p ro je ct e n gin e e rin g
p ro ce sse s. Th e d ata flo ws are su mma-
rize d in
3
.
Th e se p ackage s may also h ave mo d -
u le s o r in te rface s th at facilitate valve
an d o rifice p late calcu latio n s. Th e y
e n ab le sign ifican t p arts o f th e co n tro l
syste m to b e au to matically co n figu re d ,
allo w th e te le co mmu n icatio n s syste m
to b e e n gin e e re d an d also e n ab le in -
te rfacin g with main te n an ce , calib ra-
tio n an d p u rch asin g syste ms.
ABB is wo rkin g to ge th e r with In te r-
grap h an d In n o te c lo o kin g at ways o f
makin g in stru me n tatio n d e sign d ata
availab le to all th e e n gin e e rin g p art-
n e rs an d th e ir syste ms. Th e th re e ke y
te ch n o lo gie s b e in g u se d to ach ie ve
th is are :
Sh are d typ e -lib rarie s an d a me ch a-
n ism fo r map p in g b e twe e n th e se
typ e s
Ve n d o r-n e u tral XML-b ase d fo rmat
fo r d ata e xch an ge to p re se rve o b je ct
re latio n sh ip s
We b se rvice s co mmu n icatio n fo r
o p e n tran sp o rt b e twe e n ve n d o rs
syste ms
Th e first re su lt o f th e se e ffo rts is re al-
ize d as a sh are d typ e -lib rary fo r S800
an d S900 I/ O h ard ware an d ABBs
Pro ce ss En gin e e rin g To o l In te gratio n
(PETI) ap p licatio n so ftware ,
as d iscu sse d in th e fo llo win g
se ctio n s.
Shared libraries: Accelerating
hardware engineering
In o rd e r to h e lp in stru me n ta-
tio n an d h ard ware d e sign e n -
gin e e rs to u se th e SPI p ack-
age e fficie n tly, a se t o f d e fin i-
tio n file s h as b e e n d e ve lo p e d
b y ABB to re p re se n t th e mo st
co mmo n 800xA h ard ware
co mp o n e n ts. On ce imp o rte d
in to SPI, th e se lib rarie s can b e
u se d to cre ate o b je cts su ch as
2
Extract from an ARC insight document
Oct.28, 2004
3
Plant instrument engineering data inputs and outputs
SPI
DATABASE
INPUTS
Process Data
Process Line
Information
3D Model
P&ID Data
Supplier Instrument
Specification Sheets
Electrical System
Instrumentation
OUTPUTS
Instrument Lists and
specifications
Alarm Schedules
Cabling Details
I/ O Termination Details
Marshalling Panel Design
Measurement Ranges
and Units
Loop Drawings
Hook- up Drawings
Hook- up Equipment BOMs
Termination Drawings
Cable and Core idents
From an operations perspective,
engineering & design tools
coupled with information
management solutions form the
basis of lifecycle engineering.
Having this data available
greatly reduces plant downtime,
improves plant performance, and
assists in better plant revamp
planning.
ABB Review
I/ O mo d u le s. Th e SPI u se r can d rag
an d d ro p th e d e sire d I/ O mo d u le typ e
o n to th e p ro je ct win d o w. Th e fie ld
sign als can th e n b e allo cate d to th e I/
O ch an n e ls an d au to matically cro ss-
wire d to th e fie ld te rmin als an d IS
b arrie rs as re q u ire d . Drawin gs may
th e n b e ge n e rate d fro m th e SPI syste m
sh o win g th e co rre ct te rmin atio n n u m-
b e rs, te rmin al layo u t, cab le an d co re
n u mb e rin g e tc.
S800 an d S900 I/ O d e fin itio n file s are
availab le fo r d o wn lo ad b y th ird p ar-
tie s fro m th e In te rgrap h we b site , o r
fo r ABB u se rs o n ly, fro m ABBs in te r-
n al So lu tio n Ban k.
Th e e xp an d e d SPI Re fe re n ce Exp lo re r
fo ld e r in / 4 sh o ws so me o f th e d e -
fin e d co mb in atio n s o f S800 I/ O mo d -
u le s an d te rmin atio n u n its. Th e My
List o p tio n allo ws a su b se t o f I/ O
mo d u le s an d b ase s to b e d e fin e d fo r
u se o n a p articu lar p ro je ct, th u s aid in g
d e sign stan d ard izatio n .
800xA h as, fro m its in ce p tio n , u se d
th e id e a o f typ e lib rarie s to d e fin e fre -
q u e n tly u se d o b je cts with in th e au to -
matio n p ro je cts ap p licatio n s. Th e se
lib rarie s h ave b e e n d e ve lo p e d fo r a
n u mb e r o f in d u strial se cto rs e .g.,
ch e mical an d p h armace u tical, o il an d
gas, u tilitie s an d fo r co mmo n fu n c-
tio n al are as su ch as fie ld d e vice s,
e q u ip me n t mo d u le s an d safe ty ap p li-
catio n s.
Th e e xte n sive u se o f typ e -lib rarie s is a
ke y e le me n t in au to matin g th e ge n e ra-
tio n o f ap p licatio n o b je cts wh ich are
b ase d o n in fo rmatio n fro m th e e n gi-
n e e rin g d atab ase syste m u se d b y th e
In stru me n tatio n an d Co n tro l Syste m
Hard ware En gin e e rs. ABBs Pro ce ss
En gin e e rin g To o l In te gratio n
(PETI) p ro vid e s a me ch an ism
to map in te rco n n e ctio n s b e -
twe e n SPI in stru me n t e n titie s
an d th e 800xA asp e ct o b je ct
typ e s. In stru me n t tags cre ate d
in SPI are u se d to au to -cre ate
th e co rre sp o n d in g o b je cts
with in th e 800xA co n tro l an d
fu n ctio n al stru ctu re s. Th e SPI
p ro p e rty is th e n u se d to se t
attrib u te valu e s in 800xA.
On ce th e o b je ct h as b e e n cre -
ate d , ch an ge s mad e to p aram-
e te rs d u rin g in stallatio n an d
co mmissio n in g can b e au to matically
writte n b ack to th e SPI d atab ase ,
main tain in g th is as th e maste r.
An open approach: Neutral format for
data exchange and web services
Th e p ro je ct e n gin e e rin g p artn e rs u se a
wid e varie ty o f to o ls with in co mp ati-
b le d ata re p re se n tatio n . As th e se to o l
p ro vid e rs re le ase n e w ve rsio n s, fo r-
mats fro m e arlie r ve rsio n s b e co me o b -
so le te . Pre se rvin g th e d e sign d ata
acro ss to o ls an d acro ss th e d e cad e s o f
a p ro ce ss p lan ts life cycle is th e mo ti-
vatio n fo r u sin g a stan d ard fo rmat
b ase d o n XML to re p re se n t d e sign
d ata. Th e CAEX stan d ard XML-b ase d
fo rmat o rigin ate d with in ABB. It is
n o w an ap p ro ve d DIN stan d ard an d
cu rre n tly u n d e r re vie w b y IEC. Th is
u ltra-fle xib le fo rmat is u se d with in
PETI to re p re se n t p lan t d e sign d ata
fo r b i-d ire ctio n al tran sp o rt b e twe e n
th e e n gin e e rin g syste m an d 800xA, as
sh o wn in
5
.
PETI o ffe rs two d iffe re n t ways to
acce ss th e e n gin e e rin g d atab ase . A
stan d -alo n e imp o rt/ e xp o rt u tility can
b e u se d b y th e EPC to e xp o rt th e d ata
as a file fo r su b se q u e n t imp o rt b y th e
co n tro l syste m e n gin e e r. Alte rn ative ly,
a we b se rvice can b e u se d to e xtract
d ata an d tran sfe r it e le ctro n ically. In
e ith e r case th e d ata is tran sfe rre d in
CAEX fo rmat.
Integrated Tools in Use:
Experience from Projects
Th e PETI p ackage h as b e e n u se d su c-
ce ssfu lly o n o n e re ce n t ch e mical an d
p h armace u tical p ro je ct in th e UK, an d
is cu rre n tly b e in g u se d o n se ve ral o il
an d gas p ro je cts in No rway an d th e
UK.
UK ChemPharm and O&G
In th e UK Ch e mPh arm p ro je ct, th e
ABB h ard ware d e sign e n gin e e r
wo rke d with in th e EPCs o ffice s u sin g
th e ir SmartPlan t
In stru me n tatio n sys-

te m to d e sign th e I/ O an d co n tro lle r
cab in e try su p p lie d b y ABB. Th e h ard -
wire d I/ O syste m ad o p te d was S900
an d a sign ifican t amo u n t o f Fo u n d a-
tio n Fie ld b u s in stru me n tatio n was also
u se d , p articu larly fo r co n tro l valve s.
Th e SPI was u se d to ge n e rate strip
d rawin gs, sh o win g all te rmin atio n s
an d in te rco n n e ctin g wirin g an d p n e u -
matics. Th e se we re u se d in co n ju n c-
tio n with e xte rn ally-p re p are d stan d ard
p an e l d e sign s to b u ild th e 12 p an e ls
re q u ire d . Th e same d o cu me n tatio n
was u se d fo r in sp e ctio n an d te stin g.
No o th e r d e taile d d e sign d o cu me n ta-
tio n was re q u ire d .

6
sh o ws o n e o f th e co mp le te d p an e ls
with e xamp le s o f th e SPI d o cu me n ta-
tio n u se d . A similar ap p ro ach is n o w
b e in g u se d fo r two UK b ase d o il an d
gas p ro je cts b u t with th e
ABB h ard ware d e sign e n gi-
n e e rs b ase d in th e ABB
o ffice s an d wo rkin g o n th e
EPCs SmartPlan t
In stru -
me n tatio n syste m. Th e se
syste ms will re mo te ly u se
te rmin al se rve r te ch n o lo gy
to main tain syste m se cu rity.
Norwegian oil and gas
BP h as b e e n su p p o rtive in
th e u se o f PETI o n th e Val-
h all p ro je ct b ase d in No rway
an d h ave gu id e d ABB in e x-
4
ABB S800 Hardware type library for SPI
5
Data Transport using CAEX between SmartPlant and 800xA
SmartPlant
Instrumentation
800xA
Type
Mapping
CAEX
(DIN- 44366)
CAEX
(DIN- 44366)
DB Import /
Export Utility
Web Service
Automation
Solution
Library
Process Engineering Tool Integration
ABB Review
te n d in g PETI to su p p o rt an o n lin e ve r-
sio n o f th e ir alarm re sp o n se man u al
(ARM). Th e ARM d ata is ce n tralize d in
SPI b u t will b e sh are d with o p e rato r
grap h ic d isp lays o n ABBs 800xA sys-
te m. PETI e n ab le s e xp e rie n ce d o p e ra-
to rs an d p ro ce ss e n gin e e rs to vie w
an d , if th e se cu rity le ve l p e rmits,
mo d ify alarm se ttin gs as a sin gle
sh are d d atase t, allo win g th e maste r
e n gin e e rin g d atab ase to b e ke p t as-
b u ilt th ro u gh o u t th e life time o f th e
p lan t.
End-custome rs are also inte re ste d in
the ability for 800xA op e rators to ac-
ce ss SPI loop drawings, instrume nt
sp e cifications and othe r docume nts di-
re ctly via the op e rator workp lace .
The se docume nts, which are re le vant
to op e rations and mainte nance func-
tions, are re nde re d live from the SPI
database se rve r, whe re the y can re adily
be maintaine d as-built. Some e xam-
p le s of this 800xA Workp lace inte gra-
tion are shown in the scre e nshots in
7
.
On e o u tco me o f th e se p ro je cts h as
b e e n a re fin e me n t o f e n gin e e rin g
wo rk-flo ws b e twe e n cu sto me r, EPC,
ABB an d o th e r p ackage su p p lie rs.
Early agre e me n t b e twe e n all p artie s
o n stan d ard s to b e u se d fo r lib rarie s
an d d ata tran sfe r b e twe e n syste ms is
e sse n tial.
SmartPlant integration: An enabler for a
main automation contractor
In so me large co n tracts, th e au to ma-
tio n ve n d o r h as a e xp an d e d ro le typ i-
cally kn o wn as Main Au to matio n
Co n tracto r (MAC). In th is ro le , ABB
can b e ad d itio n ally re sp o n sib le fo r th e
in stru me n tatio n sco p e , cre atin g th e in -
stru me n t list fro m th e re ce ive d P&IDs
an d e n su rin g e ach in stru me n t is fu lly
sp e cifie d an d cap ab le o f fu lfillin g its
p ro ce ss lin e fu n ctio n . A similar le ve l
o f re sp o n sib ility with re sp e ct to
switch ge ar, cab lin g an d th e e le ctrical
in stru me n tatio n e n gin e e rin g ap p lie s if
th e e le ctrical p ackage is in clu d e d
with in ABBs sco p e .
Progress in IT is allowing
project engineering part-
ners to upgrade their own
tools and add features to
cope with these new
challenges.
In ad d itio n to th e se e n gin e e rin g re -
sp o n sib ilitie s co me th e ad d e d d ata
man age me n t tasks re late d to p u rch as-
in g, in stallatio n , co mmissio n in g an d
d o cu me n tin g all th e se d e vice s.
The data inte gration ap p roach de -
scribe d he re is a ke y e nable r for ABB
in this strate gic role . Instrume nt lists
will no longe r be issue d to the MAC by
the EPC. Effe ctive e xe cution re quire s
that this inte rface be automate d, and in
addition e nd-custome rs will e xp e ct that
a MAC contractors database will be
fully inte grate d with othe r de sign data-
base s, for e xamp le P&IDs and 3D p lant
mode ls. Use of SPI as the instrume nta-
tion and p ane l de sign tool will he lp
minimize the risks of taking the MAC
role . The SPI database has out-of-the -
box synchronization with P&ID, Ele c-
trical and 3D de sign, and be cause of
the PETI inte rface also with 800xA.
Th e syste ms b u sin e sse s with in ABB
alre ad y fu n ctio n as syste m in te grato rs.
Usin g th is n e w te ch n o lo gy ABB can
ad d itio n ally d e ve lo p th e MAC ro le to
b e co me th e d ata in te grato r. Th e e n gi-
n e e rin g d atab ase syste m will d e live r
ad van tage s fo r b o th th e o wn e r/ o p e ra-
to r an d ABB d u rin g th e p lan t life cycle .
David Dobson
ABB UK Process Industries
St. Neots, UK
david.dobson@gb.abb.com
Robert Martinez
ABB Oil&Gas Strategic R&D
Billingstad, Norway
robert.martinez@no.abb.com
7
PETI screenshot (top left) and workplace integration of SPI with 800xA
6
Completed cabinet with an example
of wiring diagrams automatically
generated with PETI
As process plants get larger and more complex,
automation systems must handle an ever-increasing
number of signals. At the same time, the number of
electrical consumers increases, making an electrical
control system essential. The electrical control system is
an automation system in itself providing an interface be-
Integrated elec tric al
and automation systems
Tom F. Nestli, Peter Tubaas
tween the process control and the electrical consumers
and actuators. ABB takes responsibility for all these
systems and their integration. By letting ABB handle the
integration and all the interfaces, customers benefit from
faster project execution, reduced re-engineering, higher
quality, and higher operational efficiency.
ABB Review
ABB Review
E
le ctrical syste ms are cle arly a co re
p art o f an y p ro ce ss p lan t, p ro vid -
in g e le ctrical e n e rgy to d rive mo to rs,
e n e rgize h e ate rs, p o we r ligh tin g an d
au xiliary e q u ip me n t. Th e e le ctrical
syste m is in variab ly co mp le x, re lyin g
o n th o u san d s o f co mp o n e n ts an d kilo -
me te rs o f cab lin g. Th e co mp le xity o f
th e syste m in cre ase s with th e size o f
th e p ro ce ss p lan t. Su ch large p ro ce ss
p lan ts are re lian t o n au to matio n sys-
te ms to o p e rate e fficie n tly an d safe ly.
Th e se au to matio n syste ms will typ ical-
ly re sp o n d to te n s o f th o u san d s o f sig-
n als in a q u ick, p re d ictab le an d re li-
ab le man n e r. Th e se amle ss in te gratio n
o f th e e le ctrical an d au to matio n sys-
te ms are h igh ly d e sirab le in a p ro ce ss
p lan t, a b e n e fit re co gn ize d b y ABB at
th e Stato il Sn h vit o r Sn o w Wh ite
liq u e fie d n atu ral gas (LNG) p lan t.
He re , th e Ele ctrical Co n tro l an d Su p e r-
visio n Syste m (ECSS) co mmu n icate s
with a wid e ran ge o f e q u ip me n t an d
e n su re s a stab le p o we r su p p ly to th e
LNG facility.
Snhvit
Th e Sn h vit fie ld n ame d afte r th e
fairytale ch aracte r sn o w wh ite was
d isco ve re d mo re th an 20 ye ars ago .
Th e ro ad to d e ve lo p th is gas fie ld h as
b e e n lo n g an d win d in g, b u t th e p ro j-
e ct is fin ally clo se to p ro d u ctio n start.
It is p lan n e d to go o n -lin e d u rin g th e
su mme r o f 2007.
Th e p ast fe w ye ars h ave tu rn e d th e
u n in h ab ite d islan d o f Me lk ya
1
, n o t
far fro m th e to wn o f Hamme rfe st, in to
th e large st b u ild in g site in No rth e rn
Eu ro p e , an d th e large st co n stru ctio n
p ro je ct th at No rway h as e ve r se e n .
No system is more critical
to the processing plant
than the combined safety
and automation system.
Soon, gas from the Snhvit fie ld, ap -
p roximate ly 140 kilome te rs offshore in
the Bare nts Se a, will be flowing into
the gas p roce ssing p lant for tre atme nt
and ship p ing to the global LNG mar-
ke t. The core p roducts of the p lant will
be lique fie d natural gas (LNG, 5.67 bil-
lion m
3
/ ye ar), lique fie d p e trole um gas
(LPG, up to 250,000 tonne s/ ye ar) and
conde nsate (up to 900,000 m
3
/ ye ar).
All p roducts will be e xp orte d by ship .
Snhvit is the first develop ment in the
Barents Sea. The oil and gas fields were
discovered in the early 1980ies. Com-
bined with the adjacent Albatross and
Askeladd fields, Snhvit contains more
than 300 billion m
3
of natural gas. Gas
will be extracted from the seabed using
subsea equip ment, which are op erated
remotely from Melkya. The subsea
control system was delivered by ABB in
the UK (now Vetco Aibel). The top side
of the subsea control system, which is
an integrated p art of the overall Safety
and Automation System (SAS), was
delivered by ABB in Norway.
Complete control of the plant
Sn h vit is an e xtre me ly co mp le x in -
stallatio n . Th e p ro ce ss is e xte n sive ,
e n co mp assin g su b se a co n tro l p ro ce ss-
in g, co mp le x LNG p ro ce sse s, an d sto r-
age an d lo ad in g o f th e fin al p ro d u cts.
No syste m is mo re critical to th e p ro -
ce ssin g p lan t th an th e co mb in e d safe -
ty an d au to matio n syste m. Th e n u m-
b e r o f sign als ru n n in g th ro u gh th e
Sn h vit p ro ce ss is e n o rmo u s; th e Pro -
ce ss Co n tro l an d Data Acq u isitio n
(PCDA) syste m h as to h an d le mo re
th an 30,000 sign als simu ltan e o u sly. An
u n sch e d u le d h alt in p ro d u ctio n is e x-
tre me ly e xp e n sive . Th e re fo re , ABBs
co n tro l syste ms are co n stru cte d an d
te ste d to p ro vid e th e h igh e st le ve l o f
se cu rity an d min imal d o wn time .
The hot exhaust gases
from the gas turbines are
used to provide heat for
the parts of the process
that demand high temper-
atures.
Th e p h ilo so p h y o f p ro ce ss p lan t o wn -
e rs in ge n e ral, an d Stato il in p articu -
lar, is to p ro vid e its o p e rato rs with a
sin gle win d o w in to th e p lan t. ABBs
800xA Exte n d e d Au to matio n syste m
p ro vid e s th is facility an d was, th e re -
fo re , ch o se n fo r th e Sn h vit p ro je ct.
Plant power demand
Co mp le xe s fo r liq u e fie d n atu ral gas
re q u ire a re liab le an d stab le e n e rgy
su p p ly. Mo st LNG p lan ts are , h o we v-
e r, situ ate d in are as in wh ich th e p o w-
MS Nordlys, one of the ships of Hurtigruten The Norwegian coastal
ship operator entering the port of Hammerfest.
1
Map of northern Norway.
ABB Review
e r su p p ly is e ith e r u n re liab le o r n o n -
e xiste n t. Th e Sn h vit p lan t is n o e x-
ce p tio n an d mu st, th e re fo re , re ly o n
its o wn p o we r su p p ly.
Snhvit contains more
than 300 billion m
3
of
natural gas. Gas will be
extracted from the seabed
using subsea equipment,
which are operated
remotely from Melkya.
To me e t th e p o we r d e man d , th e Sn h -
vit p lan t co n tain s a 1.65 TWh p o we r
p lan t with five gas tu rb in e -d rive n ge n -
e rato rs o f ab o u t 50 MW e ach . Th e se
p o we r th e large re frige ratio n co mp re s-
so rs o f u p to 65 MW, d rive n b y vari-
ab le -sp e e d e le ctrical mo to r, th at are
re q u ire d to liq u e fy gase s. Th e h o t e x-
h au st gase s fro m th e gas tu rb in e s are
u se d to p ro vid e h e at fo r o th e r p arts o f
th e p ro ce ss. Th is se t-u p save s e n e rgy
an d p ro vid e s ab o u t te n ad d itio n al u p -
time d ays p e r ye ar d u e to th e mu ch
h igh e r availab ility o f e le ctrical d rive rs
(as co mp are d to gas tu rb in e d rive rs).
Th e Sn h vit p lan t n o t o n ly in clu d e s its
o wn p o we r statio n an d large co mp re s-
so r d rive rs, b u t also a large d istrib u -
tio n n e two rk with se ve ral th o u san d
re lative ly small e le ctrical co n su me rs.
A large varie ty o f ABB e le ctrical co m-
p o n e n ts are in clu d e d in ABBs d e live r-
ie s to th e p lan t. Th e se in clu d e h igh
vo ltage switch ge ar o f th e EXK-0 typ e ,
rate d fo r 145 kV, an d me d iu m vo ltage
switch ge ar o f th e Un iGe ar ZS1 typ e ,
rate d fo r 6.6 kV an d 11 kV. Also in -
clu d e d are o p tical arc d e te ctio n sys-
te ms to p ro vid e e arly d e te ctio n an d
q u ick p ro te ctive actio n o f switch ge ar
to e xtin gu ish arcs. Fu rth e r, MNS typ e
switch ge ar is u se d at lo w vo ltage le v-
e ls o f 400 V an d 690 V. So me 500 cu -
b icle s su p p lyin g p o we r to ab o u t 2,500
co n su me rs are in clu d e d at th e se vo lt-
age le ve ls; o f wh ich so me 600 co n -
su me rs are In su m starte rs (in te llige n t
mo to r starte rs) an d 75 co n su me rs are
variab le sp e e d d rive s o f ACS 800 typ e .
ABBs p ro te ctio n an d co n tro l u n it
(REF542) is u se d th ro u gh o u t th e p lan t
to p ro vid e th e h igh e st le ve l o f se cu rity
an d se le ctive p ro te ctio n actio n s in th e
e ve n t o f a fau lt in th e p o we r syste m.
Electrical control and supervision
system
Th e co mp le x n atu re o f th e e le ctrical
syste m re q u ire s an au to mate d ECSS.
Th is syste m is re q u ire d to u n ite th e
th o u san d s o f mo to rs, switch e s, co n -
tacto rs an d circu it b re ake rs, an d to
min imize th e e ffe cts sh o u ld a fau lt
d e ve lo p . A sin gle u n sch e d u le d sh u t-
d o wn fo r th e e n tire p lan t is e xtre me ly
e xp e n sive .
Th e ECSS is at th e h e art o f th e e le ctri-
cal syste m an d co mmu n icate s with th e
vast ran ge o f ABB p ro d u cts u sin g se ri-
al lin ks an d Eth e rn e t. It is also lin ke d
with th e au to matio n syste m an d o th e r
th ird -p arty d e live rie s. Th e syste m co n -
sists o f 48 AC800M co n tro lle rs. Th e
ECSS p ro ce sse s so me 44,000 sign als at
an y o n e time mo re th an th e p lan ts
au to matio n syste m. Th e ECSS p ro vid e s
a wid e ran ge o f fu n ctio n s, e n ab lin g a
stab le p o we r su p p ly to th e p lan t, lo w-
e rin g o p e ratio n co sts an d re d u cin g
e missio n s, wh ile at th e same time in -
cre asin g safe ty.
The past few years have
turned the uninhabited
island of Melkya, not far
from the town of Ham-
merfest, into the largest
building site in Northern
Europe, and the largest
construction project that
Norway has ever seen.
An imp o rtan t p art o f th e ECSS is th e
Po we r Man age me n t Syste m (PMS)
1)
.
Sin ce a re lative ly small fau lt may le ad
to a cascad e o f e q u ip me n t sh u td o wn s
th at co u ld affe ct a large p art o r th e
e n tire p lan t, fau lts mu st b e h an d le d
q u ickly an d ap p ro p riate ly to avo id a
d o min o e ffe ct. ABBs PMS is also
b ase d o n th e 800xA Exte n d e d Au to -
matio n syste m an d is d e sign e d to
mo n ito r, co n tro l an d p ro te ct all se c-
tio n s o f a p ro ce ss p lan t. It in clu d e s
fu n ctio n s su ch as:
Su p e rviso ry co n tro l an d d ata acq u i-
sitio n (SCADA), in clu d in g ge n e rato r,
circu it b re ake r, mo d e an d mo to r
co n tro l
Power control, including tie line con-
trol, p eak shaving and load sharing
An ABB engineer taking an overview of the plant at Melkya
(Photo: Peter Tubaas, ABB)
Two ABB engineers discsussing the plans for the day at the LNG plant in
Melkya (Photo: Peter Tubaas, ABB)
ABB Review
Lo ad sh e d d in g, in clu d in g fast, slo w
an d fre q u e n cy b ase d lo ad sh e d d in g,
as we ll as man u al lo ad sh e d d in g
ABB can draw on more
than 50 years of experi-
ence with automation
and electrical systems
to optimize their inte-
gration.
Pro b ab ly o n e o f th e mo st imp o rtan t
an d mo st fre q u e n tly re lie d u p o n p arts
o f th e PMS is th e lo ad sh e d d in g fu n c-
tio n , wh ich h e lp s e n su re th at th e co n -
se q u e n ce s o f an y o n e fau lt in th e
e le ctrical syste m h as th e smalle st p o s-
sib le imp act o n th e fu n ctio n in g o f th e
p lan t. ABB h as d e live re d an d co mmis-
sio n e d mo re th an 30 PMSs wo rld wid e ,
d e mo n stratin g th at th e PMS su b stan -
tially imp ro ve s p lan t u p time , e fficie n -
cy an d re liab ility.
Th e ECSS n o t o n ly p ro vid e s an in te r-
face b e twe e n th e p ro ce ss p lan ts au to -
matio n an d e le ctrical syste ms; it also
p ro vid e s in d isp e n sab le fu n ctio n ality
an d re liab ility in a p lan t wh e re a sys-
te m sh u td o wn co u ld co st millio n s o f
d o llars. Alth o u gh fu ll co mmu n icatio n
an d d ata e xch an ge with th e p ro ce ss
p lan ts au to matio n syste m is p ro vid e d ,
th e ECSS is n o t d e p e n d in g o n it to
o p e rate . On th e co n trary, th e ECSS
can o p e rate in iso latio n to e n su re safe
an d re liab le o p e ratio n o f th e e le ctrical
syste m.
Main electrical vendor approach
In th e p ast, o il co mp an ie s an d e n gi-
n e e rin g, p ro cu re me n t an d co n stru c-
tio n (EPC) co n tracto rs h ave ve ry o fte n
p u rch ase d d iffe re n t typ e s o f e q u ip -
me n t (e g, tran sfo rme rs, h igh vo ltage
switch ge ar, me d iu m vo ltage switch -
ge ar an d lo w vo ltage switch ge ar) u n -
d e r se p arate co n tracts. Pro je ct risks
can b e re d u ce d , h o we ve r, b y in clu d -
in g mo st o f th e e le ctrical e q u ip me n t
an d syste ms as we ll as e n gin e e rin g
u n d e r o n e large co n tract. Th e re su lt
is lo we r co sts an d faste r p ro je ct e xe -
cu tio n with safe r syste ms th at are fu lly
in te grate d an d in te ro p e rab le . Safe ty is
imp ro ve d d u rin g in stallatio n an d co m-
missio n in g sin ce p ro je ct co -o rd in atio n
is mo re e asily ach ie ve d with o n ly o n e
co n tracto r.
Stato il re co gn ize d th e me rit o f su ch
an ap p ro ach an d me rge d all p u rch ase s
o f h igh vo ltage , me d iu m vo ltage an d
lo w vo ltage switch ge ar, as we ll as th e
ECSS, fo r th e Sn h vit p ro je ct in to a
sin gle co n tract. In ad d itio n to e q u ip -
me n t d e live ry, ABB h as p ro vid e d a
wid e ran ge o f e n gin e e rin g se rvice s,
in clu d in g a lo n g list o f e le ctric n e t-
wo rk stu d ie s. Th e se are re q u ire d to
e n su re safe o p e ratio n an d maximu m
e fficie n cy o f th e p lan t.
Sin ce th e Sn h vit p lan t is p h ysically
co n n e cte d to th e n o rth e rn No rwe gian
p o we r grid , it so o n b e came o f in te re st
to stu d y th e d yn amic b e h avio r o f th e
e n tire p lan t in clu d in g th e gas tu r-
b in e ge n e rato r se ts an d its co n n e c-
tio n to th e grid . ABB h as p e rfo rme d a
d yn amic stab ility stu d y th at was u se d
to se t an d ad ju st th e p arame te rs o f th e
p o we r man age me n t syste m, as we ll as
th e d e d icate d ge n e rato r co n tro l algo -
rith ms. Th is e n su re s n o t o n ly stab le
o p e ratio n o f th e p ro ce ss p lan t, b u t
also e n su re s th at th e p ro ce ss p lan t
co n trib u te s to th e stab ility o f th e
n o rth e rn No rwe gian p o we r grid as
re q u ire d b y th e grid o p e rato r.
Complexes for liquefied
natural gas require a reli-
able and stable energy
supply. Most LNG plants
are, however, situated in
areas in which the power
supply is either unreliable
or non-existent.
ABB at the cutting edge
ABB can d raw o n mo re th an 50 ye ars
o f e xp e rie n ce with au to matio n an d
e le ctrical syste ms to o p timize th e ir
in te gratio n . Un itin g th e e le ctrical an d
au to matio n syste ms is b e co min g a
n e ce ssary fe atu re o f large p ro ce ss
p lan ts. Op e ratin g su ch p lan ts with o u t
an au to mate d syste m is almo st u n -
th in kab le , n o t o n ly fo r safe ty re aso n s,
b u t also fo r re aso n s o f co st savin gs
an d in cre ase d e fficie n cy. Cu sto me rs
like Stato il re ly o n e xp e rie n ce d co m-
p an ie s like ABB to e n su re safe an d
re liab le p lan t o p e ratio n s.
Tom F. Nestli
ABB AS Process Automation Division
Oslo, Norway
tom.nestli@no.abb.com
Peter Tubaas
ABB Corporate Communications
Billingstad, Norway
peter.tubaas@no.abb.com
Footnote
1)
See art icle Not on my wat ch on pp 3034 of t his
issue of ABB Review Special Report .
Powerful
renovation
Rejuvenating the Scholven coal-fired power station
to meet new market requirements
Harald Bruns, Stefan Lauxtermann
Many of Germanys existing power stations will continue to operate well into the
next decade, so it is very important to optimize and maintain existing installa-
tions. E.ON Energie, the largest privately-owned provider of energy services in
Europe, recognizes the key role of process control systems as the data, infor-
mation and nerve centers of its plants. Outdated technology and new opera-
tional requirements demand focused capital investment. E.ON Energie has,
therefore, implemented a program to upgrade the process control infrastructure
at the 2200 MW, six-unit Scholven power plant in Gelsenkirchen, Germany. This
included replacement of the 345 MW Unit C process control system with ABBs
System 800xA.
ABB Review
ABB Review
E
.ON En e rgie is a mu ltin atio n al
co rp o ratio n , se rvin g 15 millio n
cu sto me rs acro ss Eu ro p e with gas an d
e le ctricity. It re lie s o n state -o f-th e -art
co n tro l syste ms to e n su re cu sto me r
satisfactio n o n a lo cal le ve l an d to
maximize e fficie n cy acro ss th e gro u p .
Wh e n th e p ro ce ss co n tro l syste m at
th e co mp an ys Sch o lve n p o we r p lan t
n e e d e d u p d atin g, E.ON ap p ro ach e d
ABB with a cle arly-sp e cifie d list o f
re q u ire me n ts. Th e se in clu d e d :
fu lly au to matic o p e ratio n o f th e
p o we r statio n p ro ce sse s d u rin g
n o rmal lo ad o p e ratio n , start-u p s,
lo ad ramp s, sh u td o wn s, stan d stills,
an d d u rin g u p se ts
an ab ility to o p e rate an d mo n ito r
th e e n tire syste m fro m o n e co n tro l
co n so le u sin g in d ivid u al d isp lays
an d large scre e n s
straigh tfo rward p ro ce ss mo n ito rin g
to b e carrie d o u t b y a sin gle p ro ce ss
o p e rato r
fast an d accu rate fau lt an alysis to
min imize th e risk o f o u tage s an d to
re d u ce d o wn time , sh o u ld o u tage s
o ccu r
time - an d fu e l-o p timize d startu p
with fu ll co n sid e ratio n o f mate rial
co n strain ts ch an ge o ve r time fro m
o il to co al firin g to b e as sh o rt as
p o ssib le
Alth o u gh o rigin ally d e sign e d to o p e r-
ate as a b ase lo ad u n it, th e ch an ge d
marke t co n d itio n s n o w re q u ire th e
Sch o lve n p o we r p lan t to se rve as an
in te rme d iate lo ad u n it. Th e o p e ratin g
mo d e s th at mu st b e su p p o rte d wh e n
ge n e ratin g p o we r are tu rb in e fo llo w
mo d e , in wh ich th e tu rb in e co n tro ls
th e live ste am p re ssu re , an d b o ile r
fo llo w mo d e , in wh ich th e b o ile r
co n tro ls th e live ste am p re ssu re . Bo th
mo d e s mu st su p p o rt th e co o rd in ate d
u n it co n tro l fo r p u re an d mo d ifie d
slid in g live ste am p re ssu re typ ical fo r
o n e -th ro u gh b o ile rs. Th e u n it mu st
satisfy th e UCTE grid co d e re q u ire -
me n ts fo r b o th p rimary an d se co n d ary
fre q u e n cy co n tro l. Primary fre q u e n cy
co n tro l is ach ie ve d b y th ro ttlin g th e
main ste am valve . Se co n d ary fre q u e n -
cy co n tro l is acco mp lish e d wh ile
main tain in g p rimary co n tro l cap ab ili-
ty. Th is me an s th at th e lo ad ch an ge s
re su ltin g fro m in cre ase d d e man d may
b e ramp e d u p b y me an s o f fe e d -fo r-
ward co n tro l u sin g th e fu e l flo w
o n ly.
A fu rth e r re q u ire me n t was, th at th e
u n it h ad to b e ab le to fo llo w d e man d s
fro m d isp atch co n tro l ce n te r, ie , to b e
ab le to acco mmo d ate fre q u e n t, h igh ly
d yn amic lo ad swin gs an d trian gle s.
E.ON also sp e cifie d a n e e d fo r p artial
lo ad o r islan d syste m o p e ratio n ; ie ,
lo ad re je ctio n to au xiliary syste ms
d e man d (h o u se lo ad ) o r islan d n e t-
wo rk o p e ratio n . Partial lo ad o p e ratio n
at 33 p e rce n t (400 t/ h o f live ste am)
o f th e fu ll ratin g o f th e u n it was sp e ci-
fie d (re circu latio n ).
Scope of the replacement program for
the process control system
In ad d itio n to in stallin g th e n e w p ro -
ce ss co n tro l syste m, ABB re d e sign e d
th e e n tire co n tro l ro o m. Th e e xistin g
actu ato rs an d se n so rs h ad to b e u p -
grad e d an d , in so me case s, re p lace d .
All u p grad e s acco mmo d ate E.ONs
n e e d fo r th e e n tire p o we r p ro d u ctio n
p ro ce ss to o p e rate au to matically d u r-
in g start-u p s an d sh u t-d o wn s. Mo st o f
th e e xistin g fie ld cab lin g re main e d in -
tact, alth o u gh so me n e w wirin g was
re q u ire d to acco mmo d ate th e n e wly
in stalle d actu ato rs an d se n so rs.
Th e p lan ts n e w tu rb in e co n tro l sys-
te m is b ase d o n th e ABBs Syste m
800xA with AC 870P co n tro lle r. Th is
was u se d to imp le me n t a Tu rb o tro l

tu rb in e co n tro l ap p licatio n p ackage
fo r th e re gu latio n an d p ro te ctio n o f
th e main tu rb in e . Th e in te grate d tu r-
b in e , th e u n it an d th e p ro ce ss co n tro l
p latfo rm cre ate s n u me ro u s syn e rgie s
an d ad van tage s fo r u se rs.
Th e co n tro l syste m fo r th e p lan ts so o t
b lo we rs an d b u rn e r h ad alre ad y b e e n
imp le me n te d u sin g PLCs (p ro gram
lo gic co n tro lle rs). Bo th syste ms we re
in te grate d via Pro fib u s (p ro ce ss fie ld
b u s). Th e d e sign o f th e in te rface e n -
su re d th at th e syste ms co u ld b e mo n i-
to re d an d o p e rate d in acco rd an ce with
E.ONs sp e cifie d p ro je ct stan d ard .
Model-based unit control
ABBs Mo d an au to matio n co n ce p t was
u se d to me e t th e ch alle n gin g sp e cifi-
catio n s re gard in g p rimary an d se co n d -
ary co n tro l cap ab ility. Th is co n ce p t
co o rd in ate s th e two main co n tro l vari-
ab le s o f th e p o we r p lan t; fu e l se t
p o in t an d tu rb in e co n tro l valve s, o n
th e b asis o f d yn amic p aralle l mo d e ls.
It co n siste n tly ap p lie s a co mb in atio n
o f mo d e l-b ase d fe e d fo rward co n tro l
an d d yn amic se t p o in t co n tro l. Th is is
d o n e fo r th e tu rb in e co n tro l as we ll as
fo r th e se t p o in ts o f th e main ste am
valve p re ssu re an d fu e l co n tro l. Th e
Mo d an u n it co n tro l is p ate n te d an d
u se s th e tu rb in e co n tro l valve an d th e
fu e l se t p o in t valu e fo r th e ste am ge n -
e rato r as co n tro l variab le s. Th e b asic
o u tlin e sh o wn in
1
is gre atly simp li-
fie d an d ap p lie s to tu rb in e fo llo w o p -
1
Outline of model- based unit control
dyn.
pressure
Model
dyn.
feed- forward
control boiler
dyn.
MW Model
dyn.
feed- forward
control
turbine
turbine valve
position controller
remote dispatcher
setpoint
Unit SW
f: grid- frequency
deviation
p
LS
setpoint fuel
P
EI
(DVG)
P
SG
(boiler output load)
90
%
80
30 s 10 min
time
pressure
controller
fuel
controller
- +
- +
+
-
turbine load
controller
RH
<)
G
P
EI
P
-
Coordinated boiler folowing operation mode
4 3 2 1
Powerful renovation
ABB Review
e ratio n . Th e Mo d an co n ce p t
also allo ws o th e r o p e ratin g
mo d e s su ch as b o ile r fo llo w
o p e ratio n .
Control room design
Th e u n it co n tro l co n so le
2

was in stalle d in a n e w twin
co n tro l ro o m th at se rve s
u n its B an d C o f th e p lan t.
Th e n e wly-d e sign e d ro o m in -
co rp o rate s cle arly d e fin e d
wo rk are as fo r th e o p e rato rs,
sh ift su p e rin te n d e n t, e le ctri-
cian s (au xiliary syste ms) an d
th e e le ctrical e q u ip me n t iso -
latio n man age me n t.
Th e co n tro l syste m ch an ge -
o ve r fo r u n it B an d th e mo ve in to th e
n e w co n tro l ro o m are sch e d u le d to
o ccu r d u rin g th e an n u al main te n an ce
sh u td o wn in 2007.
Th e d isp lay scre e n s are o n ly th e e xte r-
n al in d icatio n o f a sign ifican t in cre ase
in th e d e gre e o f au to matio n at th e
p lan t. As a re su lt o f th e e n h an ce me n ts,
th e o p e rato rs jo b d e scrip tio n h as
ch an ge d fro m man u ally co n tro llin g th e
p ro ce ss to o n e mo n ito rin g an d co rre ct-
in g a n o w fu lly au to matic co n tro lle d
p ro ce ss. It was th e re fo re all th e mo re
imp o rtan t to d e sign th e co n tro l ro o m
e n viro n me n t to b e stimu latin g so th at
e mp lo ye e s wo u ld b e b e tte r ab le to
co n ce n trate . Th e in d ivid u al o b je ctive s
th at we re ach ie ve d are as fo llo ws:
Care fu lly d e sign e d co n tro l ro o m
arch ite ctu re with cle ar se p aratio n o f
are as fo r u n its B an d C.
Ce n tral p o sitio n in g o f th e scre e n s
fo r au xiliary se rvice s at th e sh ift
su p e r viso rs wo rkstatio n .
An are a th at th at allo ws sh are d u se
o f th e e q u ip me n t iso latio n co u n te r
fo r th e two u n its.
Dire ct an d in d ire ct wo rk are a illu mi-
n atio n ; th e ce ilin g is u se d as a re -
fle cto r to p ro vid e an e ve n ly lit wo rk
are a.
Ce ilin g, e q u ip p e d with micro -p o ro u s
aco u stic p an e ls, e ve n ly d istrib u te s
air an d min imize s n o ise .
Lo w-le ve l ligh tin g to imp ro ve visib il-
ity o f large r scre e n s.
A novel concept for operation
and monitoring
In ch o o sin g Syste m 800xA, E.ON se -
le cte d a p ro ce ss co n tro l syste m th at
h as a b ro ad ran ge o f n e w fu n ctio n s,
wh ile main tain in g a u n ifo rm u se r in -
te rface . Th e sco p e o f th e fu n ctio n s
go e s far b e yo n d co n ve n tio n al o p e rat-
in g an d mo n ito rin g syste ms, e n co m-
p assin g b o th in fo rmatio n man age me n t
an d e n gin e e rin g.
Th e u n d e rlyin g d ata acce ss, sto rage
an d man age me n t syste m is b ase d o n
ABBs p ate n te d asp e ct-o b je ct te ch n o l-
o gy. Th e o b je cts re p re se n t p ro ce ss
e le me n ts o f varyin g co mp le xitie s,
su ch as d rive s an d me asu re me n ts,
co al mills, fe e d p u mp s, tu rb in e s o r
b o ile r syste ms. Th e asp e cts are ch ar-
acte ristic d ata asso ciate d with th e se
co mp o n e n ts th at are re q u ire d fo r sys-
te m o p e ratio n an d main te n an ce .
Usin g th is syste m, asp e ct d ata is
sto re d o n ly o n ce an d can b e calle d
u p o n fro m vario u s o b je cts. Examp le s
o f asp e cts in clu d e :
Fu n ctio n d iagrams
Op e ratio n an d d iagn o stic d isp lays
Main te n an ce man age me n t fu n ctio n s
Au to CAD d rawin gs (e g, co n n e ctio n
d rawin gs, P&I-d iagrams)
Mo n ito rin g came ra image s
File s in PDF fo rmat fo r
scan n e d -in , n o n -p ro ce ss-
ab le d o cu me n ts su ch as
man u als
Su p p lie r we b site s
Micro so ft Exce l d o cu me n ts
(tab u lar calcu latio n s,
ad ap te d p ro to co ls, e tc.)
Micro so ft Wo rd d o cu me n ts
(o p e ratin g an d calib ratio n
in stru ctio n s, d ata sh e e ts,
e tc.)
Th is e n d s p ain stakin g se arch -
e s fo r d ata th at are d istrib u t-
e d acro ss vario u s lo catio n s,
co mp u te rs an d ap p licatio n s.
Use rs n avigate in tu itive ly
th ro u gh th e e n tire p lan t an d
are th e re fo re ab le to main tain a co n -
stan t o ve rvie w.
Use rs can co n figu re th e p ro ce ss d is-
p lays to su it th e ir o wn p articu lar re -
sp o n sib ilitie s, se ttin g th e ir o wn p re fe r-
e n ce s, allo win g th e m to ch o o se ap -
p ro p riate wo rk me th o d s. Th e fast,
fle xib le , se cu re acce ss to re le van t in -
fo rmatio n an d d ata make s it p o ssib le
fo r o p e rato rs to carry o u t th e ir mo n i-
to rin g an d o p e ratin g activitie s e ffi-
cie n tly an d accu rate ly.
Alarm management for fast reaction to
faults
A ran ge o f n e w fe atu re s h as b e e n in -
te grate d in to Syste m 800xA. On e e x-
amp le is a d istin ct p lan t o ve rvie w in
th e h e ad e r lin e
3
. A su mmary alarm
lin e ap p e ars u n d e rn e ath it. It sh o ws
th e mo st re ce n t u n ackn o wle d ge d
alarm th at h as th e h igh e st p rio rity. In
Syste m 800xA, u se rs can ju mp d ire ctly
fro m th e h e ad e r lin e to th e asso ciate d
p lan t d iagram. An o th e r ke y fe atu re is
th at th e h e ad e r lin e in d icate s h o w
man y me ssage s th e re are p e r p lan t
se cto r an d wh ich h as th e h igh e st p ri-
o rity.
2
The new control room at Scholven
3
Plant overview header line, a new integrated feature of System 800xA
a b c d e f
a
Plant overview
b
Plant event and alarm list
c
Navigation strategy
d
Online help
e
Alarm line
f
Date and time
Powerful renovation
ABB Review
Th e e n tire alarm list can b e
se le cte d fro m th e u n it are a
o r fro m a d e d icate d se le c-
tio n p o in t at th e to p o f th e
scre e n . It is p o ssib le to sto re
in d ivid u al n o te s fo r e ach
alarm fo r th e alarm list as
we ll. Th e in d ivid u al alarm
list e le me n ts can b e sh o wn
o r h id d e n an d b e liste d in
an y o rd e r. Th e alarm list can
also b e so rte d b y th e in d i-
vid u al e le me n ts. Th is can b e
ve ry u se fu l, fo r e xamp le , to
so rt acco rd in g to time
stamp , p lan t e q u ip me n t tag
o r p rio rity. Th e alarm list
can b e e xp o rte d d ire ctly to
Exce l fo r fu rth e r an alysis
u sin g co p y an d p aste .
Analyzing the process using
trend curves
Pro ce sse s can b e re liab ly an alyze d
with th e h e lp o f tre n d -ch art d isp lays.
A wid e ran ge o f fu n ctio n s, so me q u ite
in n o vative , are availab le in Syste m
800xA to ge n e rate su ch tre n d ch arts.
Bo th re al-time d ata an d h isto rical d ata
are p re se n te d se amle ssly in th e se
ch arts. Th e time in te rval can b e se le ct-
e d b y th e u se r. Re al-time tre n d ch ar-
acte ristics can b e co mp are d to cu rve s
ge n e rate d ye ste rd ay, last we e k o r last
mo n th u sin g th e time o ffse t fu n c-
tio n . A zo o m fu n ctio n is also avail-
ab le , wh ich can b e u se d to call u p all
d ata with in a p articu lar time in te rval
to th e e xact min u te
4
. Ne w fu n ctio n s
fo r th e ch art d isp lays in clu d e a magn i-
fyin g glass an d th e ab ility to cre ate
h o rizo n tal lin e s o r d e fin e h o rizo n tal
an d ve rtical are as.
Process quality monitoring
As a re su lt o f th e lib e ralizatio n o f
th e e n e rgy marke t an d ch an gin g
e n viro n me n tal re strictio n s th e re is a
n e e d fo r d e taile d kn o wle d ge o f th e
cu rre n t an d th e h isto rical q u ality o f
th e p ro ce ss man age me n t in p o we r
p lan ts.
As a consequence p lant op erators face
a multitude of challenges. On the one
hand, the liberalization of the energy
market creates an ever-increasing cost
p ressure. On the other hand, environ-
mental restrictions aim to reduce the
outp ut of carbon dioxide. Both chal-
lenges can be dealt with through re-
duced fuel consump tion by increasing
the efficiency of energy conversion in
the p ower p lant.
An alternative to cost-intensive con-
struction of new p ower p lants is to im-
p rove the quality of energy conversion
in existing p ower p lants. Even if the
efficiency of the p rocess cannot be
ramp ed up arbitrarily by changing the
way a p lant op erates, an attemp t can
be made to come as close as p ossible
to the op erational op timum.
Th e imp le me n tatio n o f p ro ce ss q u ality
man age me n t syste ms at th e d iffe re n t
p o we r p lan ts with in E.ON is d e sign e d
to allo w p lan t p e rso n n e l to mo n ito r
an d o p timize p lan t o p e ratio n in o rd e r
to ach ie ve su stain e d imp ro ve me n ts o f
th e p ro ce ss q u ality.
E.ONs d e cisio n to imp le me n t p ro ce ss
q u ality mo n ito rin g in mo st o f th e ir
p lan ts was also d rive n b y th e re q u ire -
me n t to h ave co mp arab le o p e ratio n al
ke y p arame te rs o f th e ir main p ro d u c-
tio n u n its.

Th e p ro ce ss q u ality man age me n t sys-
te m at th e Sch o lve n p o we r p lan ts
Un it F co n sists o f o n e se rve r PC an d
se ve ral clie n ts. Th e PIMS d atab ase fo r
sto rage o f an alo g an d b in ary p ro ce ss
valu e s, calcu latio n re su lts an d valid at-
e d valu e s is in stalle d o n th e se rve r
PC. Th e p ro ce ss valu e s are co lle cte d
fro m d iffe re n t co n tro l syste ms so u rce s
(Sie me n s Te le p e rm, ABB 800xA). Pro -
ce sse s su ch as th e fo llo win g
also ru n o n th is co mp u te r
Calcu latio n o f cu rre n t p e r-
fo rman ce in d icato rs o f all
majo r p lan t co mp o n e n ts
an d th e to tal p lan t.
Simu latio n o f lo ad d e p e n -
d e n t re fe re n ce d ata o f all
majo r p lan t co mp o n e n ts.
Calcu latio n o f th e q u ality
facto rs o f all majo r p lan t
co mp o n e n ts an d th e to tal
p lan t p ro ce ss d ata valid a-
tio n .
Calcu latio n s re su ltin g in
tre n d s an d p ro ce ss grap h ics
can b e vie we d o n vario u s cli-
e n t co mp u te rs lo cate d in th e
main co n tro l ro o m an d in th e
ad min istrative b u ild in g. Clie n t
co mp u te rs can b e u se d to cre -
ate an d mo d ify th e simu latio n o r d ata
valid atio n mo d e l. A n e two rk lice n se
fo r th e e n gin e e rin g so ftware is fo r th is
p u rp o se in stalle d .
E.ON KGW1 p lan t man age me n t d e cid -
e d to imp le me n t a p ilo t p ro je ct fo r th e
Sch o lve n p o we r p lan ts 676 MW u n it
F. Afte r su cce ssfu l imp le me n tatio n an d
acce p tan ce in Octo b e r 2005, an o rd e r
fo llo we d fo r th e imp le me n tatio n o f
p ro ce ss q u ality mo n ito rin g fo r u n its C
an d E.
Outlook
Afte r Un it C h ad b e e n su cce ssfu lly
re starte d o n sch e d u le , E.ON gave ABB
th e o rd e r to u p grad e Un it E p ro ce ss
co n tro l syste m to Syste m 800xA. Th e
ch an ge o ve r to o k p lace d u rin g th e
2006 main te n an ce o u tage . E.ON also
p lan s to u p grad e th e p ro ce ss co n tro l
syste m fo r Un it B d u rin g th e 2007
main te n an ce o u tage . Th e se ste p s will
make o p timu m u se o f p o te n tial syn e r-
gie s.
Harald Bruns
Power systems, ABB AG
Mannheim, Germany
harald.bruns@de.abb.com
Stefan Lauxtermann
Power systems, ABB AG
Minden, Germany
stefan.lauxtermann@de.abb.com
4
Zoom function showing all data within a chosen time interval.
a
Zoom window
b
Ruler function
c
X- Y plot
d
Time off- set
a b
c
d
Powerful renovation
Analytic s in Shanghai
Serving the needs of the Asian market and beyond
Barry Williams, Dan Mantey
ABB Review
The design, construction and installation of analytical sampling systems are
critical to the safe and efficient operation of modern industrial plants. This
is especially true in heavy manufacturing process such as petrochemicals
and refining. These sampling systems, and the large shelters that house
them, were in the past typically built by specialized companies in North
America or Western Europe and then shipped across the globe. The boom
in petrochemical and oil and gas investment in China and Southeast
Asia,and the Middle East changed the market dynamics. Responding to this
need ABB made a strategic decision in 2002 to locate an Analytical Systems
Integration Unit (SIU) in Shanghai, P.R. China.
ABB Review
I
n d o in g th is, ABB saw th at it was
p o sitio n in g itse lf to b e tte r se rve th e
n e e d s o f th e Asian marke t, e sp e cially
Ch in a. Th is in clu d e d co ve rin g th e
lo n g te rm se rvice n e e d s o f its cu sto m-
e rs. By d e sign in g an d b u ild in g sys-
te ms in Ch in a, ABB co u ld b o th re d u ce
th e co sts o f fab ricatio n an d avo id
large sh ip p in g co sts fro m No rth Ame r-
ica an d Eu ro p e . To e n su re su cce ss it
was n e ce ssary fo r ABB to re cru it an d
p ro p e rly train lo cal p e rso n n e l with th e
n e ce ssary e n gin e e rin g skills an d th e
mo tivatio n to e n su re th e o n -time d e -
live ry o f h igh q u ality an alytical sam-
p lin g syste ms.
Th e Sh an gh ai SIU starte d o p e ratio n in
Jan u ary 2003 with o n ly fo u r fu ll-time
staff. In itial p ro je cts we re su b co n tract-
e d to a lo cal th ird p arty ve n d o r fo r
man u factu rin g. In th e me an time a
p lan was fo rmu late d to d e ve lo p a to -
tally in te grate d SIU, wh ich wo u ld e m-
p lo y all ABB p e rso n n e l. All ke y fu n c-
tio n s wo u ld b e lo cate d in th e same
facility in o rd e r to assu re tigh t co n tro l
o f p ro je ct man age me n t, q u ality an d
cu sto me r co mmu n icatio n s. Th e p lan
was fu lly re alize d in Ap ril 2004 wh e n
th e o p e ratio n mo ve d to th e Waigao q -
iao Fre e Trad e Zo n e in Sh an gh ai.
It was also re co gn ize d th at th e Sh an g-
h ai SIU wo u ld n e e d to in cre ase its
p e rso n n e l co n sid e rab ly in o rd e r to
e n su re th at p ro je cts co u ld b e e xe cu t-
e d an d d e live re d in a time ly an d e ffi-
cie n t man n e r. Th e in itial fo cu s was to
fin d p ro je ct man age rs, an alyze r sp e -
cialists an d syste m d e sign e n gin e e rs.
ABB se ts h igh e xp e ctatio n s fo r te ch n i-
cal e xce lle n ce , kn o wle d ge o f th e b u si-
n e ss, e xp e rie n ce , sp e cialist skills,
p ro je ct man age me n t cap ab ilitie s an d
in te r-p e rso n al skills, wh ich are all
re q u ire d to me e t th e ch alle n ge s an d
th e d e man d s re late d to wo rkin g with
b o th Ch in e se an d in te rn atio n al clie n ts.
ABB was fo rtu n ate to se cu re th e se r-
vice s o f kn o wle d ge ab le Ch in e se p e r-
so n n e l with e xp e rie n ce o f an alytical
syste ms fro m th e o il, gas an d p e tro -
ch e mical fie ld s. Th e ve ry cap ab le lo cal
staff was su p p le me n te d b y se ve ral ke y
e xp atriate s fro m Eu ro p e with a b ro ad
ran ge o f e xp e rie n ce in su p p lyin g large
scale an alyze r syste ms glo b ally.
Poorly designed analyzer
systems have a significant
additional financial impact
over the life cycle of the
plant due to plant shut-
downs, design changes,
increased maintenance,
and increased call out
charges and spare parts
holdings.
ABBs go al was to d e live r p ro je cts
with th e same q u ality, me th o d o lo gy
an d e fficie n cy as fro m th e SIUs in
Eu ro p e an d Ame rica. De sp ite th e h igh
e xp e rie n ce le ve ls o f th e lo cal Ch in e se
staff a co n sid e rab le amo u n t o f skills
train in g was re q u ire d an d imp le me n t-
e d via th e fo llo win g co u rse s:
Pro je ct man age rs ABB accre d ite d
Pro je ct man age rs co u rse .
En gin e e rs an d d e sign e rs e xte rn al
an d in te rn al te ch n ical co u rse s tailo r-
mad e to me e t th e ir jo b re q u ire -
me n ts.
Sale s, e n gin e e rin g an d se rvice p e r-
so n n e l ABB p ro d u ct an d th ird p ar-
ty an alyze r co u rse s.
Wo rksh o p p e rso n n e l e le ctrical,
me ch an ical an d we ld in g co u rse s.
All staff safe ty train in g.
ABBs Sh an gh ai SIU is n o w a to tally
in te grate d o p e ratio n an d h as a staff o f
61, wh ich is e n gage d in th e fo llo win g
d iscip lin e s: e xte rn al/ in te rn al sale s,
p ro je ct man age me n t, e n gin e e rin g, d e -
sign , p ro cu re me n t, b u sin e ss su p p o rt,
q u ality assu ran ce , man u factu rin g, in -
sp e ctio n , te stin g, co mmissio n in g,
train in g, se rvice an d su p p o rt. Th e
2000m Sh an gh ai SIU facility was cu s-
to m d e sign e d an d p u rp o se b u ilt to
me e t o u r man u factu rin g flo o r sp ace
re q u ire me n t co mp le te with te st, we ld -
in g, sto re s an d mate rial q u aran tin e
are as.
Th e Sh an gh ai SIU in itially se rve d th e
rap id ly e xp an d in g marke t in Ch in a,
e sp e cially in th e ch e micals se cto r.
No w, afte r b u ild in g u p o n a stro n g
re p u tatio n fo r p ro vid in g q u ality an a-
lyze r syste ms, th e Sh an gh ai SIU e x-
p o rts syste ms to o th e r co u n trie s in th e
Asia Pacific re gio n , as we ll as se rvic-
in g th e Eu ro p e an an d Mid d le Easte rn
marke ts.
Sin ce its start in 2003 an d u n til th e
e n d o f 2006, th e Sh an gh ai SIU h as
ABB Review
su cce ssfu lly d e live re d o ve r 47 an alyz-
e r h o u se s. Th e se d e live rie s in clu d e
ab o u t 185 ABB an alyze rs
Factbox
. Ove r
33 p e rce n t o f th e d e live re d an alyze rs
are man u factu re d b y ABB, wh ile th e
re main in g sh are is so u rce d fro m vari-
o u s th ird p arty su p p lie rs. Th e re are
se ve ral cu sto me rs in Ch in a, wh o u se
th ird p arty an alyze rs, b u t still re q u ire
ABB to d e sign , co n stru ct an d d e live r
th e samp lin g syste m d u e to th e q u ali-
ty o f its wo rk.
ABB co n sid e rs its p e o p le its gre ate st
asse t an d th e staff in Sh an gh ai is n o t
vie we d an y d iffe re n tly. It h as b e e n in -
stru me n tal in e n su rin g a co n tin u ally
e xp an d in g o p e ratio n re su ltin g in b o th
an in cre ase d marke t sh are an d clie n t
b ase . Sale s p e rso n n e l are e n co u rage d
to b rin g p ro sp e ctive cu sto me rs to th e
facility to se e th e q u ality o f th e ABB
p ro d u cts first h an d .
Th e Sh an gh ai SIU h as b e e n award e d
an d wo rks to th e fo llo win g q u ality as-
su ran ce stan d ard s:
ISO 9001: 2000
ISO 14001: 2004.
Since its start in 2003
and until the end of 2006,
the Shanghai SIU has
successfully delivered
over 47 analyzer houses.
These deliveries include
about 185 ABB analyzers.
Th e Sh an gh ai SIU assu me s to tal re -
sp o n sib ility fo r th e p ro je ct fro m p u r-
ch ase o rd e r to clie n t h an d o ve r; o n go -
in g se rvice su p p o rt is also availab le
via ABBs stro n g se rvice n e two rk,
wh ich is p re se n t in Ch in a as we ll as in
almo st an y o th e r e n d -u se r d e stin atio n
co u n try. Se rvice s ran ge fro m sp are
p arts su p p o rt an d d e man d se rvice to
fu ll re sid e n t main te n an ce se rvice co n -
tracts. ABB in Ch in a cu rre n tly h as a
d o ze n se rvice e n gin e e rs d e d icate d to
an alytical syste ms. Th is e n ab le s ABB
to p ro vid e its cu sto me rs with e xce l-
le n t lo cal afte r sale s su p p o rt. With in
Ch in a th is is a re al ABB ad van tage ,
sin ce mo st su p p lie rs d o n o t man u fac-
tu re an alytical syste ms in th e co u n try.
Th e n u mb e r o f se rvice e n gin e e rs will
co n tin u e to in cre ase b o th in Ch in a
an d ab ro ad as cu sto me rs d e man d fast-
e r re sp o n se time s fro m th is h igh ly
train e d cad re o f p e rso n n e l.

Th is fu ll valu e -ch ain ap p ro ach p ro -
vid e s th e clie n ts with a sin gle co mmu -
n icatio n ch an n e l, an d th e same ABB
mu lti-d iscip lin e p ro je ct te am is in -
vo lve d in th e p ro je ct th ro u gh o u t its
life cycle . Th is re su lts in re d u ce d
co sts, lo n g te rm re liab ility, e ase o f
main te n an ce an d mo st imp o rtan tly,
lo we r to tal co st o f o wn e rsh ip d u e to
p artn e rin g with a sin gle so lu tio n s p ro -
vid e r.
The number of service
engineers will continue to
increase as customers
demand faster response
times.
Th e majo rity o f clie n ts n o w re alize
th at p o o rly d e sign e d an alyze r syste ms
h ave a sign ifican t ad d itio n al fin an cial
imp act o ve r th e life cycle o f th e p lan t
d u e to p lan t sh u td o wn s, d e sign
ch an ge s, in cre ase d main te n an ce , an d
in cre ase d call o u t ch arge s an d sp are
p arts h o ld in gs.
ABB Sh an gh ai SIUs fu lly in te grate d
o p e ratio n with a mu lti-n atio n al an d
mu lti-d iscip lin e staff h as th e e xp e ri-
e n ce an d track re co rd to h an d le majo r
glo b al an alyze r syste m p ro je cts. ABB
is ab le to take ad van tage o f th e co st
stru ctu re o f th e o p e ratio n , wh ich al-
lo ws th e SIU to d e live r q u ality an alyz-
e r syste ms at e xtre me ly co mp e titive
p rice s in th is ve ry p rice o rie n te d mar-
ke t p lace .
Barry Williams
ABB Engineering (Shanghai) Ltd.
Shanghai, China
barry.williams@cn.abb.com
Daniel P. Mantey
ABB Global Analytical Business
Raleigh, NC, USA
dan.mantey@us.abb.com
Factbox
Major project applications awarded to ABB Shanghai SUI
Application System delivered Year of order
LDPE 2 Houses 2003
OXO & AA/ AE 5 Houses + Field Systems 2003
LDPE pH/ Conductivity/ Hydro Leak 2003
LOP 7 Houses + Field Systems 2003
MA/ PA/ FA 7 Houses + Field Systems 2003
Olefins 4 Houses + Field Systems 2004
Thermoxidizer 1 House 2004
Methanol 1 House 2004
Isocyanates 7 Houses + Field Systems 2004
Naptha FTIR Analyser/ Sample 2005
Acetic Acid 1 House + Field Systems 2005
CEMS 3 Houses 2006
OXO & AA/ AE 2 Houses 2006
Acetic Acid 1 House 2006
Silicone 9 Houses 2006
Refinery 8 Houses + Field Systems 2006
Proc ess Analytic al
Tec hnology
Integrated PAT solutions for the Life Sciences industry
Thomas Buijs
Pharmaceutical manufacturers have
been providing medicines for more
than 60 years using tried and tested
formulations and manufacturing and
quality management processes. In
recent years new innovations in mea-
surement, control and IT technologies
have helped them to manage their
processes more efficiently, with higher
productivity as a result.
In addition to these innovations, a
specific initiative has also been
making its presence felt. Known as
the Process Analytical Technology
(PAT) Initiative, its goal is to under-
stand and better control the entire
manufacturing process within the
pharmaceutical industry. Processes
are actively managed to achieve a
high degree of repeatability and
efficiency, and quality assurance
becomes continuous and real-time
activity.
ABB is working in partnership with its
customers to deliver a systems
approach to PAT. From measurements
to process improvement, ABB
supports PAT implementation and the
delivery of real business benefits.
ABB Review
Risk management
64
ABB Review
P
ro ce ss An alytical Te ch n o lo gy (PAT)
is a syste m fo r d e sign in g, an alyz-
in g, an d co n tro llin g man u factu rin g
p ro ce sse s b ase d o n an u n d e rstan d in g
o f th e scie n tific an d e n gin e e rin g p rin -
cip als in vo lve d , an d id e n tificatio n o f
th e variab le s wh ich affe ct p ro d u ct
q u ality. Th e PAT in itiative is b ase d o n
th e FDA (Th e US Fo o d an d Dru g Ad -
min istratio n ) b e lie f th at: q u ality can -
n o t b e te ste d in to p ro d u cts; it sh o u ld
b e b u ilt-in o r sh o u ld b e b y d e sign .
Th e p rimary go al o f PAT is to p ro vid e
p ro ce sse s wh ich co n siste n tly ge n e rate
p ro d u cts o f a p re d e te rmin e d q u ality.
Effe ctive PAT imp le me n tatio n is fo u n d -
e d o n d e taile d , scie n ce -b ase d u n d e r-
stan d in g o f th e ch e mical an d me ch an i-
cal p ro p e rtie s o f all e le me n ts o f th e
p ro p o se d d ru g p ro d u ct. In o rd e r to
d e sign a p ro ce ss th at p ro vid e s a co n -
siste n t p ro d u ct, th e ch e mical, p h ysical,
an d b io p h armace u tical ch aracte ristics
o f th e d ru g an d o th e r co mp o n e n ts o f
th e d ru g p ro d u ct mu st b e d e te rmin e d .
Th e ro le o f o n -lin e ad van ce d me asu re -
me n t syste ms is p ivo tal to re alizin g th e
b e n e fits o f PAT. Ho we ve r, th e tran sfo r-
matio n o f p ro ce ss p e rfo rman ce to p ro -
vid e gre ate r e fficie n cy an d co st e ffe c-
tive n e ss, in ad d itio n to assu re d q u ality,
re q u ire s mu ch mo re th an th e ap p lica-
tio n o f me asu re me n t te ch n o lo gie s.
Re alizin g su ch gain s also re q u ire s an
in te grate d me asu re me n t, co n tro l,
wo rkflo w man age me n t an d in fo rma-
tio n e n viro n me n t wh ich me e ts th e
n e e d s o f re se arch an d d e ve lo p me n t,
man u factu rin g an d q u ality p ro ce sse s
with in th e b u sin e ss.
Using PAT, ABB offers a unique indus-
trial solution so that its customers in the
Life Sciences industry can enhance their
p rocesses to deliver the benefits of PAT,
from p rocess investigation right through
to achieving op erational excellence.
The benefits of PAT
In a n u tsh e ll, th e b e n e fits o f PAT can
b e su mme d u p in th e fo llo win g se n -
te n ce s: PAT imp ro ve s asse t u p time an d
availab ility fo r p h armace u tical u n it
o p e ratio n s b y u p to 40 p e rce n t. Co sts
are re d u ce d b y u p to 30 p e rce n t wh ile
fu n d ame n tal p ro d u ct q u ality is main -
tain e d . Ho w th is is ach ie ve d is o u t-
lin e d in th e fo llo win g p aragrap h s.
Better process understanding
Th e p h ysical an d ch e mical p ro ce sse s
in vo lve d in th e man u factu re o f p h ar-
mace u ticals are co mp le x an d n o t we ll
u n d e rsto o d . Ho we ve r, d u rin g b o th th e
d e ve lo p me n t an d man u factu rin g stag-
e s, PAT-e n ab le d p ro ce sse s p ro vid e
acce ss to in fo rmatio n rich d ata in re -
al-time wh ich can b e min e d to fin d
th e critical q u ality p arame te rs th ro u gh
mu ltivariate an alysis. On ce th e se are
d e te rmin e d , it is th e n e asie r to e stab -
lish accu rate co n tro l sch e me s fo r th e
re le van t p ro ce ss p arame te rs so th at a
mo re ro b u st p ro ce ss can b e e stab -
lish e d in a sh o rte r time frame an d
righ t-first time p ro d u ctio n is e n su re d .
Repeatable batch trajectory
Qu ality co n tro l re q u ire s a h igh ly d e -
taile d le ve l o f p ro ce ss u n d e rstan d in g.
ABB o ffe rs a co mb in atio n o f ad van ce d
an d re gu lato ry co n tro l b ase d o n ro -
b u st p ro ce ss mo d e ls th at d e live r ve ri-
fiab le re su lts. Th e PAT so lu tio n s d e te ct
an d man age critical co n tro l p o in ts in
th e p ro ce ss so th at d e viatio n s fro m a
re q u ire d p ro file are co rre ctly man age d
an d fe d b ack in to th e h igh p e rfo r-
man ce co n tro l zo n e .
Reduction in overall cycle time
Pro ce ssin g to a q u ality-b ase d e n d -
p o in t is a ke y p art o f th e PAT q u ality
assu ran ce re gime . Th is e limin ate s
waste d cycle time asso ciate d with p ro -
ce ssin g u sin g a fixe d time -b ase d e n d -
p o in t in clu d in g su b se q u e n t re p ro ce ss-
in g time an d p ro vid e s a stre amlin e d
wo rkflo w th ro u gh th e facility.
Reduction in Quality Assurance (QA)
costs
Re d u ctio n in Ou t o f Sp e cificatio n
(OOS) e ve n ts an d co n se q u e n t in ve sti-
gatio n le ad s to sign ifican t co st sav-
in gs. PAT e n ab le d u n it o p e ratio n s
re d u ce th e re lian ce o n lab o rato ry te st-
in g an d asso ciate d le ad time s, th u s
re d u cin g th e o ve rh e ad co sts asso ciat-
e d with p ro d u ct q u ality.
Improvement in Overall Equipment
Effectiveness (OEE)
OEE is th e in d u stry acce p te d to o l to
me asu re an d mo n ito r p ro d u ctio n
p e rfo rman ce . It can b e ap p lie d at th e
mach in e , man u factu rin g ce ll o r p lan t
p ro ce ss le ve l. Makin g cycle time s
re p e atab le an d re d u cin g in -b atch
d o wn -time th ro u gh imp ro ve d co n tro l
an d e arly fau lt d e te ctio n d e live rs a
mo re fle xib le agile asse t with mu ch
imp ro ve d OEE.
ABBs PAT Center of Excellence (CoE)
Fo llo win g th e n e e d to o ffe r an in te -
grate d ap p ro ach to PAT, ABB cre ate d
a Co E in 2004. Its man d ate is to d e ve l-
o p ABB p ro d u cts an d se rvice s wh ich
will e n ab le cu sto me rs to re ap th e b e n -
e fits o f PAT. Th e PAT Co E b u ild s o n
ABB An alyticals e xp e rie n ce o f p ro vid -
in g Ph armace u tical PAT Fo u rie r Tran s-
fo rm In frare d
1)
(FTIR) an d Fo u rie r
Tran sfo rm Ne ar In frare d (FT-NIR)
an alyze rs to th e marke t fo r th e p ast
te n ye ars, as we ll as ABBs p o sitio n as
a le ad e r in Au to matio n an d Co n tro l, in
p articu lar with its 800xA p latfo rm.
Th e PAT Co E le ve rage s ABBs glo b al
re so u rce s, wh ich in clu d e e xp e rie n ce d
re se arch an d d e ve lo p me n t p e rso n n e l,
ap p licatio n sp e cialists, ch e mo me tri-
cian s, p ro ce ss e n gin e e rs, IT e n gin e e rs,
se n io r valid atio n co n su ltan ts an d
ad van ce d p ro ce ss co n tro l sp e cialists.
Its man d ate co ve rs th e e n tire ran ge o f
PAT ap p licatio n s:
In itial in te gratio n with Man u factu r-
in g Exce lle n ce p ro grams
Mu ltivariate an alysis
Basic an d ad van ce d an alyze rs
Data gath e rin g
Data sto rage
Data min in g
Syste m in te gratio n
Co n n e ctivity with man u factu rin g an d
b u sin e ss syste ms
Ad van ce d Pro ce ss Co n tro l (APC)
Analytical and measurement
technologies the platform for PAT
At the he art of any PAT syste m is a
se rie s of me asure me nts made on re al
p roce sse s unde r re alistic manufactur-
ing conditions. Data from conve ntion-
al p roce ss me asure me nt syste ms (e g,
te mp e rature , p re ssure and flow) give
some insight into manufacturing p ro-
ce sse s so as to achie ve a basic le ve l of
p roce ss unde rstanding. Howe ve r, man-
ufacturing p roce sse s are usually too
comp le x for simp le ap p roache s to be
e ffe ctive in achie ving p roce ss unde r-
standing and control. An in de p th
de gre e of unde rstanding and tight con-
Risk management
Footnote
1)
See also Waves t o dat a , ABB Review 3/ 2006
pp 7374.
ABB Review
trol can only be achie ve d by e mp loy-
ing the corre ct te chnologie s to me asure
re le vant p roce ss p arame -te rs. The se
te chnologie s are ofte n base d on che mi-
cal comp osition and/ or p hysical form
me asure me nts, ie analytical te chnique s.
ABB h as to p class an alytical te ch n o lo -
gie s, fro m FT-IR/ NIR sp e ctro sco p y
righ t th ro u gh to mass sp e ctro me try
an d Gas ch ro mato grap h s. Fu lly in te -
grate d in to ABBs In d u strial IT (IIT)
co n ce p ts, th e syste ms h ave u n p aral-
le le d co n n e ctivity cap ab ility an d p ro -
vid e a ro b u st me asu re me n t p latfo rm
fo r all PAT ap p licatio n s. Co n n e cte d to
th e IIT in fo rmatio n b ackb o n e , th e
p ro ce ss d ata d e ve lo p e d can b e u se d
in e ve ryth in g fro m ad van ce d co n tro l
to p ro ce ss tro u b le sh o o tin g.
FT-IR/ NIR analytical solutions
FT-NIR is, by far, the most widely used
and p roven analytical technology for
PAT ap p lications. ABB has ten years of
exp erience in sup p lying off-line, at-line
and on-line FT-IR/ NIR PAT solutions to
the p harmaceutical industry and is a
p referred sup p lier of most of the lead-
ing comp anies. Turn-key analytical so-
lutions are p rovided for research and
develop ment for scale-up , drug sub-
stance, and drug p roduct manufacturing.
Typ ical d ru g su b stan ce so lu tio n s
in clu d e :
Re actio n mo n ito rin g
Fe rme n tatio n mo n ito rin g
Crystallizatio n mo n ito rin g
Drye r mo n ito rin g
So lve n t Re co ve ry mo n ito rin g
Typ ical d ru g p ro d u ct ap p licatio n s are :
Raw mate rial id e n tificatio n
Ble n d mo n ito rin g
Sp ray co atin g mo n ito rin g
Flu id b ad d rye r mo n ito rin g
So lid d o sage fo rm co n te n t u n ifo rmity
Mo istu re in lyo p h ilize d so lid s
Eve n th o u gh th e availab le an alytical
te ch n o lo gy fu lfills a wid e varie ty o f
me asu re me n t n e e d s, th e re is still a
ve ry wid e In fo rmatio n Te ch n o lo gy
gap wh ich is p re ve n tin g th e in d u stry
fro m e fficie n tly gath e rin g an d u sin g
th is d ata in re al-time fo r p ro ce ss u n -
d e rstan d in g an d co n tro l. To b e mo re
sp e cific, mo st o f th e ad van ce d PAT
an alyze rs cu rre n tly availab le d o n o t
sh are a co mmo n u se r in te rface an d
d ata fo rmat, an d d o n o t o ffe r th e co n -
n e ctivity re q u ire d to e fficie n tly e x-
ch an ge th is d ata with p lan t an d b u si-
n e ss syste ms. Fu rth e rmo re , th e d ata is
h igh ly scatte re d an d is n o t availab le in
re al-time in a ce n tral lo catio n .
The Industrial
IT
for Process Analytical
Technology suite
To ad d re ss th e se d rawb acks, ABB is
cu rre n tly d e ve lo p in g an In d u strial
IT

PAT su ite th at fe atu re s an in te grate d
IT p latfo rm u sin g p ro ve n an alytical
an d au to ma-tio n co re co mp o n e n ts.
Th is p latfo rm is b ase d o n th e award
win n in g 800xA In d u strial IT Au to ma-
tio n te ch n o lo gy
2)
. Th e co n ce p t
1
is
b ase d aro u n d a fle xib le , mo d u lar,
scale ab le an d o p e n arch ite ctu re
2

wh ich u se s OPC a stan d ard co mmu -
n icatio n p ro to co l to e xch an ge d ata
b e twe e n mo d u le s.
FTSW800 Analyzer control process
software for data acquisition
This flexible, op en architecture p rocess
analyzer software
3
is designed for
imp lementing analytical methods and
control sequences. It offers a single
p latform for the local control of multi-
p le analyzers from sp ectroscop y (IR,
UV-VIS, Raman etc) to other advanced
analyzer typ es (p article size, acoustics,
HPLG, mass sp ectroscop y etc). In addi-
tion, it p rovides unified engineering and
Footnote
2)
ht t p:/ / www.abb.com/ product guide Informat ion on
ABBs 800xA Indust rial
IT
Aut omat ion t echnology is
found under t he Cont rol Syst ems sect ion.
Risk management
1
Industrial
IT
for PAT concept
Plant data (LIMS,
EBR, MES, PLC,
DCS, etc...)
3
rd
Party Historian (IP21... )
Advanced
Process Control
(ABB or 3
rd
party)
FTSW 800 FTSW 800 FTSW 800 FTSW100 FTSW100
Reactor
NIR Drying Monitor
Blender
Monitor
Control Network
AC800M
controller or 3
rd
Party PLC
temperature
LOCAL
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Vector and scalar data
FBRM
Particle Size
Raman
Spectrometer
3
rd
party SCADA & Batch Engine
3
rd
party Visualization
AC800M
controller or 3
rd
Party PLC
On- Line
Predictor
PAT Asset
Optimization
PAT Data
Management
(with Audit Trail)
PAT Method
Central
Configuration
FTSW 800
Configuration
Multivariate
Data Analysis
(ABB or 3
rd
party)
Data
Visualization &
Export
Operator
Interface
PAT Data Manager PAT Clients
Crystallise
Milling
ph
S
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ABB Review
op erator interfaces as well as tools for
multivariate analysis and p redictions.
Data storage: PAT data manager
Th e man age me n t o f PAT d ata is h igh ly
co mp le x n o t o n ly b e cau se th e flo w o f
in fo rmatio n is e n o rmo u s, b u t b e cau se
it also in clu d e s a mix o f d ata fo rmats
(sp e ctral, ve cto r an d scalar d ata) th at
make s it d ifficu lt fo r stan d ard h isto ri-
an s to h an d le . Fu rth e rmo re , th e ce n -
tralizatio n o f PAT d ata is n o t su fficie n t
as it n e e d s to b e co mb in e d with th e
b atch in fo rmatio n co min g fro m th e
p ro ce ss co n tro l syste m (PCS) an d th e
b u sin e ss syste ms.
ABBs PAT d ata man age r is u n iq u e in
th at it sto re s all th e d ata in a sin gle
d istrib u te d d atab ase an d can h an d le
h u ge flo ws o f b o th scalar an d ve cto r
d ata co min g fro m th e an alyze rs, th e
PCS an d SCADA syste ms: It h an d le s
th e b atch stru ctu re d ata, th e ve cto r
an d scalar d ata, alarms an d e ve n ts as
we ll as a co mp le te au d it trail. It can
also e xch an ge d ata with o th e r th ird
p arty h isto rian s
Data mining, visualization, multivariate
analysis, and batch Management
Th e In d u strial
IT
fo r PAT su ite in clu d e s
a wid e ran ge o f mo d u le s to p ro vid e
an o p e rato r wo rkp lace , ce n tral me th -
o d co n figu ratio n , mu ltivariate an alysis
b atch co n figu ratio n an d man age me n t
as we ll as asse t man age me n t fo r an a-
lytical an d p ro ce ss e q u ip me n t. Th e
syste m also h as th e ab ility to co n n e ct
to th ird p arty co mme rcial mu ltivariate
an alysis to o ls fo r o ff-lin e an d re al-time
p re d ictio n s.
Control
Co n tro llin g p ro ce sse s in a fle xib le an d
re p e atab le man n e r re q u ire s p ro ce ss
u n d e rstan d in g to b e re alize d with in
re gu lato ry an d ad van ce d co n tro l e n vi-
ro n me n ts, wh ile at th e same time tak-
in g ad van tage o f a ran ge o f p ro ce ss
mo d e ls. Th is is facilitate d b y d yn amic
so lu tio n s p re d ict, co n tro l an d in fe r-
e n tial me asu re me n t p latfo rms wh ich
in te grate with o p e rato r in te rface , an d
re gu lato ry co n tro l an d p ro ce ss d ata
man age me n t co mp o n e n ts.
The way forward
PAT p ro vid e s an o p p o rtu n ity to mo ve
fro m th e cu rre n t te stin g to d o cu me n t
q u ality p arad igm to a co n tin u o u s
q u ality assu ran ce p arad igm th at can
imp ro ve a co mp an ys ab ility to e n su re
th at q u ality h as b e e n b u ilt-in o r is
b y d e sign . No t o n ly th at, b u t it give s
co mp an ie s a gre ate r in sigh t an d
u n d e rstan d in g o f th e ir p ro ce sse s; it
p ro vid e s th e p o te n tial fo r sign ifican t
re d u ctio n in p ro d u ctio n (an d d e ve lo p -
me n t) cycle time s; an d it min imize s
th e risk o f p o o r p ro ce ss q u ality.
PAT will re vo lu tio n ize th e way p h ar-
mace u ticals are mad e an d will fo re ve r
ch an ge th e face o f th e in d u stry. Th is
is wh y ABBs in ve stme n t in PAT is th e
sin gle b igge st d e ve lo p me n t in itiative
in Life Scie n ce s, an d it also p re se n ts
th e co mp an y with an e xce p tio n al
o p p o rtu n ity to b e co me th e marke t
le ad e r in Life Scie n ce s.
Thomas Buijs
ABB Automation Technology
Process Automation
Quebec, Canada
thomas.l.buijs@ca.abb.com
3
Local trending with FTSW800 software
Risk management
2
Industrial
IT
for PAT network architecture
Other
Server
SCADA
Historian
Batch
Manager
SCADA OPC
Server
PAT Data
Manager
(Consolidation)
Plant Network/ Intranet/ Internet
Visualization Clients
& Chemometric tools
Optional
PAT Data
Manager
Visualization
Clients
& Chemometric
tools
Control Network
3
rd
Party
Analyzer
ABB
Analyzer
PAT IT System
1 to 6
FTSW800/
Analyzers
Router/
Firewall
FTSW800 FTSW800
Todays processing industries are
experiencing increased demands to
reduce schedules and costs, while
maintaining more stringent quality
and safety standards. The trend
towards consolidation of the process
control, shutdown, facility, electrical
control and maintenance manage-
ment systems into a single unified
platform continues, with increasing
Flexib ility guaranteed
Streamlining applications and process changes
with ABBs Extended Automation System 800xA libraries
John Croft
demands for access to additional, rel-
evant and up to date information.
ABBs Extended Automation System
800xA responds to these demands. It
integrates the process control with all
extended automation applications
and smart devices in a single opera-
tions, engineering and information
management environment. By extend-
ing the device and equipment libraries
within the System 800xA. ABB has
introduced the worlds first truly ge-
neric, reusable software library for
batch applications in the pharmaceu-
tical and fine chemical sectors.
Risk management
ABB Review
ABB Review
T
h e ab ility o f ABBs Exte n d e d Au to -
matio n Syste m 800xA
1)
to gath e r
in fo rmatio n fro m mu ltip le p lan t so u rc-
e s an d tran sfo rm it in to re le van t in fo r-
matio n fo r a d ive rse se t o f u se rs su ch
as main te n an ce te ch n ician s, p ro ce ss
e n gin e e rs, p ro d u ctio n man age rs, o r
p lan t o p e rato rs e n ab le s p lan ts to
p e rfo rm smarte r an d b e tte r with su b -
stan tial co st savin gs.
Th e ad van tage s o f u sin g th e Syste m
800xA d e vice an d e q u ip me n t lib rarie s
o n a p ro je ct re su lt fro m u sin g stan -
d ard ize d co n figu rab le o b je cts with
p re se rve d in te grity an d in h e ritan ce ,
wh ile e n su rin g an d main tain in g th e
n e ce ssary fle xib ility.
No w ABB h as take n th in gs to a n e w
le ve l. To e xte n d th e d e vice an d e q u ip -
me n t lib rarie s, th e co mp an y h as d e -
ve lo p e d a lib rary
2)
o f o b je cts an d te m-
p late s wh ich e ffe ctive ly p ro vid e p re -
e n gin e e re d co mp o n e n ts to e n gin e e r
a b atch ap p licatio n with th e min imu m
o f co n figu ratio n . Fu rth e rmo re , th e se
co mp o n e n ts can b e u se d o ve r an d
o ve r again with o u t an y n e e d fo r p ro j-
e ct sp e cific co n tro lle r p ro grammin g.
Th e ab ility to e mp lo y tru ly ge n e ric
Ph ase s, Un it an d Eq u ip me n t Mo d u le
stru ctu re s, an d d e vice o b je cts re su lts
in sign ifican t time savin gs in sp e cifi-
catio n , e n gin e e rin g, te stin g an d vali-
d atio n , all o f wh ich u ltimate ly re d u ce s
th e time to marke t fo r n e w p ro d u cts.
Similarly it allo ws p ro ce ss e n gin e e rs
to make ch an ge s to e xistin g re cip e
o p e ratio n s an d Ph ase s with o u t th e
n e e d fo r p ro grammin g e xp e rtise .
Extending the equipment library
Th e e xte n sio n s to th e e q u ip me n t li-
b rary b u ild u p o n th e alre ad y p ro ve n
lib rarie s in o rd e r to d e live r similar
b e n e fits fo r b atch ap p licatio n s. Th e y
p ro vid e a co mp re h e n sive lib rary o f
ge n e ric Ph ase s, Un it an d Eq u ip me n t
Mo d u le te mp late s, to ge th e r with a
to o lkit o f co mp o n e n ts d e sign e d to o p -
timize th e sp e cificatio n an d b u ild in g
o f b atch ap p licatio n s u tilizin g ISA
S88
3)
style Eq u ip me n t Mo d u le s an d
cu sto mize d Pro ce ss Un its. Ge n e ric
Ph ase s e n ab le n e w p ro d u cts to b e in -
tro d u ce d b y d e ve lo p in g n e w re cip e s
o n ly, all in co mp lian ce with cGMP
(cu rre n t Go o d Man u factu rin g Practic-
e s) an d FDA (Fo o d an d Dru g Ad min -
istratio n ) valid atio n re q u ire me n ts, th u s
min imizin g th e sco p e an d co mp le xity
o f te stin g. Be cau se it h as b e e n d e -
sign e d to b e in te grate d with stan d ard
d e vice lib rary co n tro l o b je cts, th e
e q u ip me n t lib rary sh are s co mmo n te r-
min o lo gy, e n gin e e rin g p rin cip le s, se -
cu rity an d n amin g co n ve n tio n s. Th is
e n su re s th e in fo rmatio n d isp laye d to
o p e rato rs is co n siste n t wh ile e n gin e e r-
in g an d te stin g time is gre atly re -
d u ce d .
Th e se e xte n sio n s we re p o ssib le b e -
cau se o f th e Asp e ct-Ob je ct
TM
d e sign o f
ABBs Exte n d e d Au to matio n Syste m
800xA. Th e y b re ak n e w gro u n d b y
d istrib u tin g th e co n tro l in te llige n ce
th ro u gh a co n tro l h ie rarch y, th u s e n -
ab lin g tru ly ge n e ric, p re -te ste d an d re -
u sab le lib rary o b je cts to b e p ro vid e d
fo r Un its, Eq u ip me n t Mo d u le s an d
Ph ase s
1
. It is th e o n ly syste m th at
p ro vid e s tru ly ge n e ric Ph ase s th at can
b e u se d o u t o f th e b o x. It re mo ve s a
le ve l o f co mp le xity, me an in g th at
h igh ly q u alifie d p ro gramme rs are n o
lo n ge r n e e d e d . A p ro ce ss e n gin e e r
can carry o u t mu ch o f th e ap p licatio n
e n gin e e rin g at th e re cip e le ve l. Th is
way th e syste m maximize s re u se at
th e p h ase le ve l, allo win g cu sto me r
e n gin e e rs to fo cu s mo re o n wh at th e y
actu ally make rath e r th an o n th e in tri-
cacie s o f p ro grammin g.
ABB has introduced the
worlds first truly generic,
reusable software library
for batch applications in
the pharmaceutical and
fine chemical sectors.
With o th e r availab le syste ms, e ach
b atch ap p licatio n n e e d s sign ifican t
co n figu ratio n an d co n tro lle r p ro gram-
min g e ve ry time fo r e ve ry p ro je ct,
p articu larly fo r Eq u ip me n t Mo d u le s
an d Ph ase s. Th is in cu rs ad d itio n al
time an d co st as th e se co mp o n e n ts
1
The library extensions distribute the control intelligence through a
control hierarchy
Philosphy of Approach
Recipe
Generic Library Modules
PC Equipment Library
Phases Unit
Equipment
Modules
Control
Modules
PC Device
Library
Reactor, fermenter,
separator, etc.
Vapor services,
inlet manifold, agitator, etc.
Valves, pumps, loops, etc.
Product
Recipe
Unit
Procedures
Operations
2
Devices are encapsulated in Equipment Modules, which combine one
or more control devices together into a common function
Mix
M
Temperature
Control
Charging
Pressure
Control
Transfer/
Storage
Medium A
Medium B
Inert gas
Vacuum
Outlet Air
Heat
Cool
Fl
Fl
F
F
E
TC
E
T
P
E
PC
E
LI L
E
Risk management
Footnotes
1)
For more indept h informat ion, please refer t o
www.abb.com/ product / us/ 9AAC115756.
aspx?count ry=US (November 2006)
2)
A library is a collect ion of foundat ion object s (com-
ponent solut ions) from which unique inst ances can
be creat ed. Each inst ance is effect ively a clone of
t he foundat ion object .
ABB Review
Th e u se o f an S88 stru ctu re d frame -
wo rk an d a p re -te ste d an d p ro ve n
co mp o n e n t lib rary make s sp e cifica-
tio n , imp le me n tatio n an d co n figu ra-
tio n o f co n tro l syste ms le ss co mp le x
an d le ss time co n su min g. Th e lib rary
co mp o n e n ts are also u se d in a h ie rar-
ch ical man n e r.
The libraries
Th e d e vice lib rary p ro vid e s a large
p o rtfo lio o f te ste d p ro ce ss co n tro l
d e vice s su ch as mo to rs an d o n / o ff
valve s. Each d e vice is re p re se n te d in
th e lib rary b y an o b je ct e n rich e d with
asp e cts, in clu d in g co n tro lle r co d e ,
face p late an d grap h ic d isp lay e le me n t
wh ich su p p o rt d e vice man age me n t
o ve r th e e n tire life cycle . De vice s
h ave co n figu rab le ge n e ral o p tio n s,
in clu d in g alarm an d state co lo rs, u se r-
d e fin ab le fu n ctio n s an d te xt with
n ative lan gu age su p p o rt. De vice s are
e n cap su late d in Eq u ip me n t Mo d u le s,
makin g th e re u se o f co mp le x p ackag-
e s o f d e vice co n tro l simp le , accu rate
an d re p e atab le . Eq u ip me n t Mo d u le s
co mb in e o n e o r mo re co n tro l d e vice s
to ge th e r in to a co mmo n fu n ctio n
2
,
wh ich in tu rn can b e u se d acro ss se v-
e ral u n its to p ro vid e a h igh d e gre e o f
re u se , as we ll as e n su rin g o p e ratin g
co n siste n cy th ro u gh th e p lan t, an d
re d u cin g e n gin e e rin g an d te stin g
e ffo rt. Un its are co n figu re d to re p re -
Capital Productivity: Leveraging System
800xAs object- oriented technology, the
libraries provide the ultimate balance be-
tween flexibility and standardization. This
minimizes project specific library develop-
ment and the project specific software,
thereby minimizing the cost of developing a
batch automation solution while maximizing
the plant operability.
Global Responsibility: The library objects
are developed under stringent Quality Assur-
ance standards, tested and encapsulated to
ensure functional integrity. This can greatly
reduce project testing and compliance docu-
mentation, especially for validated projects.
Risk Management: The fact that ABB
maintains the libraries minimizes risk by
ensuring the future migration and upgrade
path. It enables modifications and enhance-
Factbox
The ABB System 800xA extended libraries when applied to batch processes deliver:
ments to be made as plant requirements
develop over time logically and consistently.
In addition remote support and service is
simplified which minimizes the risk to plant
production.
Operational Profitability: The use of the
libraries provides efficient commissioning
and maintenance due to the transparency,
granularity and diagnostics. Operator re-
sponse time to process and batch events is
reduced; they can immediately see the root
cause affecting a phase, an Equipment
Module or a Unit and can fully trust that the
trip and interlock displays are correct and up
to date with the configuration, because they
are automatically built.
4
The library of generic Phases requires no
configuration. Parameters define the actions
to be taken by a Phase to achieve a
process action
Adjust PV
Adjust Alarm
Timer
Transfer
Quality
Moitor
will in variab ly n e e d to b e re -valid ate d .
In ad d itio n , th e n e w lib rarie s, allo w
man u al co n tro l at all le ve ls via face -
p late s, an d th e y p ro vid e th e gran u lari-
ty, tran sp are n cy an d d iagn o stics to
e n ab le e fficie n t co mmissio n in g an d
main te n an ce .
Th e co mp o n e n t o b je cts p ro vid e d b y
th e lib rarie s in clu d e Co n tro l Mo d u le s,
Eq u ip me n t Mo d u le s, Un its an d Ph as-
e s. Th e se o b je cts are u se d to b u ild u p
sin gle d e vice s, fro m Eq u ip me n t Mo d -
u le s an d Un its, to o p e ratio n s an d re ci-
p e s th at u ltimate ly co n tro l th e p lan t.
3
Units are configured to represent the physical plant units and
comprise multiple equipment modules, associated process
measurements and applicable process phases
Risk management
ABB Review
fro m th e Ph ase face p late u n d e r man u -
al co n tro l.
Op e ratio n p ro ce d u re s re p re se n t th e
p ro ce ss ste p s n e ce ssary to co n tro l th e
man u factu re o f a b atch o f p ro d u cts.
Th e y d rive th e p lan t via o n e o r mo re
p ro ce ss Ph ase s b y su p p lyin g su itab le
p arame te rs. In ad d itio n , o p e ratio n
p ro ce d u re s ge n e rally h an d le th e co o r-
d in atio n o f mu ltip le p h ase in itiatio n s
an d n o n time -critical activitie s, su ch
as o p e rato r q u e stio n s, mo n ito rin g
fo r p h ase start co n d itio n s, d ata
re co rd in g.
Th e ABB lib rary o b je cts are d e ve lo p e d
u n d e r strin ge n t Qu ality Assu ran ce an d
Safe ty Assu ran ce stan d ard s, an d are
te ste d an d e n cap su late d to e n su re
fu n ctio n al in te grity. Th e y are main -
tain e d b y ABB to e n su re fu tu re migra-
tio n an d u p grad e p ath s.
System 800xA in Korea
En gin e e rs can se le ct wh ich fo u n d atio n
o b je cts to u se fro m th e lib rarie s to
satisfy th e re q u ire me n ts o f an au to -
matio n so lu tio n , an d th is make s th e
lib rarie s ap p licab le fo r mo st ap p lica-
tio n se cto rs. Ko re as Ye o ch u n NCC
Co . Ltd (YNCC)
4)
d e mo n strate d th is b y
se le ctin g, in a stro n gly co mp e titive
e n viro n me n t, th e 800xA in te grate d
p ro ce ss co n tro l an d safe ty syste m to
u p grad e th e p e tro ch e mical co mp an ys
n u mb e r two e th yle n e p lan t in o rd e r
to imp ro ve th e facilitys p e rfo rman ce .
YNCC se le cte d ABB an d Syste m 800xA
d u e to fe atu re s su ch as in te grate d
co n tro l, safe ty an d th e ad van ce d
p ro ce ss/ in te rlo ck visib ility p ro vid e d
b y th e ABB De vice Lib rary an d th e
d istrib u te d co n tro l syste ms Asp e ct
Ob je ct te ch n o lo gy.
Acco rd in g to th e co mp an y, Usin g
ABBs e xp e rtise an d th e d e vice lib rary,
th e e n gin e e rin g will b e simp lifie d an d
mad e co n siste n t acro ss th e so lu tio n ,
an d co mmissio n in g co sts will b e re -
d u ce d . De vice lib rary o b je cts n o t o n ly
e n su re th e b e st p ractice in d e vice e n -
gin e e rin g an d co n tro l, b u t also au to -
matically ge n e rate d isp lays fo r o p e ra-
to rs o f an y in te rlo cks th at may b e
p re se n t th at co u ld d e lay p ro d u ctio n .
As a p ro ve n an d fu lly su p p o rte d ABB
lib rary, YNCC is assu re d th at fu tu re
u p grad e s an d e n h an ce me n ts to th e
syste m so ftware will b e imp le me n te d
with o u t issu e an d re te stin g. Th is o p ti-
mise s YNCCs cap ital p ro d u ctivity n o t
o n ly fo r th e in itial in stallatio n , b u t
also o ve r th e life cycle o f th e p lan t.
John Croft
Batch Automation Consultant
ABB UK Process Industries
john.croft@gb.abb.com
Footnotes
3)
ISA S88 bat ch product ion st andards define good
design and operat ion pract ices t o improve cont rol
of bat ch manufact uring plant s.
4)
Yeochun NCC Co. (YNCC), Lt d is Koreas leading
pet rochemical company.
se n t th e p h ysical p lan t u n its
3
. Th e y
co mp rise mu ltip le Eq u ip me n t Mo d -
u le s, asso ciate d p ro ce ss me asu re me n ts
an d ap p licab le p ro ce ss p h ase s. Th e
Un its in clu d e th e state mo d e l fo r h an -
d lin g p ro ce ss u p se ts an d co n tro l d e -
vice p h ysical e rro rs, an d th e y p ro vid e
a fe atu re fo r mo n ito rin g q u ality criti-
cal p ro ce ss valu e s.
A lib rary o f ge n e ric Ph ase s
4
is in -
clu d e d ; th e se re q u ire n o co n figu ratio n
(lo gic is u n ch an ge d fo r e ach in stan ce
o f u se ) n o te stin g an d n o valid atio n .
Th e se t o f ge n e ric Ph ase s was se le ct-
e d to maximize re u se . Parame te rs
d e fin e th e actio n s to b e take n b y a
Ph ase to ach ie ve a p ro ce ss actio n . All
o f th e ge n e ric Ph ase s are availab le to
o p e ratio n s u n d e r b atch re cip e co n tro l
an d can b e su p e rvise d b y an o p e rato r
The Financial Director?
We can implement a full automation solution
for our batch plant, with all its inherent bene-
fits, for significantly less cost than previously.
The solution benefits both CAPEX (capital
expenditure) at the engineering and installa-
tion phase and OPEX (operating expenditure)
throughout the entire life cycle of the system
and plant.
The Business Manager?
We have a plant automation solution that
gives us the flexibility to introduce new prod-
ucts, improve productivity and make delivery
promises with the minimum of risk. It enables
manufacturing to be adjusted at short notice
thereby allowing new products to be intro-
duced much faster. Similarly we can scale up
production utilizing proven solutions based
upon these objects and the flexibility of the
800xA batch management package.
The Plant Manager?
I have confidence that I can maximize my
plant throughput, consistency and quality
because my automation is based upon a
proven solution route that is easily under-
stood by my operations staff. We can sort
out plant upsets quickly and efficiently our-
selves. My operators like the control and su-
pervision it gives them they can feel in
charge of the plant and can confidently
optimize production. By having a consistent
approach to the control I can utilize my oper-
Factbox
What do these libraries mean to:
ating staff flexibly I do not need to select
based upon system operating experience.
The Process Engineer?
I can readily understand how the control is
structured and therefore I can sort out most
problems without the need to call in a control
engineer or automation specialist I feel
more in control. I can easily modify existing
recipes to improve productivity, quality or
yield and can introduce new product recipes
myself.
The Automation Specialist?
I can authorize a batch automation solution
that is secure and flexible with the minimum
of risk. Because it adheres to S88, I need to
provide the minimum of training to new
staff.
The Control Engineer?
I can focus on the processing requirements
rather than the system when engineering a
batch solution. I can engineer a batch solu-
tion with the confidence that the operations
staff will be able to maintain it throughout its
lifecycle I will not get called out so often to
sort out problems, such as which interlock is
holding up production. I can focus on inves-
tigating control techniques and improving
productivity.
Risk management
With the goal of minimizing project
risk and increasing engineering reuse
and quality, ABB Process Automation
has established an organizational
model called Center of Excellence,
or CoE. Each ABB industry unit has
established one or more CoEs to
serve the unique needs of a particular
market or industry. The role of the
CoE is to develop products and
applications for a particular market
and to then make them available for
global use by local ABB units. The
CoE is also responsible for technical
development and technical leadership
in project execution, together with
Center of exc ellenc e
Serving local and global markets from China
Jane-Zhen Yu, Sidney-Yueshan Chen
local ABB units. Local ABB units are
distributed in different countries
around the world and represent the
interface to the ABB customer during
project execution, as well as for daily
contact. The CoE represents ABBs
industry know-how, while the local
ABB unit is the contact to the cus-
tomers. Finally, the CoE provides
strategic sales support to major
project pursuits around the world,
ensuring that ABB is offering the most
optimum solution to meet a custom-
ers budget and functional require-
ments.
ABB Review
Risk management
ABB Review
H
istorically, ABB CoEs we re base d
p rimarily in We ste rn Europ e and
North Ame rica. Traditionally, this is
whe re ABBs core comp e te ncie s re sid-
e d for many industrie s. Howe ve r, in
vie w of the huge cap ital inve stme nts in
Asia, coup le d with the wide sup p ly of
highly e ducate d e ngine e rs throughout
the re gion, it was time for ABB to com-
mit to an Asian base d CoE. The boom-
ing ste e l industry in China gave ABB
its chance . Within ABBs Me tals busi-
ne ss, it was de cide d to e stablish a CoE
for Proce ssing Line and Tube Mills
(CoE PLT), in Be ijing, China. Since its
e stablishme nt in 2002, the CoE PLT has
be come one of the most succe ssful
units in ABB Proce ss Automation. Be n-
e fiting from the local dynamic and
booming ste e l industry and its own
te chnical and e ngine e ring comp e te nce ,
CoE PLT has unde rgone a rap id de ve l-
op me nt, and has strive d to e xte nd its
footp rint in and outside China.
Why China for processing line and tube
rolling mill CoE?
It h as b e e n p ro ve n as a ve ry wise
d e cisio n , said Ch riste r Sko gu m, h e ad
o f Co E PLT an d Pro ce ss Au to matio n
d ivisio n No rth Asia. In our global
management team, we have a clear
and common understanding many
of the future demands exist in the
new world, and our local team is
ready to take on the business in both
the new markets as well as the old tra-
ditional markets
Ou r first-e ve r ce n te r o f e xce lle n ce
in Asia h as ach ie ve d a re markab le
ach ie ve me n t, p ro u d ly ad d e d Fu Jian -
p e n g, h e ad o f th e lo cal b u sin e ss u n it
fo r me tals in Ch in a, we h ave in -
cre ase d b u sin e ss 500 p e rce n t sin ce its
e stab lish me n t.
To d ay 50 p e rce n t o f th e wo rld s ste e l
p ro d u ctio n is in Asia, an d 85 p e rce n t
o f th e in cre me n tal gro wth is in Ch in a.
Th e co u n try re ach e d 349 millio n to n s
in 2005 an d fo re cast an ad d itio n al
10 p e rce n t gro wth in th e ye ar afte r.
Th e rap id ly gro win g marke t give s Co E
PLT a fab u lo u s o p p o rtu n ity to d e ve lo p
its b u sin e ss an d p e o p le . Th e n e w
p ro je cts in Ch in a are amo n g th e
wo rld s le ad in g lin e s in te rms o f ca-
p acity an d te ch n o lo gy. So me e xam-
p le s wh e re Co E PLT h as d e live re d
p ro ce ss au to matio n so lu tio n s are :
Pan gan g Gro u p 340 tu b e mill lin e
wo rld large st se amle ss ste e l tu b e
p ro d u ctio n lin e
Nin gb o Bao xin stain le ss ste e l lin e
wo rld large st stain le ss ste e l p ro ce ss-
in g lin e s
Taiyu an Iro n & Ste e l wo rld large st
co ld an n e alin g an d p icklin g p ro -
ce ssin g lin e
Bao ste e l p ro ce ssin g lin e th e wo rld
th ird faste st ste e l p ro d u ctio n lin e
A mixture of local and expatriate experts
form a winning team
Th e su cce ss o f th e Co E PLT was d e -
p e n d e n t o n ABBs ab ility to d e live ry
th e h igh q u ality o f e n gin e e re d so lu -
tio n s wh ich we re e xp e cte d o f th e cu s-
to me rs, b u t to u se lo cal Ch in e se e n gi-
n e e rs an d p ro je ct man age rs fo r imp le -
me n tatio n . Th e d e cisio n was take n to
re lo cate ke y ABB Me tals e n gin e e rs to
Be ijin g, wh e re th e y co u ld d e ve lo p lo -
cal co mp e te n ce wh ile u sin g th e e xp e -
rie n ce s b u ilt o ve r man y ye ars with
p ro je cts in Eu ro p e an d th e Ame ricas.
Th e p ro je ct o p e ratio n te am co n tin u e s
to b e th e ke y to su cce ss.
Each ABB industry unit
has established one or
more centers of excel-
lence to serve the unique
needs of a particular
market or industry.
Nare n d ra Gu p ta, an ABB ve te ran in
th e me tal fie ld , wh o h as b e e n in
Ch in a sin ce 1999, le ad s th e o p e ratio n
te am. Th e te am fo cu se s o n p ro je ct
e xe cu tio n an d man age me n t as we ll as
te ch n o lo gy d e ve lo p me n t an d lo caliza-
tio n . Th e Co Es e arly su cce sse s h ave
allo we d th e lo cal te am to b u ild u p
e xte n sive fie ld e xp e rie n ce in te ch n o l-
o gy, ap p licatio n an d p ro je ct man age -
me n t.
Our team is formed by a group of
young professional, well-educated and
very hard working people. They are
l ocated where the business is in the
world and where abundant skilled
engineers are available at world-class
cost structure, said Christer. They
are always ready to learn new things
and will bring our metals business to
the next level.
References in the domestic market
Pangang Group 340 tube mill line
world largest seamless steel tube
production line
ABBs CoE PLT China te am he lp e d
Pangang Group Che ngdu Iron & Ste e l
Co., Ltd. (CSST) build a tube p ro-
duction line for the large st scale in
2005
1
.
Th e se amle ss ste e l tu b e p ro d u ctio n
lin e was a ke y p ro je ct in me tal in d u s-
trie s. Th is was re co gn ize d as h igh
te ch n o lo gy p ro je ct b y th e Natio n al
Re fo rm an d De ve lo p me n t Co mmissio n
d u rin g th e p e rio d o f macro co n tro l
o n me tals an d so me o th e r o ve r-h e ate d
in d u strie s. Th e lin e h as se t a fe w
re co rd s in th e me tal in d u stry:
Th e 340 tu b e mill lin e ad o p te d th e
mo st ad van ce d te ch n o lo gy in clu d in g
th e late st p ro ce ss co n tro l syste m
an d me d iu m vo ltage d rive syste m.
Risk management
ABB Review
Th e d iame te r o f 340 mm is
th e large st scale se amle ss
ste e l tu b e in Ch in a.
Th e sh o rte st co ld an d h o t
co mmissio n in g p e rio d (le ss
th an th re e mo n th s).
Th e so le lin e in th e in d u stry
wh ich h as a o n e -time h o t
trial su cce ss.
ABBs sco p e o f d e live ry in -
clu d e s MV an d LV d rive s,
b asic au to matio n , le ve l II p ro -
ce ss co n tro l an d LV mo to rs.
Th e 340 lin e is an o th e r
su cce ssfu l re fe re n ce o f ABB
Co E PLT Ch in a te am, afte r th e
co mp le tio n o f two similar
p ro je cts in Tian jin City an d
Hu n an Pro vin ce .
Ningbo Baoxin stainless steel
line world largest stainless
steel processing line
ABB te ch n o lo gy su p p o rte d
th e d e ve lo p me n t o f th e
wo rld s large st stain le ss ste e l
p ro ce ssin g lin e in Nin gb o
Bao xin Stain le ss Ste e l Co .,
Ltd .
2
, an d h e lp e d Bao xin
mo re th an d o u b le its p ro d u c-
tio n cap acity.
Co E PLT p ro vid e d e q u ip me n t an d sys-
te ms to h e lp d e ve lo p th e large st h o t
an d co ld an n e alin g an d p icklin g lin e
in th e wo rld , as we ll as state -o f-th e -art
ro llin g mills. ABB will su p p ly sp e cial-
ize d te ch n o lo gie s fo r ro llin g, flatn e ss
co n tro l an d me tal co n d itio n in g, as
we ll as p ro ce ss co n tro l p ro d u cts,
d rive s an d mo to rs.
Th is wo rk will su p p o rt Bao xin s d rive
to b o o st its cu rre n t an n u al o u tp u t o f
300,000 to n s o f fin ish e d p ro d u cts to
700,000 to n s. ABB h as alre ad y d e -
sign e d , e n gin e e re d an d co mmissio n e d
a co mp le te an n e alin g an d p icklin g
lin e fo r an o th e r p art o f th e Nin gb o
facility, as we ll as p ro vid in g o th e r
sp e cialize d e q u ip me n t an d te ch n o lo -
gie s.
Taiyuan Iron & Steel world largest cold
annealing and pickling processing line
Co E PLT wo n an o rd e r fro m Taiyu an
Iro n & Ste e l Gro u p , to su p p ly th e
wo rld large st co ld an n e alin g an d p ick-
lin g p ro ce ssin g lin e in 2004.
Un d e r th e te rms o f co n tract, ABB is
p ro vid in g th e cu sto me r with a b asic
au to matio n syste m, a co mp u te r p ro -
ce ss syste m, an d AC d rive s an d mo to rs
fo r th e lin e . Pro d u ctio n cap acity is
e xp e cte d to re ach 500,000 to n s an n u -
ally. Th e d e live ry is slate d fo r co mp le -
tio n in o n e ye ar.
Today 50 percent of the
worlds steel production is
in Asia, and 85 percent of
the incremental growth is
in China. The country
reached 349 million tons
in 2005 and forecast an
additional 10 percent
growth in the year after.
Taiyuan Iron & Steel (Group ) Co., Ltd.
(TISCO), founded in 1934, is a giant
iron and steel comp lex whose main
p roduct is steel p late. It is Chinas larg-
est stainless steel p roduction enterp rise.
Baosteel processing line
the world third fastest steel
production line
Co E PLT h e lp e d Bao ste e l
3

to b u ild a ste e l p ro ce ssin g
lin e with a sp e e d o f 1,040
me te rs p e r min u te , makin g it
th e faste st p ro d u ctio n lin e in
Ch in a, an d th e th ird faste st
in th e wo rld .
Th is is th e first carb o n ste e l
p ro d u ctio n lin e at Bao ste e l
Sh an gh ai h e ad q u arte rs.
ABB has successfully execut-
ed many p rojects for Baosteel
group , one of the major iron
and steel makers in China.
CoE China serving industry
needs outside China
Th e su cce ss o f th e Co E PLT
in Ch in a rap id , b u t n o t su r-
p risin g. Ho we ve r, th e re al
ke y to a su cce ssfu l Co E is
th e ab ility to su p p o rt p ro j-
e cts glo b ally, n o t ju st with in
th e Ch in e se marke t. Co E PLT
is su p p o rtin g man y o rd e rs
o u tsid e o f Ch in a, in co u n -
trie s as d ive rse as Ne th e r-
lan d s an d Me xico . Th e se
p ro je cts in clu d e AC/ DC mo to rs an d
d rive s, au to matio n syste ms, co n tro l
d e sks, mo ve me n t co n tro l ce n te rs
(MCCs), e le ctrical an d me ch an ical
e re ctio n , fu ll syste m e n gin e e rin g an d
co mmissio n in g.
The key to success
ABB h as Co Es in me tals, ch e micals,
o il an d gas, p u lp an d p ap e r, marin e
an d o th e r in d u strie s. ABB is co n -
vin ce d th is is th e righ t ap p ro ach to
e n su re co n siste n t p ro je ct e xe cu tio n ,
re gard le ss o f in d u stry, sco p e o r ge o -
grap h ic lo catio n . Th e su cce ss o f th e
Co E PLT in Be ijin g sh o ws th at su ch
ce n te rs can b e lo cate d clo se to th e
marke t d e man d with o u t sacrificin g
q u ality o r e fficie n cy.
Jane-Zhen Yu
Sidney-Yueshan Chen
ABB China Ltd.
Shanghai, China
jane-zhen.yu@cn.abb.com
sidney-yueshan.chen@cn.abb.com
1
Pangang Groups 340 tube mill line is Chinas largest seamless steel
tube production line
2
ABB helped the Chinese steelmaker Baoxin more than double
its production capacity and create the worlds largest hot and cold
annealing and pickling lines
Risk management
Rolling mill
simulator
A new platform for testing, analysis and
optimization of cold rolling mills.
Axel Brickwedde, Frank Feldmann, Nicolas Soler
The cold rolling of flat metal products especially in tandem or multi-stand
mills is a highly complex process where the product quality is influenced by
various aspects. With the help of a hardware-in-the-loop simulator, the com-
plete rolling process can be simulated and tested in real-time. This allows
pre-commissioning and pre-optimizations before the actual commissioning
work is done on the plant site. This reduces project schedule and safety risks
and guarantees a much faster plant start-up.
I
n h o t an d co ld ro llin g mills, th e d e -
man d s o n mill p ro fitab ility, p ro d u c-
tivity an d p ro d u ct q u ality are o n th e
rise . Th ickn e ss an d flatn e ss to le ran ce s
are d e cre asin g wh ile su rface q u ality
mu st fu rth e r imp ro ve . At th e same
time , mill fle xib ility h as to match th e
gro win g varie ty o f p ro d u cts, wh ile
h igh mill p ro d u ctivity (th ro u gh p u t an d
yie ld ) is a ke y issu e to re main in g
co mp e titive in th e glo b al e co n o my.
Strip q u ality an d mill th ro u gh p u t are
in flu e n ce d b y vario u s facto rs su ch as
me ch an ical d e sign , e le ctrical an d h y-
q u ality, a p o we rfu l co n tro lle r is n e e d -
e d to h an d le all re q u ire d fu n ctio n s
fro m lo w le ve l b in ary co n tro l u p to
ad van ce d an d so p h isticate d co n tro l
so lu tio n s. Th e h igh e n d AC 800PEC
co n tro lle r fro m th e 800xA Au to matio n
p latfo rm is o u tstan d in gly we ll su ite d
to me e t th e se re q u ire me n ts [1].
Th e co mp le xity o f th e p ro ce ss an d th e
co rre sp o n d in g re q u ire me n ts with re -
sp e ct to th e co n tro l syste m are risin g
with th e n u mb e r o f stan d s b e in g in -
vo lve d . Tan d e m Co ld Ro llin g Mills
(TCM) with u p to fo u r o r five stan d s
in a ro w can b e co n sid e re d as a mo st
d e man d in g e xamp le o f wh at h as to b e
h an d le d b y th e co n tro l syste m
1
.
So me o f th e main asp e cts e xp lain in g
th e co mp le xity are :
h igh ly n o n -lin e ar p ro ce ss, e g with
re sp e ct to ro ll-gap
in te rstan d co u p lin g an d in te ractio n
via strip
lo o p in te ractio n s fro m in te rstan d -
te n sio n an d th ickn e ss co n tro l lo o p s
ro llin g sp e e d d e p e n d an t tran sp o rt-
d e lay b e twe e n stan d s
o n -lin e trackin g fo r h e ad , tail an d
strip we ak p o in ts
syn ch ro n izatio n re q u ire d fo r all
stan d in te ractio n s
varie ty o f d iffe re n t d istu rb an ce s, e g
e cce n tricitie s, co il-b u mp , in p u t-
th ickn e ss an d h ard n e ss d istu rb an ce ,
Co u lo mb frictio n , e tc
vario u s o p e ratio n al mo d e s, e g
th re ad in g, acce le ratio n /
d e ce le ratio n , tail-o u t, lo w / h igh
sp e e d
large ran ge o f th ickn e ss re d u ctio n
fro m 6 mm d o wn to 0.2 mm
d rau lic e q u ip me n t, au xiliary su p p lie s
an d co n tro l strate gy. Th e man y asso ci-
ate d variab le s h ave to b e tigh tly co n -
tro lle d to me e t p ro d u ct q u ality targe ts.
Th e e n tire co n tro l p ro ce ss e n te rs in to
e xtre me p arame te r ran ge s, e sp e cially
wh e n o n e co n sid e rs co n tro llin g u p to
40 to n s o f mo vin g p arts to a p re cisio n
o f 1 m with ro llin g sp e e d s o f u p to
100 km/ h .
To b e ab le to co n tro l su ch a large an d
co mp le x p lan t an d me e t th e h igh d e -
man d s o n p ro ce ss sp e e d an d p ro d u ct
ABB Review
Risk management
ABB Review
ings from the actual rolling op eration, a
non-linear dynamic simulation model
of the p rocess was develop ed, validat-
ed and extended with resp ect to con-
trol functionalities
3
. This allows the
simulation of rolling a comp lete coil in-
cluding threading, acceleration, decel-
eration, tail-out, changeover between
different op erational control modes for
thickness and tension control, tracking
of head and tail and dynamic p rogram
change, eg for continuous rolling.
Th is simu latio n se tu p can b e u se d to
te st an d d e ve lo p n e w co n tro l co n ce p ts
in o rd e r to imp ro ve th ickn e ss q u ality
an d to me e t th e in cre asin g d e man d s
with re sp e ct to o ff-gau ge le n gth . Fo r
th is p u rp o se th e co mp le te p ro ce ss
mo d e l is re alize d as an o ff-lin e simu la-
tio n p ro gramme d in MATLAB
/ Simu -
lin k
[3], th u s allo win g fle xib le te stin g,

o p timizatio n s an d e valu atio n s with far
mo re d e gre e s o f fre e d o m th an o n th e
actu al p lan t.
Th e p e rfo rman ce o f d iffe re n t co n tro l
strate gie s, me ch an ical co n figu ratio n s,
se n so r e q u ip me n t an d d rive s can b e
co mp are d in simu latio n stu d ie s. Fro m
th e se , th e mo st su itab le se tu p can b e
se le cte d an d e ffe ctive p ro ce ss im-
p ro ve me n ts id e n tifie d . Dyn amic simu -
latio n can also b e u se d to an alyze
cu sto me r sp e cific p ro b le ms su ch as
o scillatio n s, wh ich can h ave a n e ga-
tive imp act o n p ro d u ct q u ality.
On-line hardware-in-the-loop simulator
Th e n o n -lin e ar p ro ce ss mo d e l
3
,
wh ich was d e ve lo p e d fo r o ff-lin e sim-
u latio n , was tran sfe rre d an d co mp ile d
fo r re al-time mo d e (u sin g MATLAB
Re al Time Wo rksh o p
[3]) an d d o wn -
lo ad e d o n to th e ABB Pro ce ss Co n tro l-
le r AC 800PEC. Co n n e ctin g th is p lan t
mo d e l to th e AC 800PEC p ro ce ss co n -
tro lle rs th at h an d le th e co mp le te au to -
matio n an d ap p licatio n so ftware fo r
th e actu al p lan t allo ws fu ll ro llin g o p -
e ratio n as a Hard ware -in -th e -Lo o p
(HIL) simu latio n in re al-time
2
,
4
.
Th e re su lt is a h igh ly d yn amic p lan t-
an d p ro ce ss-simu lato r th at acts in re al-
time an d allo ws gh o st ro llin g fo r:
Te stin g in th e lab with o u t h avin g
th e actu al p lan t availab le .
Te stin g, p re -co mmissio n in g an d p re -
o p timizatio n o f co n tro lle r-ap p lica-
tio n so ftware .
Te stin g o f in te rface an d in te ractio n ,
e g b e twe e n th e ap p licatio n so ftware
o f th e d iffe re n t co n tro lle rs.
Data e valu atio n an d an alysis b ase d
o n p ro ce ss sign als th at wo u ld n o t
b e availab le o n p lan t site as me a-
su re d sign als.
Te stin g with o u t risk o f strip -b re aks,
in stab ilitie s o r cau sin g d amage s to
th e actu al p lan t.
Te stin g with o u t th e n e e d fo r vario u s
te st-co ils.
Train in g fo r o p e ratio n al p e rso n n e l
to ge t familiar with th e n e w au to ma-
tio n syste m as we ll as man -mach in e
in te ractio n .
Re d u cin g o n -site co mmissio n in g an d
p lan t start-u p time .
Modular and Scalable
Th e n o n -lin e ar d yn amic p ro ce ss mo d -
2
Ghost rolling using tandem cold rolling mills
(TCM) process model as real- time simulator
Simulation
TCM Process
Exp lo itin g th e fu ll p ro d u ctio n p o te n -
tial re q u ire s an o ve rall an d we ll-in te -
grate d ap p ro ach to co ld ro llin g mill
au to matio n , o p timizatio n , co n tro l,
ad ap tatio n an d su p e rvisio n .
Th is ap p ro ach h as to co ve r:
me ch an ical an d h yd rau lic syste ms
d rive train s
mate rial flo w
visu alizatio n an d co n tro l syste m
mo d e lin g an d simu latio n
p ass sch e d u lin g an d se t-u p
te ch n o lo gical co n tro l
su p e rvisio n an d d iagn o sis so lu tio n s
To efficiently design, test, analyze and
op timize such a comp lex system, simu-
lations based on a p rocess model are
necessary. This is the best and only way
to fully understand the comp lete system
with its various interactions without
having the actual p lant available.
Th e re fo re a n o n -lin e ar d yn amic p ro -
ce ss mo d e l o f a mu lti-stan d co ld ro ll-
in g mill was d e ve lo p e d to me e t th e
te ch n o lo gical d e man d s o f su ch a co m-
p le x syste m with re sp e ct to re q u ire d
p ro d u ct q u ality, d istu rb an ce re je ctio n ,
p lan t stab ility an d re liab ility, safe o p -
e ratio n an d fast co mmissio n in g. Th is
is e sp e cially imp o rtan t in case o f a re -
vamp in o rd e r to ke e p th e d o wn time
to se t u p th e n e w au to matio n syste m
as sh o rt as p o ssib le an d to gu aran te e
a fast start-u p to fu ll o p e ratio n .
Off-line simulation
Based on p rocess and p lant data as
well as measurements and data record-
1
Four stand rolling mill configuration
Risk management
ABB Review
e l fo r o ff-lin e an d o n -lin e simu latio n
co n sists o f d iffe re n t mo d u le s fo r co il-
e r/ u n co ile r, strip , stan d , actu ato rs,
se n so rs, filte rs, co n tro l, e tc.
3
. Th is al-
lo ws th e mo d u lar an d fle xib le d e sign
o f d iffe re n t mu lti-stan d co ld ro llin g
mill co n figu ratio n s. Th e p lan t d e -
scrib e d h e re is a fo u r-stan d co ld ro ll-
in g mill with an u n co ile r at th e e n try
an d a co ile r at th e e xit sid e .
In o rd e r to b e ab le to p e rfo rm u se fu l
an d d e p e n d ab le e valu atio n s, th e p ro -
ce ss mo d e lin g h as to b e d e taile d
e n o u gh to co ve r all d o min an t static,
d yn amic an d n o n -lin e ar e ffe cts. So me
e xamp le s o f th e fe atu re s th at are
b e in g co ve re d are :
Coiler / uncoiler
variab le rad iu s as a fu n ctio n o f th e
ro llin g p ro ce ss
mu lti-mass d rive -lin e co n figu ratio n
in te grate d in d ire ct te n sio n co n tro l
sp e e d co n tro l in clu d in g fe e d -
fo rward co mp e n satio n
mo d e lin g o f to rq u e -lo o p
Stand module
d yn amic stan d mo d e l in clu d in g n o n -
lin e ar ro ll-gap
mu lti-mass mill d rive -lin e co n figu ra-
tio n
sp e e d co n tro l in clu d in g fe e d -fo r-
ward co mp e n satio n
mo d e lin g o f p o sitio n - an d to rq u e -
lo o p
Strip module
d yn amic mo d e l with variab le strip
th ickn e ss an d stiffn e ss
sp e e d -d e p e n d ab le tran sp o rt-d e lay
ge n e ratio n fo r in te r-stan d d istan ce
in te rn al mo d e lin g fo r trackin g o f
h e ad , tail an d we ld -se ams
Disturbance module
in p u t th ickn e ss d istu rb an ce b ase d
o n me asu re me n ts fro m re al p lan t
d istu rb an ce s fro m h ard n e ss an d
we ld -se ams
e cce n tricity ge n e ratio n fo r to p an d
b o tto m b acku p ro lls in clu d in g h ar-
mo n ics
co il-b u mp ge n e ratio n fo r u n co ile r
an d co ile r
co u lo mb frictio n in mill-stan d s
Control / sensor
se n so rs fo r th ickn e ss, te n sio n ,
sp e e d , ro ll-fo rce me asu re me n t
sp e e d d e p e n d an t tran sp o rt-d e lay fo r
th ickn e ss-me asu re me n t
th ickn e ss co n tro l, in te r-te n sio n
co n tro l, d istu rb an ce re je ctio n lo o p s,
d e co u p lin g lo o p s, e tc.
b u mp -le ss ch an ge o ve r b e twe e n
d iffe re n t co n tro l co n ce p ts
Fo r th e p ro ce ss mo d e lin g as h ard -
ware -in -th e -lo o p simu latio n in re al-
time all d yn amic co mp o n e n ts are d is-
cre tize d an d th e co mp le te mu lti-stan d
p ro ce ss mo d e l is e xe cu te d o n o n e
AC 800PEC co n tro lle r with a task
samp lin g time o f 1000 time s p e r se c-
o n d .
Th e co mmu n icatio n b e twe e n th e AC
800PEC with th e p ro ce ss mo d e l an d
th e AC 800PEC Co n tro lle rs fo r th e
au to matio n an d ap p licatio n so ftware
is p e rfo rme d via h igh -sp e e d o p tical
lin ks, p ro vid in g fast an d fle xib le in te r-
facin g an d co mmu n icatio n . Data-re -
co rd in g fo r an alysis an d e valu atio n
can also b e p e rfo rme d via o p tical lin k
co n n e ctio n to an ib aPDA (PC-b ase d
p ro ce ss d ata co lle ctio n an d an alysis
syste m) [4].
Ghost rolling with HIL-process simulator
Re fe rrin g to
2
, th e TCM Pro ce ss Mo d -
e l o n th e AC 800PEC is actin g as a re -
p lace me n t fo r th e actu al p lan t. Th e re -
fo re th e ap p licatio n co n tro lle rs are
o p e ratin g again st th e p ro ce ss mo d e l
in ste ad o f th e re al p lan t.
Diffe re n t se tu p s an d o b se rvatio n s can
b e p e rfo rme d with re sp e ct to th e HIL-
Pro ce ss Mo d e l in o n -lin e mo d e .
Mo d e s o f o p e ratio n can b e se le cte d
fo r th e HIL-Simu lato r, su ch as:
se le ctio n o f d iffe re n t te st-co ils
se le ctio n / activatio n o f d iffe re n t
d istu rb an ce s
o p e ratio n with o u t strip
o p e ratio n with e n d le ss co il
Cu rre n t p ro ce ss sign als an d tre n d s
d u rin g ro llin g can b e visu alize d .
Th e se in clu d e sp e e d , th ickn e ss, te n -
sio n , ro ll-fo rce , fo rward slip , p o sitio n
an d to rq u e .
3
Modular process model for a four- stand tandem cold rolling mill
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4
Interface between TCM process model and application controllers
Pilot & Coiler Mill Drives Tech. Stand 1 & 2 Tech. Stand 3 & 4
TCM Process Model
Risk management
ABB Review
Fo r a mo re d e taile d an alysis an d
e valu atio n th e p ro ce ss sign als can
b e tran sfe rre d via o p tical lin k to an
ib aPDA [4]
4
,
5
. Th is in sid e vie w
allo ws a mu ch b e tte r an d straigh t-
fo rward p e rfo rman ce an d p ro b le m
e valu atio n th an o n th e actu al p lan t.
Vario u s p ro ce ss sign als are o fte n n o t
availab le o n th e p lan t. Th e re are
u su ally n o th ickn e ss- an d sp e e d -
me asu re me n ts b e twe e n e ve ry stan d ,
an d th e actu al th ickn e ss in th e gap
can n o t b e me asu re d at all (sin ce th e
se n so r h as to b e p lace d afte r o r b e -
fo re th e stan d ). All th e se p ro ce ss
sign als are e asily availab le wh ile p e r-
fo rmin g HIL-p ro ce ss simu latio n an d
can b e u se d fo r fast an alysis an d o p ti-
mizatio n .
Ghost rolling results with
TCM HIL-simulator in real time
5
p re se n ts th e re su lts fro m p e rfo rm-
in g gh o st ro llin g with th e TCM HIL-
Simu lato r in re al-time . Th e ro llin g o f a
fu ll co il is sh o wn fo r a fo u r-stan d co ld
ro llin g mill with u n co ile r an d co ile r.
Th e p ro ce ss p e rfo rman ce is ve ry simi-
lar to th e o n e o n th e re al p lan t as co r-
re sp o n d in g p ro ce ss sign al re co rd in gs
sh o w
6
.
Th e te stin g b ase d o n gh o st ro llin g
with th e TCM HIL-simu lato r p ro ve d to
b e e xtre me ly e fficie n t with re sp e ct to
p re -co mmissio n in g an d p re -o p timiza-
tio n fo r th e p lan t-re late d ap p licatio n
an d co n tro l so ftware . Th e b e n e fit re -
su lts e sp e cially fro m th e fact, th at th e
te stin g an d o p timizatio n can b e d o n e
with o u t th e risk o f d amagin g th e re al
p lan t an d with o u t th e n e e d fo r an y
sp e cific te st co ils. Also p re -co mmis-
sio n in g can alre ad y b e starte d lo n g
b e fo re th e actu al p lan t is availab le fo r
an y kin d o f te stin g.
Summary / conclusion
Th e o ff-lin e simu latio n o f th e p ro -
ce ss allo ws fle xib le an d straigh t fo r-
ward o p timizatio n an d d e ve lo p me n t
o f n e w co n tro l co n ce p ts fo r co ld
ro llin g mills in o rd e r to me e t fu tu re
h igh d e man d s o n p ro ce ss p e rfo r-
man ce , q u ality an d re liab ility.
Th e o ff-lin e simu lato r can b e u se d
fo r p e rfo rman ce e valu atio n s an d
p lan t o p timizatio n s alre ad y in th e
d e sign p h ase .
Th e HIL-simu lato r in re al-time p ro -
vid e s fle xib le an d e fficie n t p re -co m-
missio n in g an d p re -o p timizatio n o f
th e p lan t re late d ap p licatio n an d
co n tro l so ftware , with o u t n e e d in g
th e actu al p lan t an d with o u t riskin g
d amage s to th e actu al p lan t.
Th e HIL-simu lato r sign ifican tly
re d u ce s p lan t start-u p time .
Th e HIL- simu lato r can b e ap p lie d
fo r d e mo n stratio n in re al-time .
Th e HIL- simu lato r can b e u se d fo r
o p e rato r train in g, with o u t in te rfe r-
e n ce with th e re al p lan t o r risk o f
cau sin g an y d amage s.
Th e HIL-simu lato r can b e imp le -
me n te d in th e 800xA au to matio n
p latfo rm o n a sin gle h igh p e rfo r-
man ce AC 800PEC co n tro lle r, wh ile
o p e ratin g at a samp lin g rate o f 1000
time s p e r se co n d an d co mmu n icat-
in g with th e ap p licatio n co n tro lle rs
via h igh sp e e d o p tical lin ks.
Th e mo d u lar d e sign fo r p ro ce ss-
mo d e lin g as we ll as co n tro l gu aran -
te e s fle xib le an d e asy ad ap tatio n to
d iffe re n t ro llin g mill co n figu ratio n s
an d p ro vid e s re alistic p ro ce ss mo d -
e lin g e ve n in re al-time .
Axel Brickwedde
Frank Feldmann
Nicolas Soler
ABB Automation GmbH
Mannheim, Germany
axel.brickwedde@de.abb.com
frank.feldmann@de.abb.com
References
[1] Armin Eichmann, Andreas Vollmer, Roll and
Cont rol, ABB Review 2/ 2006, pp 2629
[2] Andreas Kroll, Andreas Vollmer, Indust rial IT for
Cold Rolling Mills, ABB Review 4/ 2004, pp 4449
[3] The Mat hworks, User Manual, In part icular Mat lab,
Simulink, Real Time Workshop
[4] ibaPDA, PC- based Process Dat a Collect ion and
Analysis Syst em, www.iba- AG.com
model setup, adaptation and reference
generator
dynamic program change and head- /
tail- tracking
interstand tension- and thickness
control including pre- optimization
disturbance compensation and
decoupling control loops
bumpless changeover between different
control modes
full coil rolling including threading, dv/ dt,
constant speed and tail- out
interface setup for communication
between different AC 800PEC
Controllers
interface setup to Operator Interface
and data- recording system (eg, ibaPDA)
Factbox
Various features can be pre- tested
using HIL TCM Simulator
5
Ghost rolling with HIL- TCM simulator for full coil
6
Process signals from coil rolling on real plant
Risk management
The last decade has seen a sustained
increase in the acceptability of field-
bus solutions for process automation
needs. While the underlying reasons
for this trend include rapid advance-
ments in the fields of digital commu-
nication and microprocessor technol-
ogies, the end result is that the tradi-
tional boundaries between centralized
control systems and devices in the
field have disappeared. In the new
process automation architecture
paradigm, intelligent field devices and
control systems form a single system,
fused by a high-speed digital Field-
bus. Now, in addition to the process
value, status, diagnostics and any
other information embedded in a
device, with its enhanced and ever
growing intelligence, can be trans-
ferred to the control system, making
the device visible and usable from
remote locations such as the pro-
cess-automation level. Currently,
PROFIBUS, HART and Foundation
Fieldbus are the most commonly used
fieldbus standards. ABBs Device In-
tegration Center tests hundreds of
devices every year to ensure maxi-
mum intercompatibility of its control
systems with devices from a whole
range of vendors.
ABB Review
Risk management
The c hallenge of
d evic e integration
Making sure plug-and-play equals plug-and-work
Ahmad Khan, Stefan Bollmeyer, Friedrich Harbach
ABB Review
F
ie ld b u s in te gratio n can p ro vid e
man y b e n e fits to u se rs, ye t, d e -
sp ite co mp atib ility stan d ard s, th e re
are risks th at a syste m will n o t wo rk
co rre ctly with a give n d e vice . A ke y
go al o f o p e n ve n d o r in d e p e n d e n t
fie ld b u s te ch n o lo gie s is to in te grate
d e vice s fro m mu ltip le man u factu re rs
in to au to matio n syste ms. Th e o re tical-
ly, th e imp le me n tatio n o f fie ld b u s
stan d ard s allo ws p lu g-an d -p lay co n -
n e ctivity b e twe e n a d e vice an d its
au to matio n syste m. Ho we ve r, se ve ral
facto rs make it d ifficu lt to ach ie ve th is
id e al situ atio n . Th e se in clu d e :
Diffe re n t in te rp re tatio n o f stan d ard s
amo n g d iffe re n t d e sign e rs an d im-
p le me n te rs, b y b o th th e d e vice ve n -
d o rs an d au to matio n syste m man u -
factu re rs.
Ch an ge s an d u p d ate s in th e stan -
d ard s.
Diffe re n ce s in th e sp e e d with wh ich
ad ap tatio n s to stan d ard s are imp le -
me n te d b y th e au to matio n syste ms
su p p lie r an d th e d e vice ve n d o rs.
Fre q u e n tly th e typ ical life cycle s o f
d e vice s an d au to matio n syste ms d if-
fe r, re su ltin g in mu ltip le ve rsio n s o f
d e vice s an d au to matio n syste ms b e -
in g o n th e marke t at an y o n e time .
Atte mp ts to e xp lo it in fre q u e n tly
u se d stan d ard s to p ro vid e p ro d u ct
d iffe re n tiato rs.
ABBs Field Device Integration Center
In 2004, ABB d e cid e d to e stab lish a
Fie ld De vice In te gratio n Ce n te r
(FDIC), to e n su re th at d e vice s an d
ABB Syste ms wo u ld wo rk to ge th e r.
Th e go al o f FDIC is to p ro vid e te ste d
so lu tio n s fo r all th e co mmo n ly u se d
fie ld d e vice s o n th e marke t, wh e n
u se d in co n ju n ctio n with ABB au to ma-
tio n syste ms.
Th e DIC is mad e u p o f two main ce n -
te rs: Min d e n in Ge rman y, an d Ban ga-
lo re in In d ia. Th e activitie s at th e se
lo catio n s are assign e d acco rd in g to
in d ivid u al are as o f e xp e rtise an d te ch -
n ical stre n gth s.
The goal of FDIC is to
provide tested solutions
for all the commonly used
field devices on the
market, when used in
conjunction with ABB
automation systems.
Th e Fie ld b u s p ro d u ct man age me n t
te am in Min d e n fo cu se s o n id e n tifyin g
an d d e fin in g th e d e vice s th at n e e d to
b e te ste d fo r in te gratio n , b ase d o n
re gu lar in te ractio n s with sale s an d
marke tin g staff, an d cu sto me rs. Th e
targe te d d e vice s are p rio ritize d an d
assign e d fo r in te gratio n acco rd in g to
facto rs su ch as p h ysical availab ility o f
h ard ware / so ftware an d o ve rall marke t
d e man d fo r th e p articu lar d e vice typ e .
Th e FDIC we b p age , acce ssib le via
www.ab b .co m, p ro vid e s a list o f all
d e vice s th at h ave u n d e rgo n e in te gra-
tio n te stin g.
Th e in te gratio n te am in Ban galo re
p e rfo rms b asic co n n e ctivity as we ll as
ad van ce d in te gratio n te sts fo r fie ld
d e vice s. Th e lab is we ll e q u ip p e d
with d e d icate d an d stan d ard ize d te st
b e n ch e s to carry o u t in te gratio n te sts
with th e late st re le ase d ve rsio n s o f
ABBs co n tro l syste ms in clu d in g
800xA, Me lo d y/ AC870P an d Fre e lan ce
800F.
Th e in te gratio n lab h as b e e n mo d e le d
o n th e co n ce p t o f th e so ftware p ro -
d u ctio n lin e . Th e ke y fe atu re s in clu d e :
Stan d ard ize d so ftware d e ve lo p me n t
an d te st p ro ce sse s, u p d ate d with th e
late st re le ase o f stan d ard s an d sp e c-
ificatio n s
In sp e ctio n o f h ard ware an d so ftware
to filte r o u t th o se d e vice s th at h ave
a h igh ch an ce o f failin g d e taile d
in te gratio n te sts
Stan d ard ize d an d strict q u ality
ch e cks fo r all p h ase s o f d e ve lo p -
me n t, te st an d re le ase
Clo se co o p e ratio n with th e Fie ld b u s
R&D te am in Min d e n
Th e Fie ld De vice To o l (FDT)/ De vice
Typ e Man age rs (DTM) te ch n o lo gy is
fu lly in te grate d with ABBs co n tro l
syste ms.Th e DTM is e ith e r ge n e ric,
wo rkin g fo r a family o f d e vice s, o r
sp e cific to a sin gle d e vice . Th e d e -
vice -sp e cific DTM is co gn izan t o f all
in stru me n t ru le s, in clu d in g co n figu ra-
tio n , d iagn o sis an d main te n an ce . It
h as a simp le in tu itive u se r in te rface
th at allo ws p ro je ct e n gin e e rs to acce ss
all d e vice fu n ctio n alitie s. A ke y task
fo r FDIC is to su b je ct DTMs to e xte n -
sive te stin g to re d u ce th e risk o f lo s-
in g fu n ctio n ality wh ile u sin g DTMs in
ABBs co n tro l syste m. Th e re p o rt fo r
e ach d e vice te ste d an d re le ase d b y
FDIC carrie s in fo rmatio n ab o u t th e
fu n ctio n in g o f DTM in th e targe t ABB
co n tro l syste m.
The Integration Cycle
Th e in te gratio n te st cycle is typ ically
12 we e ks lo n g an d re su lts in a p o rtfo -
lio o f in te grate d d e vice s th at is co n tin -
u o u sly e xp an d in g. Th e in te gratio n
te sts are p e rfo rme d o n d e vice s th at
are availab le o n th e o p e n marke t.
A typ ical in te gratio n cycle in clu d e s
1
ABBs Extended 800xA automation system integrates the three major fieldbus protocols
in a single structure
Product Documentation
Configuration
Commissioning
Operation
Maintenance Management
Parameterization
Asset Monitoring
Diagnosis
Real Object
Object Type, delivered with the
Device Type Library
Each device type object includes
aspects for
Risk management
ABB Review
b asic co n n e ctivity te sts, to ve rify
cyclic d ata tran sfe r b e twe e n th e d e -
vice an d th e au to matio n syste m, an d
d e taile d te sts with DTMs to ve rify th e
d e vice fe atu re s in clu d in g p arame te rs,
co n figu ratio n , d iagn o stics e tc. De -
taile d te sts are also carrie d o u t to
e n su re d e vice asse t mo n ito r fu n ctio n -
ality, wh ich in clu d e th e asse ssme n t o f
th e p e rfo rman ce o f o th e r h igh e r-le ve l
ap p licatio n s su ch as calib ratio n man -
age me n t, co mp u te rize d main te n an ce
man age me n t, d e vice in te ro p e rab ility,
b u s maste r an d o th e r ke y fe atu re s
(ap p licab le to Fo u n d atio n Fie ld b u s).
All d e viatio n s d e te cte d d u rin g te stin g
are re co rd e d in a fo rmal d e fe ct track-
in g syste m an d an alyze d in co n su lta-
tio n with Fie ld b u s R&D. De p e n d in g
o n th e se ve rity o f th e o b se rve d d e via-
tio n , d e vice so ftware is e ith e r re le ase d
fo r ge n e ral u se via th e ABB So lu tio n s
Ban k, o r re je cte d . If th e d e vice so ft-
ware h as b e e n re je cte d fo r re le ase ,
th e cau se o f re je ctio n is in fo rme d to
d e vice ve n d o r so th at n e ce ssary im-
p ro ve me n ts can b e d o n e fo r a re -te st
an d re le ase at a late r d ate .
Cooperation with device vendors
Co o p e ratio n with d e vice ve n d o rs is
cru cial to th e o ve rall su cce ss o f d e vice
in te gratio n . Th e FDIC re ce ive s in fo r-
matio n fro m d e vice ve n d o rs in ad -
van ce o f n e w re le ase s, in clu d in g th e
ke y in p u ts re q u ire d fo r De vice Sp e cif-
ic Asse t Mo n ito rs. It sh are s re su lts
re gard in g th e in te gratio n p e rfo rman ce
o f d e vice s with ve n d o rs an d d iscu sse s
an y failu re s o b se rve d d u rin g in te gra-
tio n te sts. Fe e d b ack fro m th e FDIC
o fte n re su lts in imp ro ve me n ts in
d e vice so ftware an d , in so me case s,
firmware .
Commitment to device lifecycle support
Sin ce it b e gan in 2004, th e FDIC h as
p laye d a ke y ro le in makin g fie ld b u s
so lu tio n s e asy to imp le me n t an d e ffi-
cie n t to main tain o ve r th e d e vice life
cycle .
Th e p rimary b e n e fits to th e e n d cu s-
to me r in clu d e :
Ve rifie d in te r-o p e rab ility
Re -u se o f p ro ve n so lu tio n s
Re d u ce d e n gin e e rin g an d
co mmissio n in g e ffo rt
Su p p o rt, via ABBs stan d ard su p p o rt
o rgan izatio n , in clu d in g acce ss to
in te gratio n e xp e rts.
Po ssib ility o f co n tin u o u s imp ro ve -
me n t as FDIC take s care o f re le asin g
u p d ate d ve rsio n s o f d e vice s
Re d u ce d risk an d imp ro ve d safe ty o f
th e man u factu rin g p lan t
Sin ce th e e n d o f 2005, th e FDIC h as
wo rke d o n a stan d ard th ro u gh p u t o f
120 d e vice s p e r q u arte r. Th e to tal
n u mb e r o f in te grate d d e vice s ap -
p ro ve d e ach ye ar is ap p ro ximate ly
425, fro m mo re th an 50 d e vice ve n -
d o rs. Ho we ve r, if th e FDIC was to
e valu ate its th ro u gh p u t b y th e me a-
su re s u se d b y so me o f its co mp e tito rs
(wh o co u n t su b -varian ts o f d e vice s,
e g d iffe re n t o p e ratin g vo ltage ran ge s,
se p arate ly), th e n th e to tal n u mb e r o f
in te grate d d e vice s te ste d wo u ld p ro b -
ab ly b e in th e re gio n o f 1000 p e r ye ar
an d th e n u mb e r o f d e vice s in th e in te -
grate d p o rtfo lio wo u ld e xce e d 2000.
All deviations detected
during testing are record-
ed in a formal defect
tracking system and
analyzed in consultation
with Fieldbus R&D.
Th e FDIC is a sin gle p o in t o f co n tact
fo r all fie ld b u s in te gratio n n e e d s, co v-
e rin g th e wh o le su ite o f ABBs co n tro l
syste ms fo r p ro ce ss au to matio n . It
p e rfo rms an e sse n tial se rvice , main -
tain in g ABBs re p u tatio n fo r re liab ility
an d in te rco mp atib ility o f its co n tro l
syste ms.
Ahmad Khan
Bangalore, India
ahmad.khan@in.abb.com
Friedrich Harbach
Ladenburg, Germany
friedrich.harbach@de.abb.com
Stefan Bollmeyer
ABB Automation GmBH
Minden, Germany
stefan.bollmeyer@de.abb.com
Risk management
2
Device integration components in a single structure
In 1999, ABB announced its vision for
the next generation automation plat-
form, called Industrial
IT
. The goal was
to combine traditional distribution
control systems (DCS) with IT-based
business applications to provide
seamless integration between the
shop floor and the boardroom. Indus-
trial
IT
required a new process control
platform, ABBs System 800xA, which
was released in late 2003. Since then,
over 1700 800xA systems have been
sold. The main advantage of the
system is that it supports the progres-
sive development of ABBs previously
installed process control systems,
worth $ 20 billion. Customer satisfac-
tion with the 800xA system is ensured
by rigorous testing of new vesions
by multidisciplinary teams prior to
release.
The system
typ e test
A global organization ensuring that 800xA performs as advertised
Bill Anderson
ABB Review
Risk management
82
ABB Review
A
BBs award win n in g In d u strial
IT

Syste m 800xA h as b e e n e xtre me ly
su cce ssfu l sin ce its re le ase in 2003.
Th is su cce ss h as b e e n d u e to man y
facto rs. Two o f th e mo st imp o rtan t are
th e b re ad th an d sco p e o f its fu n ctio n -
ality, an d its ab ility to su p p o rt th e
e vo lvin g d e ve lo p me n t o f all ABBs
e arlie r syste ms. To fu lfill th e n e e d s o f
man y d iffe re n t in d u strie s, b u sin e ss
lan d scap e s, an d e xp e ctatio n s, ABB
e mp lo ys a glo b al su p p o rt n e two rk fo r
th e re se arch an d d e ve lo p me n t o f th e
syste m. Th is stru ctu re allo ws th e
800xA syste m to b e n e fit fro m tru ly
glo b al d e ve lo p me n t, cap italizin g o n
th e skills, tale n ts an d marke t in te lli-
ge n ce fro m a glo b al p o o l o f tale n t.
Sin ce its in tro d u ctio n , se ve ral re vi-
sio n s h ave b e e n mad e to imp ro ve
th e p e rfo rman ce o f 800xA. Th e late st
re le ase , Syste m ve rsio n 5.0 (SV5.0)
was re le ase d late in 2006. With e ach
re le ase , co mp an ie s like ABB mu st
e n su re th at th e n e w ve rsio n h as b e e n
co mp re h e n sive ly te ste d an d is re ad y
fo r cu sto me r u se . Th e p ro b le m is h o w
to te st a syste m d e vise d b y mo re th an
20 d iffe re n t p ro d u ct d e ve lo p me n t
te ams to e n su re th at it me e ts ABB
q u ality stan d ard s in all in d u strie s
se rve d b y ABB, in all lo catio n s aro u n d
th e glo b e . Th e so lu tio n is ABBs
Syste m Typ e Te st (STT) o rgan izatio n .
The role of System Type Test (STT)
STT is a glo b al o rgan izatio n with lo ca-
tio n s in Vste rs (Swe d e n ), Min d e n
(Ge rman y), an d Wickliffe , Oh io
(USA), with ad d itio n al su p p o rt fo r
Micro so ft se cu rity p atch te stin g fro m
Ban galo re (In d ia). Th e o b je ctive o f
th e o rgan izatio n is to te st th e 800xA
syste m in an e n viro n me n t as clo se to
cu sto me rs wo rkin g co n d itio n s as can
b e ach ie ve d .
Each STT lo catio n sp e cialize s in so me
asp e ct o f 800xA te stin g. Min d e n d e als
h e avily with th e fie ld b u s an d I/ O (in -
p u t/ o u tp u t) su b syste ms, as we ll as th e
in te rface to th e Me lo d y Op e n Co n tro l
Syste ms (OCS). Wickliffe sp e cialize s in
e xte n d e d ap p licatio n s su ch as Pro d u c-
tio n Man age me n t, In fo rmatio n Man ag-
e r, an d Asse t Op timizatio n in ad d itio n
to th e Harmo n y, MOD an d DCI OCS
syste m in te rface s. Th e Vste rs ce n te r
is re sp o n sib le fo r e n su rin g th at th e
co re 800xA syste m (PPA an d AC800M),
e n gin e e rin g, co re h isto ry re p o rtin g,
lice n sin g, calcu latio n s, e tc. o p e rate
p ro p e rly fo r all u se rs. Th e ce n te r is
also re sp o n sib le fo r th e 800xA in te r-
face to th e AC400 OCS, PLC Co n n e ct,
an d Safe gu ard Co n n e ct.
The objective of the STT
organization is to test the
800xA system in an envi-
ronment as close to cus-
tomers working condi-
tions as can be achieved
Test planning
Be fo re e ach n e w p ro d u ct o r re visio n
o f an e xistin g p ro d u ct is re le ase d ,
ABB d e vise s a glo b al syste m te st p lan
th at e n su re s all syste m le ve l an d so me
p ro d u ct le ve l re q u ire me n ts are te ste d .
Th e syste m le ve l te st is d e sign e d as a
wh o le an d is b ro ke n d o wn in to co m-
p o n e n ts fo r te stin g at e ach te st ce n te r.
All ce n te rs u se th e same te st strate gy
an d u se -case sce n ario s. Each ce n te r
fo cu se s o n d iffe re n t te st case s fo r
e ach u se case in co mb in atio n with
d iffe re n t sp e cialize d e q u ip me n t an d
ap p licatio n s.
In Vste rs, th e re are 15 te st p ro fe s-
sio n als wh o p e rfo rm a varie ty o f tasks
to make su re th e syste m wo rks as in -
te n d e d . Vste rs also re gu late s p ro d -
u ct q u ality fo r th e e n tire glo b al te st
o rgan izatio n , e n su rin g th at th e te st
p ro ce ss is strin ge n t an d e ffe ctive ,
main tain in g glo b al cu sto me r satisfac-
tio n o f n e w re le ase s o f th e 800xA
syste m, p ro d u ct ro llu p s an d se rvice
p acks. Th e ce n te r o rgan ize s p e rso n al
co mp u te rs an d AC800M co n tro lle rs
in to te st n e two rks to su p p o rt th e vari-
o u s syste m ve rsio n s an d syste m co n -
figu ratio n s.
Test development process
Wh ile d e ve lo p me n t te ams are b u sy
d e sign in g an d imp le me n tin g fu n ctio n -
ality, th e STT o rgan izatio n is d e ve lo p -
in g n e w te sts o r e n h an cin g e xistin g
te sts. Te st d e ve lo p me n t in clu d e s b o th
th e writte n p ro ce d u re , as we ll as an y
te st co n figu ratio n s an d ap p licatio n s
re q u ire d to e xe cu te th e te st p lan . Ap -
p licatio n s u se d to e xe cu te th e te sts
co me fro m se ve ral so u rce s. So me
we re d e sign e d b y th e Vste rs te st
staff to e xe cu te sp e cific fu n ctio n s,
su ch as co n tro lle d alarm b u rsts, h e avy
syste m lo ad , an d o th e r stre ss co n d i-
tio n s. Oth e r ap p licatio n s came fro m
e n d cu sto me rs an d are u se d to o p e r-
ate th e syste m in u se r-typ ical sce n ari-
o s. STT cre ate s te st case s with in th e
fo llo win g u se case s:
Syste m-wid e in stallatio n an d co n fig-
u ratio n
Risk management
The system typ e test
ABB Review
Syste m- an d ap p licatio n u p grad e s
Ap p licatio n e n gin e e rin g fo r vario u s
syste m fu n ctio n s
Ru n -time ch aracte ristics an d u sab ili-
ty o f th e syste m u n d e r n o rmal o p e r-
atio n an d tran sie n t co n d itio n s.
Re cu rre n t an d co mp le te syste m
main te n an ce
Pe rfo rman ce ch aracte rizatio n o f th e
syste m u n d e r n o rmal ru n time an d
tran sie n t co n d itio n s.
Syste m an d n e two rk se cu rity in co n -
ju n ctio n with u se case fo r e xte n d e d
syste ms.
Use case fo r sp e cial fu n ctio n s
The best results are often
produced when engineers
from end-user companies
are integrated into a test
team and able to interact
freely with ABB test engi-
neers.
Test execution process
Th e STT p ro ce ss is d e sign e d to take
th e syste m th ro u gh a se rie s o f stage s
th at gro w in sco p e an d co mp le xity to
e n su re imp ro ve me n ts in syste m q u ali-
ty at e ach ste p .
System Integration Test
At p re -p lan n e d stage s in th e p ro d u ct
d e ve lo p me n t p ro ce ss, th e p ro d u ct is
su b je cte d to a Syste m In te gratio n Te st
to e n su re th at th e in d ivid u al co mp o -
n e n ts can b e in stalle d an d ru n as an
800xA syste m. Th is starts with a small
syste m an d is in te grate d , ste p b y ste p ,
in to a fu ll, wo rkin g syste m. Th e sys-
te m co n figu ratio n s gro w p ro gre ssive ly
o ve r time , as d o ap p licatio n s an d
b asic lo ad , u n til th e syste m size an d
cap acity is re ad y fo r fo rmal te stin g.
System Type Test
Th e fo rmal STT is ru n o n ce th e ap p ro -
p riate q u ality le ve l is ach ie ve d . Th is
te st is e xe cu te d o n mo re th an 12 d if-
fe re n t syste m co n figu ratio n s, d istrib u t-
e d acro ss th e th re e ce n te rs to cre ate a
varie ty o f u se r sce n ario s. STT h as a
wid e sco p e to id e n tify all e rro rs th at
imp act cu sto me rs.
Release Acceptance Test
Wh e n th e STT is co mp le te d , a Re le ase
Acce p tan ce Te st is co n d u cte d o n th e
fin al ve rsio n o f th e so ftware to e n su re
th at it is re ad y fo r re le ase fo r man u -
factu rin g an d d istrib u tio n to e n d cu s-
to me rs.
Keys to success
One ke y to Vste rs succe ss is collab-
oration with many inte rnal ABB organi-
zations and e nd-use rs. Each te st ne t-
work is le ad by an e xp e rie nce d p rofe s-
sional te ste r. The te st te am is normally
comp ose d of a ble nd of ABB e ngine e rs
from various sp e cializations such as
te chnical sup p ort, op e rations, and fie ld
se rvice . This typ e of coop e rative col-
laboration be ne fits all of the organiza-
tions in the chain that are e xp e cte d to
p rovide a full range sup p ort to e nd-
use rs as soon as a re le ase is made . The
be st re sults are ofte n p roduce d whe n
e ngine e rs from e nd-use r comp anie s
are inte grate d into a te st te am and able
to inte ract fre e ly with ABB te st e ngi-
ne e rs. This ble nd of backgrounds,
e xp e ctations and e xp e rie nce in a te st
te am p rovide s the balance ne e de d to
p roduce a good re sult.
The System Type Test
process is designed to
take the system through a
series of stages that grow
in scope and complexity
to ensure improvements
in system quality at each
step.
Th e sto ry o f STT in Vste rs is o n e o f
co n tin u o u s imp ro ve me n t. Man y im-
p ro ve me n ts to th e p ro ce ss an d in n o va-
tio n s h ave b e e n mad e o ve r time an d
mo re are p lan n e d fo r th e fu tu re . Au to -
mate d te stin g, Au to Te st
IT
, is a gro win g
co mp o n e n t o f th e cu rre n t te sts b e in g
p e rfo rme d in all te st ce n te rs. Th is in -
n o vative to o l was d e ve lo p e d sp e cifi-
cally fo r 800xA te stin g in Vste rs an d
h as b e e n in valu ab le as a to o l to in -
cre ase te st sp e e d s, re d u cin g co st an d
h e lp in g d e ve lo p e rs d e b u g issu e s th at
are n o rmally h ard to re p ro d u ce with
man u al ste p s. Pro je cts are u n d e rway
in co llab o ratio n with th e ABB Co rp o -
rate Re se arch Ce n te r o n a n e w ge n e ra-
tio n o f p ro ce ss an d to o l imp ro ve -
me n ts. Th e n e xt ge n e ratio n o f to o ls
will au to mate man y o f th e man u al
ste p s th at te ste rs u se to d e sign an d
co n d u ct te sts an d to re p o rt re su lts.
Fin ally, an o th e r b e n e fit o f th e STT is
n o t at all re late d to fixin g b u gs.
Sin ce STT e mp lo ys b o th ABB p ro je ct
e n gin e e rs an d cu sto me rs, syste m u s-
ab ility imp ro ve me n ts are ro u tin e ly
id e n tifie d an d in co rp o rate d in to n e w
re le ase s. Ultimate ly, th e ro le o f th e
STT is to e n su re th e su cce ssfu l re le ase
o f 800xA, p ro vid in g cu sto me r satisfac-
tio n , straigh t o u t o f th e b o x.
Bill Anderson
ABB Inc., Automation Technologry Products
Warminster, PA, USA
bill.anderson@us.abb.com
Risk management
The system typ e test
The safe operation of an industrial process requires a structured approach
that must be applied to every aspect of every level of operations while
seeking to minimize the total risk posed by the process.
ABB has a long tradition of supplying safety systems for industrial
processes. This has provided the company with the experience necessary
to implement new safety standards such as IEC-61508 and IEC-61511 and
integrate these in its System 800xA control system.
Safety management
in p roc ess ind ustries
The ABB approach
Robert Martinez, Per Christian Juel, Per Fjelldalen
A
BB h as b e e n su p p lyin g safe ty
syste ms to p ro ce ss in d u strie s fo r
25 ye ars an d is th e mo st e xp e rie n ce d
su p p lie r o f p ro grammab le safe ty
syste ms. Th e first safe ty syste m was
d e ve lo p e d an d su p p lie d to Mo b il In c.
fo r th e Statfjo rd B o il an d gas p ro d u c-
tio n p latfo rm in 1979. Sin ce th e n , ABB
h as b e e n su p p lyin g in d u strial safe ty
syste ms to mo st in d u stry se gme n ts
an d majo r o p e ratin g co mp an ie s
aro u n d th e wo rld .
Th e o il in d u stry h as b e e n at th e fo re -
fro n t o f safe ty man age me n t fo r man y
ye ars. Natio n al le gislatio n fo r safe ty in
e xp lo ratio n an d d e ve lo p me n t o f th e
o il fie ld s in th e No rth Se a was fo rcin g
a sh ift in safe ty aware n e ss an d su p -
p o rtin g te ch n o lo gy lo n g b e fo re n e w
in te rn atio n al stan d ard s we re in tro -
d u ce d . ABB p laye d an imp o rtan t ro le
in th e d e ve lo p me n t o f th e te ch n o lo gy
th at to d ay fo rms th e b asis fo r mo d e rn
in te grate d au to matio n an d safe ty sys-
te ms.
Th is h as p ro vid e d ABB with th e e xp e -
rie n ce n e ce ssary to su p p o rt its p ro ce ss
in d u stry cu sto me rs in facin g th e te ch -
n ical an d o rgan izatio n al ch alle n ge s
an d co sts re late d to strict safe ty man -
85
ABB Review
ABB Review
Th e co n su ltin g ro le o f safe ty e xp e rts
was n o t fo rgo tte n . Th e p ro p o se d safe -
ty to o l ch ain was co n ce ive d to b e p o r-
tab le with a min imu m o f d e p e n d e n -
cie s an d with an o p e n d e sign simp li-
fyin g th e imp o rt o f d ata fro m a varie ty
o f so u rce s. Th e se fe atu re s are e sse n -
tial fo r ABBs safe ty co n su ltin g e n gi-
n e e rs at cu sto me r site s an d in cu sto m-
e r train in g.
In 2004 p re -p ro d u ct p ro to typ e s we re
co mp le te d fo r b o th safe ty p ro je ct
man age me n t, an d cau se an d e ffe ct
matrix p ro grammin g. Th e se p ro to -
typ e s are d iscu sse d in th e fo llo win g
se ctio n s.
Supporting safety project management
Th e ABB Pro ce ss Au to matio n b u sin e ss
are a h as imp le me n te d fo rmal an d
TV-ap p ro ve d safe ty man age me n t
with in its safe ty p ro d u ct d e ve lo p me n t
o rgan izatio n . Th is ap p ro val was a n e c-
e ssary p re -re q u isite fo r th e su cce ssfu l
d e ve lo p me n t o f th e n e w AC 800M HI
safe ty co n tro lle r. Th e kn o wle d ge -p ath
n e e d e d to gain ap p ro val p ro vid e d
valu ab le in p u t to th e p ro to typ in g o f a
to o l wh ich can b e ro lle d o u t to p ro j-
e ct te ams an d cu sto me rs, th e Co mp li-
an ce Man age r.
Co mp lian ce Man age r h e lp s th e u se r
b u ild safe ty te ams, d e scrib e me mb e r
co mp e te n ce s an d assign re sp o n sib ili-
tie s u sin g a re sp o n sib ility-acco u n tab il-
ity (RACI) ch art. Th e b u ilt-in co mp li-
an ce e d ito r allo ws in p u t o f an y re -
q u ire me n t se t. Th e IEC-61511 stan d ard
is p re -lo ad e d so th at th e u se r can b e -
co me p ro d u ctive imme d iate ly
1
. Th e
u se r can p e rfo rm a gap an alysis o n
th e re q u ire me n ts an d th e n au to mati-
cally ge n e rate ch e cklists an d sp e cifica-
tio n d o cu me n ts. Th e to o l is also lo ad -
e d with ABBs e xp e rt in te rp re tatio n o f
IEC-61511 an d th e ir ap p licab ility to
th e co mp an ys o wn syste ms. Th is fe a-
tu re allo ws ABB e n gin e e rs to re sp o n d
q u ickly an d u n ifo rmly to cu sto me r
safe ty re q u ire me n t sp e cificatio n s.
Safety system design and programming
Afte r th e Safe ty In stru me n te d Fu n ctio n
(SIF)
2)
h as b e e n co n figu re d , th e re li-
ab ility o f all its co mp o n e n ts is in p u t
to a Safe ty In te grity Le ve l (SIL) calcu -
latio n to ch e ck th at it me e ts th e targe t
risk re d u ctio n . Th is calcu latio n is n o t
trivial, e sp e cially wh e n th e e ffe cts o f
re d u n d an cy an d co mmo n -cau se fail-
u re s are co n sid e re d . Fo rtu n ate ly, a
gro u p o f safe ty e n gin e e rs at ABB
En gin e e rin g Se rvice s in En glan d h ad
e arlie r d e ve lo p e d a stan d -alo n e SIL
calcu lato r calle d TRAC (Trip Re q u ire -
me n t an d Availab ility Calcu lato r)
2
.
Th e ABB te am in No rway co mp ile d a
ro ad map fo r in te gratin g th e calcu lato r
with Syste m 800xA an d th e o th e r to o ls
in th e safe ty su ite .
Th e SIL calcu latio n s are ve ry u se fu l fo r
valid atin g th e SIF d e sign , b u t th e y can
also p ro vid e valu ab le d ata su ch as
time in te rvals afte r wh ich th e cu sto me r
mu st p e rfo rm p ro o f-te stin g o n th e SIF
co mp o n e n ts. Oth e r u se fu l figu re s fro m
th is p h ase are th e availab ility an d to tal
d o wn time , me an time b e twe e n failu re s
(MTBF), an d th e me an time to re sto ra-
1 Compliance Manger screenshot. 2 ABB TRAC (Trip Requirement and Availability Calculator)
SIL Calculator screenshot.
age me n t re gu latio n s. An o th e r imp o r-
tan t argu me n t in favo r o f ABB is th e
Syste m 800xA co n tro l syste m
1)
, p ro vid -
in g a b ro ad co lle ctio n o f o u t o f th e
b o x se rvice s e n ab lin g th e tigh tly
in te grate d man age me n t re q u ire d b y
IEC-61511
2)
: au d itin g, au th e n ticatio n ,
acce ss man age me n t, d o cu me n t man -
age me n t, asse t mo n ito rin g an d CMMS
(main te n an ce ) in te gratio n . Th e se an d
o th e r so ftware se rvice s p ro vid e fu n c-
tio n ality wh ich h e lp e n fo rce an d
p ro ve co mp lian ce d u rin g th e o p e ra-
tio n al p h ase s o f th e safe ty life cycle .
ABBs Co rp o rate Re se arch in No rway
p e rfo rme d a gap an alysis o f th e
Syste m 800xA p latfo rm ve rsu s th e
IEC-61511 man age me n t re q u ire me n ts
to d e te rmin e wh e re su p p o rt o f th e
stan d ard co u ld b e stre n gth e n e d . Th e
stu d y re ve ale d an o p p o rtu n ity to o ffe r
co mp le te life cycle co ve rage b y p ro -
vid in g su p p o rt fo r th is fu n ctio n ality in
th e fo llo win g p lan n in g an d e n gin e e r-
in g p h ase s:
Safe ty p ro je ct man age me n t.
Hazard an d risk asse ssme n t.
Safe ty fu n ctio n d e sign fo r in te grity
an d re liab ility.
Cau se an d e ffe ct matrix safe ty
p ro grammin g.
ABB Co rp o rate Re se arch , to ge th e r
with th e Safe ty se ctio n o f ABB Pro ce ss
Au to matio n , id e n tifie d th e b e n e fits o f
a Syste m 800xA Safe ty Wo rkp lace
p ackage , co mb in in g th e e xistin g an d
p ro p o se d fu n ctio n ality to p ro vid e a
se amle ss so lu tio n to b o th e n gin e e rin g
an d o p e ratio n al u se rs.
Safety management in p rocess industries
ABB Review
tio n (MTTR). Th e re is a stro n g d e man d
fro m p ro je ct te ams an d sale s e n gin e e rs
fo r in te grate d to o ls wh ich can calcu -
late an d aggre gate th is d ata to all le v-
e ls o f a co n tro l stru ctu re .
At th is stage o f th e life cycle , all SIF
h ard ware h as b e e n co n figu re d , b u t
th e safe ty ap p licatio n so ftware h as
still to b e imp le me n te d . Th e mo st
ch alle n gin g task in th is p h ase is face d
b y p ro gramme rs o f large ESD/ PSD
(e me rge n cy/ p ro ce ss sh u td o wn ) sys-
te ms. Th e se SIS syste ms sp an all p ro -
ce ss are as an d acce ss a h u ge n u mb e r
o f p ro ce ss variab le s o r tags. Sh u t-
d o wn s are typ ically stru ctu re d in a
cascad in g h ie rarch y o f man y le ve ls
with th e h igh e r e me rge n cy le ve ls
trip p in g lo we r p ro ce ss le ve ls.
Du e to th e se sp e cial re q u ire me n ts,
cau se an d e ffe ct matrix (CEM) p ro -
grammin g h as e me rge d as th e d e -facto
stan d ard fo r p ro grammin g ESD/ PSD
safe ty syste ms o r an y syste m with
in te r lo ck lo gic. In its simp le st fo rm, a
CEM is a matrix co n tain in g n ame d
tags. Th e matrix symb o ls in d icate th at
a trip o f a co lu mn s e ffe ct o ccu rs
wh e n th e co rre sp o n d in g cau se ro w
is trigge re d
3
.
To su p p o rt CEM p ro grammin g fo r
IEC 61131 co n tro l p latfo rms, ABB
d e ve lo p e d th e Syste m 800xA Safe ty
Bu ild e r to o lkit. Th e Ed ito r to o l h e lp s
u se rs sp e cify co mp le x e me rge n cy an d
p ro ce ss sh u td o wn lo gic visu ally an d
in tu itive ly with a matrix grid . High -
q u ality SIL-ce rtifie d co d e fo r th e n e w
AC 800M HI co n tro lle r is au to matically
ge n e rate d fro m th is matrix.
Th e Vie we r to o l can th e n b e in -
vo ke d to ge n e rate a fu lly-in te grate d
Syste m 800xA o p e rato r d isp lay an d
n avigatio n e le me n t
4
. Th e n avigatio n
e le me n t sh o ws th e aggre gate alarm,
o r in h ib it statu s o f th e e n tire safe ty
syste m d ivid e d in to p ro ce ss are as
sh e e ts. With o n e click, th e o p e rato r
can d rill-d o wn to th e sh e e t in alarm
an d se e at a glan ce wh ich d e vice s an d
wh ich le ve ls h ave b e e n trip p e d . On e -
click n avigatio n to all th e syste ms
d e vice s is p ro vid e d .
The System 800xA Safety Builder tools
build on the success of the Safety
Builder p roduct for Safeguard, adding
many new features and more flexibility.
System 800xA Safety Builder introduces
the p owerful concep t of single-source
engineering: drawing, p rogramming
and disp lay all based on the same un-
derlying document. The design ap -
p roach enables the underlying CEM
document to be shared with contractors
who are not System 800xA equip p ed.
They sp ecify the design in the matrix
and then send the document back for
System 800xA code and disp lay genera-
tion
5
. This facilitates flexible and dis-
tributed develop ment p ractices.
Tran slatio n e rro rs are e limin ate d b y
au to matically ge n e ratin g th e co n tro l
lo gic an d o p e rato r d isp lay fro m th e
same safe ty d e sign matrix. Th is re d u c-
e s in itial e n gin e e rin g e ffo rt b y a facto r
o f te n an d make s mo d ificatio n s e asie r
to imp le me n t, te st an d trace .
Robert Martinez
Per Christian Juel
ABB Corporate R&D
Billingstad, Norway
per.c.juel@no.abb.com
Per Fjelldalen
ABB Process Automation
Oslo, Norway
per.fjelldalen@no.abb.com
Footnotes
1)
Taft, Mark W., Indust rial
IT
Syst em 800xA, Ext end-
ing t he reach of aut omat ion t o achieve cont inuous
product ivit y improvement s , ABB Review 1/ 2004
pp 3237.
2)
See also Martinez, Robert, Juel, Per Christian,
Fjelldalen, Per, Safet y management in process in-
dust ries, Part 1 St andards , ABB Review 3/ 2005,
pp 4750 and Martinez, Robert, Fengler, Frank,
Safe inst rument s on pp 9699 of t his edit ion of
ABB Review Special Report .
3 System 800xA Safety Builder editor screen shot. 4 System 800xA Safety Builder viewer screen shot.
5 Flexible cause and effect programming.
CEM Document
Customer/ contractor designs and verifies
Engineering team
System 800xA
Safety management in p rocess industries
End users of older automation sys-
tems essentially had to invest in two
separate systems; a Basic Process
Control System and a separate Safety
Instrumented System. Nowadays sup-
pliers differ in their opinions about the
acceptability of implementing safety
and basic process control functions in
a single system with common proces-
sors. Some argue that integration
reduces overall integrity while safety,
which faces ever increasing regula-
tion, is compromised.
The debate about integration is set to
continue but one company that has
been more constructive rather than
vocal about this topic is ABB. As an
established supplier of safety systems
for hazardous processes since 1979,
ABB has recently launched the unique
800xA HI combined Safety and Con-
trol architecture as part of the suc-
cessful 800xA Extended Automation
System. With this architecture, ABB
has proved that true integration is
possible, and functional separation of
control and safety is ensured using
modern high integrity processing
techniques, firewalls and active diag-
nostics. Not only this but the system
is fully compliant with the require-
ments of the international functional
safety standards.
This article looks at the standard
requirements and discusses how
todays hardware and software tech-
nologies, in the hands of profession-
als operating under rigorous function-
al safety management procedures,
can deliver new system architectures
with higher levels of control and man-
agement functionality, and safety
compliant integrity.
Integrated
b ut sep arate
Advances in integrated and safety control
Roger W. Prew
ABB Review
88
ABB Review
W
h at are th e ad van tage s
o f in te gratin g a Safe ty
In stru me n te d Syste m (SIS)
an d a Basic Pro ce ss Co n tro l
Syste m (BPCS)? Fo r o n e th in g,
th e life time co st o f o wn e rsh ip
o f th e syste m is sign ifican tly
imp acte d , as are p ro je ct d e -
sign , e n gin e e rin g an d mo d ifi-
catio n co sts. At th e syste m
d e fin itio n p h ase , th e fle xib ili-
ty o f b e in g ab le to tran sfe r in -
p u ts an d o u tp u ts (I/ O), an d
fu n ctio n s b e twe e n th e SIS an d
th e BPCS, with o u t mate rially
alte rin g th e syste m arch ite c-
tu re , imp ro ve s th e e fficie n cy
o f th e d e sign p ro ce ss an d re -
su lts in a mo re co st e ffe ctive
so lu tio n . Du rin g syste m in te -
gratio n , th is same fle xib ility
e n su re s th at th e sp lit b e twe e n
BPCS an d safe ty match e s th e
actu al re q u ire me n t an d h as
n o t b e e n fo rce d in to an arch i-
te ctu re th at was o rd e re d man y
mo n th s e arlie r.
ABBs 800xA HI com-
bined safety and control
architecture has proved
that true integration is
possible and functional
separation of control and
safety is ensured.
Co st savin gs arisin g fro m co mmo n
co n figu ratio n to o ls, co mmu n icatio n s
n e two rks, sp are p arts, main te n an ce ,
train in g, se rvice , an d u p grad e s are
o b vio u s, b u t th e b igge st ad van tage is
an in cre ase in d ata acce ss b e twe e n
th e safe ty syste m, an d th e Distrib u te d
Co n tro l Syste m (DCS) ap p licatio n an d
p ro ce ss man age me n t to o ls. Re al
time co n n e ctio n o f p arame te rs b e -
twe e n safe ty an d DCS co n tro l ap p lica-
tio n s o n ly p o ssib le if th e two ap p li-
catio n s are e xe cu te d in a sin gle co m-
mo n co n tro lle r n o d e me an s th at
e xp e n sive fie ld e q u ip me n t an d wirin g
can b e sh are d b e twe e n th e m th u s o p -
timizin g th e p h ysical arch ite ctu re
1
.
Mo re o ve r, fu ll in te gratio n me an s th at
all d ata asso ciate d with th e Safe ty In -
stru me n te d Fu n ctio n (SIF)
1)
, su ch as
th e Safe ty In te grity Le ve l (SIL) calcu la-
tio n , syste m an d fie ld d e vice d iagn o s-
tics, trip fre q u e n cie s, trip re sp o n se s,
valve co n d itio n an d so o n , are avail-
ab le to th e BPCS Asse t Man age me n t
syste m. In ad d itio n , th e h igh le ve l
d ata co lle ctio n an d an alysis to o ls o f a
BPCS can b e e xp lo ite d in a co mmo n
an d co n siste n t way b y th e SIS
2
.
Regulations and standards
Pro ce ss safe ty h as gain e d co rp o rate
imp o rtan ce e sp e cially sin ce th e cata-
stro p h ic in cid e n ts th at o c-
cu rre d at Flixb o ro u gh
2)
(UK),
Se rve so
3)
(Italy), Bh o p al
4)

(In d ia) an d o n b o ard th e
Pip e r Alp h a
5)
No rth Se a p ro -
d u ctio n p latfo rm. No w p ro -
ce ss safe ty e xp e rtise h as e x-
te n d e d in to th e ge n e ral skill
se t o f e n gin e e rs an d o p e ra-
to rs, an d man y in d u stry-
wid e gu id e lin e s fo r p ro ce ss
safe ty h ave b e e n d e ve lo p e d .
Th e cu rre n t in d u stry ge n e ric
stan d ard fo r e le ctro n ic an d
p ro grammab le syste ms,
IEC61508
6)
, is th e re su lt o f
co n ce rte d e ffo rts b y in d u stry
an d re gu lato rs o ve r th e p ast
30 ye ars. Th e glo b al o b je c-
tive o f su ch a stan d ard is to
e n su re th at p ro p e r risk re -
d u ctio n strate gie s are ad o p t-
e d b y all in d u strie s with
h azard o u s p ro ce sse s so th at
th e in cid e n ts me n tio n e d
ab o ve can b e p re ve n te d .
Th is ge n e ric stan d ard an d
th e p ro ce ss in d u stry sp e cific stan d ard ,
IEC 61511
7)
, are e sse n tially ad viso ry.
Ho we ve r, th e y are n o w co n sid e re d
go o d p ractice b y re gu lato rs in th e
UK an d o th e r in d u strial co u n trie s an d
also as a me an s o f d e te rmin in g if a
re aso n ab le p ractical le ve l o f e le ctrical,
e le ctro n ic an d p ro grammab le e le c-
tro n ic safe ty (E/ E/ PES) h as b e e n
ach ie ve d . Th e stan d ard s are u se d to
b e n ch mark in stallatio n s an d are , to all
in te n t an d p u rp o se s, co n sid e re d man -
d ato ry.
IEC 61511 d e fin e s me th o d s o f asse ss-
in g risks asso ciate d with a p articu lar
h azard o u s p ro ce ss an d it d e te rmin e s
th e risk re d u ctio n th e safe ty syste m(s)
mu st ach ie ve . Th e stan d ard is p re -
scrip tive in th at risks mu st b e asse sse d
an d re d u ce d to as lo w as is re aso n -
ab ly p racticab le . It d o e s n o t h o we ve r
p re scrib e wh at te ch n o lo gie s an d
1
With ABB' s System 800xA HI there an increase in data access
between the safety system, and the DCS application and process
management tools
Footnotes
1)
A Safet y Inst rument ed Syst em (SIS) cont ains many safet y loops or Safet y Inst rument ed Funct ions (SIFs), each wit h it s own Safet y Int egrit y Level (SIL).
2)
ht t p:/ / www.hse.gov.uk/ comah/ sragt ech/ caseflixboroug74.ht m (January 2007)
3)
ht t p:/ / www.chm.bris.ac.uk/ mot m/ 245t / 245t h/ seveso.ht m (January 2007)
4)
ht t p:/ / www.bhopal.org/ what happened.ht ml (January 2007)
5)
ht t p:/ / www.answers.com/ t opic/ piper- alpha (January 2007)
6)
IEC 61508 is t he int ernat ional st andard for elect rical, elect ronic and programmable elect ronic safet y (E/ E/ PES) relat ed syst ems. It set s out t he requirement s for ensuring
t hat syst ems are designed, implement ed, operat ed and maint ained t o provide t he required safet y int egrit y level (SIL).
7)
The IEC 61511 st andard refines t he funct ional safet y requirement s laid down by IEC 61508 specifically for t he process indust ry sect or. It provides guidance in t he proper
applicat ion of a Safet y Inst rument ed Syst em (SIS).
Integrated but sep arate
ABB Review
arch ite ctu re s sh o u ld b e u se d to
ach ie ve th e re d u ctio n .
The 800xA HI safety
system shares a common
processing unit and other
components with the
DCS, and brings a
number of significant
enhancements to the
overall BPCS package.
Current technologies
Man y o f th e stan d -alo n e safe ty syste ms
cu rre n tly availab le o n th e marke t p re -
d ate th e n e w IEC stan d ard s an d e m-
p lo y a varie ty o f te ch n o lo gie s to
ach ie ve th e h igh in te grity co n tro l re -
q u ire d fo r safe ty ap p licatio n s. High
in te grity n o rmally su gge sts a co mb i-
n atio n o f fail safe an d fau lt to le r-
an ce o p e ratio n . Fail safe e n su re s th at
if a fau lt o ccu rs th e syste m will re act
in a p re -d e te rmin e d an d safe way
wh e re as fau lt to le ran ce min imise s th e
like lih o o d o f a failu re th at wo u ld p re -
ve n t th e syste m fro m p e rfo rmin g its
fu n ctio n s. Th e se two te rms o fte n ge t
co n fu se d ! A fau lt to le ran t syste m may
n o t b e fail safe . Ju st b e cau se it may b e
re d u n d an t o r trip le mo d u lar re d u n d an t
d o e sn t au to matically make it su itab le
fo r safe ty ap p licatio n s. Also a fail-safe
safe ty syste m d o e s n o t re q u ire re d u n -
d an cy to ach ie ve its SIL. Re d u n d an cy
is b u ilt in so le ly to imp ro ve syste m re -
liab ility an d availab ility.
Th e 1o o 2 d u al, 2o o 3 trip le an d 2o o 4
q u ad syste ms availab le o n th e marke t
to d ay co me fro m a d e sign e ra th at
u se d re d u n d an cy an d fau lt to le ran ce
as a me an s o f re d u cin g th e p ro b ab ility
o f a d an ge ro u s failu re o ccu rrin g. To -
d ay d an ge ro u s failu re mo d e s can b e
co mp le te ly d e sign e d o u t an d 100 p e r-
ce n t d iagn o stic co ve r can b e p ro vid e d
to p ro te ct in te grity with o u t re so rtin g
to d u p licatio n . Th e re q u ire me n ts o f
fail safe fo r safe ty in te grity an d
fau lt to le ran ce fo r availab ility can
n o w b e co n sid e re d in d e p e n d e n tly an d
u se d wh e n an d wh e re th e y are ap p li-
cab le
3
.
Th e re is always mu ch d e b ate ab o u t
th e h ard ware re liab ility o f e le ctro n ic
an d p ro grammab le syste ms. Ho we ve r
mo d e rn su rface mo u n t, h igh in te gra-
tio n e le ctro n ics is co n sid e re d e xtrao r-
d in arily re liab le . In an SIS, th e lo gic
so lve r h ard ware is th e mo st re liab le
e le me n t in th e e n tire safe ty lo o p !
Mo re e vid e n ce can b e fo u n d in so me
mo d e rn simp le x syste ms wh e re th e
Me an Time Be twe e n Failu re (MTBF)
figu re s are b e tte r th an th e last ge n e ra-
tio n d u al o r trip le syste ms. In fact th e
trip le an d q u ad syste ms su ffe r fro m
th e law o f d imin ish in g re tu rn s o n re li-
ab ility in th at th e in h e re n t failu re rate
rise s in p ro p o rtio n to th e in cre ase in
co mp o n e n ts an d co mp le xity.
A new generation of system
Th e n e w ge n e ratio n 800xA Exte n d e d
Au to matio n Syste m fro m ABB is fle xi-
b le e n o u gh to e ith e r co mb in e th e co n -
tro l an d safe ty fu n ctio n s with in th e
same co n tro lle r o r ke e p th e fu n ctio n s
se p arate b u t with in th e same in te grat-
e d n e two rk. Kn o wn as th e 800xA High
In te grity (HI), it is d e fin ite ly n o t a
mo d ifie d DCS o r a DCS with ad d e d
safe ty fu n ctio n ality. In ste ad it is a sys-
te m d e sign e d fro m th e o u tse t to me e t
th e re q u ire me n ts o f th e safe ty marke t
an d th e cu rre n t safe ty stan d ard s.
Safety related programs
are compiled using a limit-
ed instruction set compiler
certified for 800xA HI
safety programs.
Th e re are fo u r ke y are as th at mu st b e
ad d re sse d fo r a safe ty-re late d syste m
to me e t th e afo re me n tio n e d stan d ard s.
Man y in co rre ctly b e lie ve th at as lo n g
as th e calcu late d Pro b ab ility o f Failu re
o n De man d (PFD) is with in th e righ t
b an d , th e syste m co mp lie s. A syste m
co mp lie s o n ly wh e n th e fo llo win g
fo u r co n sid e ratio n s are me t.
Re liab ility (PFD) is o f co u rse imp o r-
tan t an d th e figu re s fo r all su b sys-
te ms th at make u p th e safe ty fu n c-
tio n mu st fo rm p art o f th e ce rtifie d
d ata se t so th at th e o ve rall lo o p SIL
can b e asse sse d .
Th e Safe Failu re Fractio n (SFF),
wh ich is a me asu re o f th e ab ility o f
th e syste m to d e te ct an d avo id
d an ge ro u s failu re mo d e s, is also
p art o f th e ce rtifie d d ata se t.
An y co n strain ts o r in te grity ad van -
tage re su ltin g fro m th e co mp le te
2
Risk graph for a related safety function to protect against a hazardous event
ABB Review
syste m arch ite ctu re mu st b e as-
se sse d an d th e imp licatio n s o n th e
SIL ratin g d o cu me n te d .
Fin ally, th e syste matic in te grity o f
th e syste m in clu d in g th e d e ve lo p -
me n t p ro ce sse s u tilize d , th e life cy-
cle safe ty man age me n t o f th e sys-
te m, an d th e me th o d s u se d to
d e ve lo p an d p ro ve h igh in te grity
so ftware mu st also co mp ly with th e
le tte r o f th e stan d ard .
A fault tolerant system
may not be fail safe. Just
because it may be redun-
dant or triple modular
redundant doesn t auto-
matically make it suitable
for safety applications.
Th e d e ve lo p me n t o f th e 800xA HI
safe ty syste m ad d re sse d th e ab o ve
issu e s. Th e d e sign te ams o p e rate d
u n d e r au d ite d fu n ctio n al safe ty man -
age me n t p ro ce sse s an d th e d e sign
co n ce p t an d d e tail was ap p ro ve d at
e ve ry stage b y TV (Th e TV Pro d u ct
Se rvice is co n sid e re d to b e th e fo re -
mo st in d e p e n d e n t ce rtificatio n au th o r-
ity in th e b u sin e ss)
4
. A ce rtificatio n
sp e cialist in th e te am, h e lp e d b y th ird
p arty co n su ltan ts, ste e re d th e d e tail
d e sign co n tin u o u sly co n firmin g co m-
p lian ce with th e re q u ire me n ts an d th e
stan d ard s.
Th e 800xA HI safe ty syste m sh are s a
co mmo n p ro ce ssin g u n it an d o th e r
co mp o n e n ts with th e DCS, an d b rin gs
a n u mb e r o f sign ifican t e n h an ce me n ts
to th e o ve rall BPCS p ackage in clu d in g:
High e r BPCS re liab ility th ro u gh :
Diagn o stics e xte n sive d iagn o stic
co ve r is a p re re q u isite fo r in te grity
De te rmin ism th e safe ty mo d e l
b rin gs with it a d e te rmin istic e xe -
cu tio n mo d e l
In te grity th is b rin gs gre ate r re li-
ab ility an d accu racy o f me asu re d
valu e s an d co n tro l actio n
Faste r co mmu n icatio n b e twe e n
BPCS an d SIS fu n ctio n s allo ws a
h igh e r d e gre e o f p ro ce ss co n tro l
o p timizatio n with re sp e ct to th e ac-
tu al safe ty b o u n d arie s (o r safe ty d is-
tan ce s).
Integrated but separate
Th e d e b ate ab o u t th e se p aratio n o f
th e safe ty fu n ctio n fro m th e BPCS will
n o d o u b t co n tin u e . Ho we ve r th e
IEC 61508 an d IEC 61511 stan d ard s d o
actu ally re co gn ise th at safe ty an d n o n -
safe ty fu n ctio n s can re sid e in th e
same syste m if it can b e sh o wn th at
th e imp le me n tatio n o f th e safe ty an d
n o n safe ty fu n ctio n s is su fficie n tly in -
d e p e n d e n t (ie , th at th e failu re o f a
n o n safe ty re late d fu n ctio n d o e s n o t
cau se a d an ge ro u s failu re o f th e safe ty
re late d fu n ctio n s) (IEC 61508-2
clau se 7.4.2.3). Th e stan d ard s also re -
q u ire th at th e p o ssib ility o f co mmo n
mo d e d e p e n d e n t failu re s is re d u ce d to
an acce p tab le le ve l. (IEC 61511 Part 1
clau se 9.5.1/ 2).
ABBs n e w ge n e ratio n Syste m 800xA
is faith fu l to th e se re q u ire me n ts. Th e
mo d u lar n atu re o f th e n e w syste m
me e ts th e stan d ard re q u ire me n ts fo r
fu n ctio n al se p aratio n an d co mmo n
mo d e failu re s. Me mo ry p artitio n in g,
se p arate e xe cu tio n co n te xts, fire walls
an d stack man age me n t te ch n iq u e s
th at co me fro m th e d e fe n ce an d h igh
in te grity d ata p ro ce ssin g wo rld s e n -
su re th at safe ty an d n o n -safe ty p ro -
grams ru n n in g in th e same p ro ce ssin g
e n viro n me n t are actu ally se p arate an d
n o n -in te rfe rin g. Th e in te grity o f th e
safe ty fu n ctio n is assu re d b y limitin g
ge n e ral co mmu n icatio n with th e Man
Mach in e In te rface (MMI) to re ad -o n ly,
an d in stitu tin g a safe write fu n ctio n
fo r o ve r-rid e s th at can o n ly b e e n -
ab le d b y man u al in te rve n tio n at th e
co n tro lle r. Pe e r to p e e r co mmu n ica-
tio n s b e twe e n safe ty an d n o n safe ty
fu n ctio n s is strictly co n tro lle d to e n -
su re in te grity o f th e safe ty fu n ctio n .
Ad d itio n al Cyclic Re d u n d an cy Ch e ck-
in g (CRC) an d re le van ce ch e ckin g
me an s th e p e e r to p e e r n e two rk can
b e co n sid e re d a gre y ch an n e l.
The 800xA HI is a system
designed from the outset
to meet the requirements
of the safety market and
the current safety stan-
dards.
De taile d an alysis was carrie d o u t
again st th e Laye rs o f Pro te ctio n An al-
ysis (LOPA)
8)
me th o d o f risk re d u c-
tio n . Th is an alysis co n firme d th at th e
3
System 800xA HI safety system architecture
Simplex SIL 2
Safety System
Duplex SIL 2 High Avail-
ability Safety System
S880 I/ O
4
ABBs 800xA HI safety system is certified to the IEC 61508
and IEC 61511 safety standards, and approved by TV
ABB Review
5
Functional Separation
LOPA credits 1000 for the Protection Layer
2 implemented in SIL2 application and 10
for protection Layer 1 implemented in non
SIL2 application.
NB. This data is provided as an example.
Actual LOPA credits achieved will be
dependent on the detailed architecture and
function.
Real and intermediate Safety Variables
are internally transmitted to the BPCS
application for control and display
Field transmitters may be optimised
Real time BPCS control functions
achieved using Safety Transmitter data
LOPA cre d its fo r p ro te ctio n fu n ctio n s,
imp le me n te d in th e DCS ap p licatio n
an d o p e ratin g in e ith e r a co mb in e d
co n tro l an d safe ty n o d e o r a se p arate
800xA n o d e , are e q u ivale n t to th o se
imp le me n te d in syste ms with to tally
d iffe re n t co n tro l an d safe ty syste ms
5
.
Th e ad d itio n al in te grity gain e d fro m
ru n n in g BPCS ap p licatio n s in th e
800xA HI co n tro lle r o u twe igh s th e
ad d itio n al risks fro m p o ssib le co m-
mo n mo d e failu re s.
To the oil and gas mar-
kets, System 800xA HI
offers a redundant archi-
tecture that can be inde-
pendently implemented at
the I/ O level and at the
operator level to add fault
tolerance.
Safe ty re late d p ro grams are co mp ile d
u sin g a limite d in stru ctio n se t co mp il-
e r ce rtifie d fo r 800xA HI safe ty p ro -
grams. Du rin g th e co mp ilin g p ro ce ss,
ad d itio n al co mp ile r te st su ite s an d
CRC e n su re th e in te grity o f th e co m-
p ile d safe ty p ro gram. Th e b lo ck e xe -
cu tio n o f th e ap p licatio n d u rin g ru n
time is ve rifie d fo r o rd e r, timin g an d
d iscre p an cy. In te rn al co mmu n icatio n s
b e twe e n p ro ce ssin g e le me n ts an d I/ O
are d u p licate d an d d o u b le ch e cke d
u sin g p ro ve n te ch n iq u e s to e n su re
th at all e rro n e o u s o r u n e xp e cte d me s-
sage s are ign o re d . Th e u se o f d ive rse
an d d issimilar h ard ware in th e I/ O
an d p ro ce sso rs, an d a TV ce rtifie d
Re al Time Op e ratin g Syste m (RTOS)
in th e safe ty mo d u le e n su re th at th e
Syste m 800xA HI me e ts th e in te grity
re q u ire me n ts o f IEC61511 o n all
co u n ts.
Highest possible reliability and
availability
Th e 800xA HI d e sign is in h e re n tly fail-
safe with n e ar 100 p e rce n t d iagn o stic
co ve rage e ve n as a simp le x ap p lica-
tio n (ABB claims 99.9 p e rce n t SFF an d
th e re are actu ally n o kn o wn d an ge r-
o u s u n d e te cte d failu re mo d e s in th e
syste m). Th is is ach ie ve d b y virtu e o f
an in itial h ard ware d e sign in te n d e d to
fu lly me e t th e re q u ire me n ts o f SIL3
(Fo u r SIL le ve ls are p o ssib le , with
SIL4 b e in g th e mo st d e p e n d ab le an d
SIL1 b e in g th e le ast)
9)
. Hard ware d i-
ve rsity in th e I/ O, lo cal CRC an d sh u t-
d o wn co n tro l to ge th e r with th e
u n iq u e p ro ce sso r/ safe ty mo d u le arch i-
te ctu re e limin ate s co mmo n mo d e
fau lts. No t o n ly th is b u t au d ite d Fail-
u re Mo d e an d Effe cts An alysis (FMEA)
an d failu re rate s p lace th e p ro d u ct
with in th e to p 6 p e rce n t o f th e SIL3
b an d . Au d ite d PFD figu re s are p u b -
lish e d an d b ase d o n a p ro o f te st in te r-
val o f e igh t ye ars.
Audited FMEA and failure
rates place ABBs 800xA
HI SIS within the top six
percent of the SIL3 band.
In th e o il an d gas marke ts safe ty lo gic
so lve r syste ms are e xp e cte d to (a) ru n
with o u t in te rru p tio n fo r at le ast fifte e n
ye ars an d (b ) e n d u re all so rts o f u p -
grad e s, mo d ificatio n an d ch an ge d u r-
in g th at time . Syste m 800xA HI o ffe rs
a re d u n d an t arch ite ctu re th at can b e
in d e p e n d e n tly imp le me n te d at th e I/ O
le ve l, th e p ro ce sso r le ve l an d at th e
o p e rato r wo rkp lace le ve l to ad d fau lt
to le ran ce an d h e n ce h igh availab ility
to an alre ad y h igh in te grity syste m
wh e re ve r it is re q u ire d . Th is re d u n -
d an t syste m can also u p grad e th e
syste m ap p licatio n safe ly o n lin e .
Th e d e b ate ab o u t grass ro o ts p rin ci-
p le s is se t to co n tin u e b u t h isto ry h as
sh o wn th at p ro gre ss is b e in g mad e b y
ch alle n gin g th e acce p te d vie w, ad -
d re ssin g th e p ro b le m fro m a d iffe re n t
d ire ctio n wh ilst co mp lyin g with th e
stan d ard s.
Roger W. Prew
ABB UK
roger.w.prew@gb.abb.com
Footnotes
8)
LOPA is a simplified risk assessment met hod for
evaluat ing t he risk of hazard scenarios and compar-
ing it wit h risk t olerance crit eria t o decide if exist ing
safeguards are adequat e, and whet her addit ional
safeguards are needed. ht t p:/ / www.primat ech.com/
info/ faq_layers_of_prot ect ion_analysis_(lopa).pdf
(January 2007)
9)
For a more comprehensive explanat ion of SIL, see
Safe inst rument s on pp 9699 of t his edit ion of
ABB Review Special Report .
Safety Application
800xA HI Safety
BPCS
Protection
Layer 1
Protection
Layer 2
SIL
Transmitters
BPCS Application
ABB is a global market leader in the area of paper machine drive systems.
The business model within the company is based on a centrally managed
but widely spread discipline. This model enables ABB to address the
specific needs of local markets and, at the same time, provide global
technological leadership. This in turn ensures the delivery of high quality
world class solutions to all customers with the same principal functionality
for control and safety.
Setting the stand ard
Global responsibility for quality and safety
Markku Haikola
ABB Review
93
ABB Review
F
o r man y ye ars ABB h as b e e n a
p io n e e r in th e d e ve lo p me n t o f
p ap e r mach in e (PM) d rive syste ms.
Th e h igh q u ality syste m so lu tio n s
d e live re d b y th e co mp an y h ave b e e n
ach ie ve d b y th e co n siste n cy an d
re p e atab ility o f th e wo rk. In o th e r
wo rd s, d e cad e s o f e xp e rie n ce an d
th o u san d s o f p ro je cts co mb in e d with
fin e ly-tu n e d o rgan izatio n al an d p e r-
so n n e l skills h ave e n ab le d th e d e ve l-
o p me n t o f te ch n o lo gical so lu tio n s th at
n o t o n ly me e t p ro ce ss re q u ire me n ts in
all p ap e r makin g p ro d u ctio n situ atio n s
b u t wh ich can also b e imp le me n te d
q u ickly an d e fficie n tly.
If the know-how contained
in the global application
standards is applied effec-
tively, on-site engineers are
able to ensure a high level
of engineering reuse of up
to 80 percent!
ABB drive syste ms can be found in
many machine s including p ulp drye rs,
p roduction machines for different p ap er
typ e s (with on- or off-line coating), the
faste st LWC winding machine s and the
most up -to-date sup e rcale nde rs for
p rinting p ap e rs and many othe rs. Eve n
though the ide a of e fficie nt re p e titive
work is not e asy to achie ve , ABB im-
p le me nts on time and to the highe st
quality, an ave rage of two PM drive
syste ms p e r we e k! So how doe s the
comp any do this? To be gin with, it is
to the custome rs and sup p lie rs advan-
tage to standardize and stabilize the
work as much as is re asonably p ossi-
ble for quick and smooth start-up s.
ABB has be e n able to do this be cause
of its PM Drives Network. The PM
Drive s Ne twork e ncomp asse s a unique
busine ss mode l and a se t of solution
standards that are the re sult of ye ars
of e xp e rie nce and e xp e rtise in p ap e r
machine drive solutions. Global ap p li-
cation standards constitute the bulk of
the ne twork and whe n the know-how
containe d in the se standards is ap p lie d
e ffe ctive ly, p rofe ssional local le ad e n-
gine e rs and le ad commissioning e ngi-
ne e rs on-site are able to e nsure a high
le ve l of e ngine e ring re use of the m up
to 80 p ercent! Standard features include
p rove n e le ctrical de sign for safe ty and
various safe ty re late d functions in the
syste m software . Engine e ring re use is
not the only factor. The quality of
ABBs PM drive s op e ration is backe d
up by cle arly de fine d domains of e x-
p e rtise . For e xamp le , local ABB e ngi-
ne e ring units are authorize d at diffe r-
e nt le ve ls to e xe cute p roje cts to the
highe st global ap p lication standards.
The se le ve ls are de te rmine d by the
e xp e cte d re p e atability of the p roje ct as
we ll as the e xp e rie nce of p roje ct e ngi-
ne e rs e ach p roje ct le ad e ngine e r is
usually ce rtifie d according to p e rsonal
e xp e rie nce . The authorize d units are
the n committe d to train and de ve lop
de dicate d PM drive e xp e rts to e ffi-
cie ntly manage the de taile d fe ature s of
the standards.
Standards for large, small and complex
systems
PM drive syste ms p rimarily take care of
p owe r transmission from the e le ctrical
motors. For a de licate p roce ss such as
p ap e r making, e ngine e rs must have
de taile d knowle dge of the se nsitive
control of me gawatt class motors as
we ll as an e xce lle nt unde rstanding of
the p roce ss characte ristics. The motors
are re gulate d by inve rte rs which are
the mse lve s highly sop histicate d de vic-
e s with many functions and fe ature s.
Providing a standard inve rte r solution
for a single unit is not that difficult, but
a standard for a coordinate d inve rte r
syste m solution (whe re te ns or e ve n
hundre ds of inve rte rs are involve d) is a
de manding task. In sp ite of the com-
p le xity, howe ve r, high p e rformance in-
All levels of the global Paper Machine (PM) drive programs are easily
monitored and accessed through standard interactive windows in the
programming tool
Standards include tens of preconfigured drive settings,
transferred automatically from a standard system
configuration chart
ABB Review
ve rte r solutions are include d in ABBs
global ap p lication standards.
Large n e w syste ms with th e late st
mach in e so lu tio n s, th e mo st ad van ce d
syste m co n tro ls, an d ge n e ral co mp le x
in te gratio n sch e me s are typ ical to o n ly
a fe w o f th e large st ABB d rive s p ro j-
e cts ye arly. In su ch case s th e e fficie n t
re u se le ve l can o n ly b e ce n trally
main tain e d . Ho we ve r, ABBs PM
Drive s Ne two rk, with d e fin e d stan -
d ard s an d ce rtificatio n e n su re s th at all
p ro je cts, n o matte r th e size o r co m-
p le xity, are su p p o rte d b y e xp e rie n ce d
p e rso n n e l at a lo cal le ve l. Op e ratin g
in th is way, ABB will always strive to
main tain th e h igh e st q u ality p o ssib le .
For small machine s and drive syste ms,
ABB has re ce ntly launche d the PMC800
basic drive . This syste m is base d on
the same functionality containe d in the
PMC800xA solution for high p e rfor-
mance machine s, but is configure d to
be use d with a wide r varie ty of avail-
able p roducts. Howe ve r more stringe nt
standards are re quire d if global solu-
tions, using a broade r se le ction of
comp one nts and functions, are to be
manage d e fficie ntly. The n, with just a
little le ss customization, clie nts will ge t
all the ne ce ssary functionality to fulfil
the ir op e rational de mands .
Safe solutions
The size of a p roject is irrelevant when
it comes to safety. Irresp ective of
whether it is a small scale revamp a
large new greenfield p roject, system
safety will not be comp romised by non-
standard engineering. Requirements and
standards regarding safety may vary
around the globe but the overall aim
amounts to the same thing. In this area,
the US, Europ e and many emerging
countries refer to the international IEC
safety standards. Having the know-how
to imp lement these and other local
standards in a p roject from scratch re-
quires extensive investment. However,
safety functionality is included in ABBs
PM Drive Network as a standard global
ap p lication solution, and is distributed
to local sp ecialists. This working model
is the safety assurance in ABB drive
deliveries. Additionally, the comp anys
global center of excellence for PM
drives sup p lies comp lete in terms of
safety and functionality fine-tuned
system software p ackages for demand-
ing machines, or machine p arts, such as
center winders, calenders, or for sp ecial
machine concep ts.
A global operation
Mo st p ap e r co mp an ie s o p e rate glo b al-
ly, an d o n a glo b al scale cu sto me rs
gain acce ss to th e same so lu tio n s an d
co n siste n t se rvice s. Th e se p ap e r co m-
p an ie s, like man y glo b al co mp an ie s,
d e p e n d to a large e xte n t o n th e avail-
ab ility o f kn o wle d ge ab le an d e xp e ri-
e n ce d lo cal su p p o rt. Ho we ve r th e re
will always b e time s wh e n wid e r se r-
vice re so u rce s are re q u ire d to so lve
p articu lar p ro b le ms. Re mo te co n n e c-
tivity is o n e o f th e mo st co mmo n ways
o f ge ttin g e xp e rt h e lp q u ickly an d e f-
fe ctive ly. Wh e th e r th e e xp e rt is o n site
o r re mo te ly co n n e cte d , a glo b al so lu -
tio n is e asie r to tro u b le sh o o t b e cau se
e n gin e e rs can q u ickly n avigate th e fa-
miliar system for any necessary changes.
With ABBs PM Drive
Network, customers are
offered high quality global
solutions with local system
service know-how,
thus giving them a real
competitive advantage.
Man y p ro ce ss an d mach in e ry su p p lie rs
also o p e rate o n a glo b al le ve l. Su p p li-
e rs n atu rally b e n e fit fro m a p ro ve n
so lu tio n ju st as mu ch as th e e n d u se r.
No wad ays, wo rkin g p ro ce sse s are
stan d ard ize d an d th e e xp e ctatio n s fo r
a smo o th an d p ro mp t start-u p are
h igh . To avo id an y u n fo re se e n an d
co stly d e lays, p ro ce ss su p p lie rs will
b e n e fit e n o rmo u sly b y b e in g in vo lve d
with th e syste m su p p lie rs in th e d e ve l-
o p me n t o f stan d ard s an d wo rkin g p ro -
ce sse s fo r p ro je cts. Th e se mu st th e n
b e mad e availab le to e ach an d e ve ry
p ro je ct irre sp e ctive o f wh e th e r th e y
are man age d lo cally o r glo b ally.
In the global p ap e r making busine ss,
it is ve ry imp ortant to me e t the same
re quire me nts in all p arts of the world.
Quick start up time s are crucial for all
custome rs and this can be achie ve d if
uniform standards and p roce sse s e xist,
e nsuring re p e atable and the re fore
p romp t work. It is also imp ortant for
custome rs to be able to e xchange e x-
p e rie nce s be twe e n mills and commu-
nication be come s e asie r if global stan-
dard solutions e xist. Not only this but
mainte nance me thods and sp e cial skills
for the diffe re nt mills or machine s can
also be unifie d.
With ABBs PM Drive Network, custom-
ers in any p art of the world are offered
high quality global solutions with local
system service know-how. In todays
business world, this gives ABBs cus-
tomers a real comp etitive advantage.
Markku Haikola
ABB Finland
markku.haikola@fi.abb.com
Over 250 Paper Machine (PM) drives specialists serve paper makers in ABBs PM drives network
Safe
instruments
Safe instruments for a safer process
Robert Martinez, Frank Fengler
The safety of a plant, its employees
and its surroundings depends on the
ability of the plant to shut down or
shift to a safe state should an abnor-
mality occur. A false trigger can lead
to a costly shutdown and unneces-
sary loss of production, whereas a
failure to trigger can possibily have
more far-reaching consequences. The
reliability and safety of a plant is
therefore dependent on the integrity
of its sensors.
Instruments are classified by their
Safety Integrity level (SIL). The SIL of
a device determines the applications
it is suitable for. In this article, ABB
Review discusses failure rates, how
they are quantified and how ABB
goes about assuring its instruments
fulfill the integrity levels that are
expected of them.
F
o r p ro ce ss in d u stry syste m b u ild e rs
an d o p e rato rs, a h azard is th e
re su lt o f a misb e h avin g p ro ce ss. Th e
safe ty in stru me n te d fu n ctio n (SIF)
mu st act to b rin g th e p ro ce ss to a safe
state . As th e n ame imp lie s, a SIF co n -
sists o f a ch ain o f in stru me n ts to d e -
te ct th is h azard o u s co n d itio n , man ip u -
late th e in p u t d ata in a p ro -
grammab le d e vice (th e CPU)
an d th e n se n d a co mman d to
th e o u tp u t in stru me n ts. Th e se
o u tp u t d e vice s are also kn o wn
as actu ato rs b e cau se th e y
act to b rin g th e p ro ce ss u n d e r
safe co n tro l o r to sh u t it d o wn
co mp le te ly. A sch e matic o f a
SIF lo o p is sh o wn in
1
.
The main challenge for p rocess
safety engineers is to identify
all the p ossible hazards related
to that p rocess and then to
quantify the imp act each of
these would have on the p lant sur-
roundings. When this risk level is
known, the p rocess safety engineer can
choose SIF instruments with a matching
Safety Integrity Level (SIL). The SIL lev-
el of the entire chain of instruments is
always that of the lowest SIL comp o-
nent ie, the weakest link in the chain.
Th e IEC 61511 stan d ard p ro vid e s p ro -
ce ss e n gin e e rs strict gu id an ce fo r th is
task, b u t also p u ts re sp o n sib ility o n
man age me n t, p ro ce ss o p e rato rs an d
p e o p le in o th e r p ro je ct life cycle p h as-
e s to e n su re th at th e p ro ce ss is ad e -
q u ate ly p ro te cte d . Th is life cycle ap -
p ro ach is so su cce ssfu l th at it h as b e -
co me th e p re fe rre d mo d e l
fo r o th e r d raft in te rn atio n al
stan d ard s fo r mach in e ry, n u -
cle ar an d e ve n fo r se cu rity.
Th e classificatio n o f safe ty
in stru me n ts b y SIL le ve l is
itse lf an e n o rmo u s ach ie ve -
me n t fo r in d u stry. Bo rn in
th e afte rmath o f th e tragic
ch e mical p lan t accid e n t at
Se ve so , Italy in 1976, th is in -
te rn atio n al stan d ard allo ws
e n gin e e rs to fo cu s o n th e
p ro ce ss h azard s, co n fid e n t
th at th e ir safe ty in stru me n ts
1
Schematic SIF loop structure
Input interfaces
(for example, A- D
converters)
Communications
Output interfaces
(for example, A- D
converters)
Input devices
(for example, sensors)
Output devices/ final elements
(for example, actuators)
Programmable
electronics (PE)
ABB Review
ABB Review
to th e e n d -cu sto me r to main tain it in
th e fie ld . Th e PFD calcu latio n is:
PFD = / 2
wh e re :
: n u mb e r o f d an ge ro u s, u n d e te cte d
failu re s p e r h o u r
: te stin g in te rval in h o u rs
A lo we r can b e ach ie ve d in o n e o f
th re e ways:
Re -d e sign o f critical p arts
In cre ase d d e te ctio n cap ab ility
In cre ase d h ard ware re d u n d an cy
Th e FMEA d o cu me n t p ro vid e s valu -
ab le in p u t to th e first ap p ro ach : re -d e -
sign fo r gre ate r in te grity. Fo r ABBs
2600T p re ssu re tran smitte r
2
, so me o f
th e ke y p o in ts we re ; CPU an d clo ck
in te grity, p o we r su p p ly mo n ito rin g,
an alo g o u tp u t stage in te grity an d so ft-
ware se q u e n ce s. An alysis also re -
ve ale d th at co u ld b e re d u ce d b y
u sin g an all-we ld e d d e sign in a critical
are a o f th e d e vice .
Th e se co n d ap p ro ach to re d u cin g
me an s ad d in g e xtra circu itry an d so ft-
ware e n ab lin g th e d e vice to d e te ct a
gre ate r n u mb e r o f d an ge ro u s in te rn al
failu re s an d alarm th e syste m acco rd -
in gly. Th is ap p ro ach in cre ase s th e
Safe Failu re Fractio n (SFF) o f th e d e -
vice , b u t at th e co st o f e xtra h ard ware
an d co d e d e ve lo p me n t. Th e SFF ratin g
o f a d e vice affe cts th e allo wab le arch i-
te ctu re if IEC 61511 o r ISA-S84 is b e -
in g u se d as th e d e sign stan d ard . An
SFF ratin g o f 90 p e rce n t o r gre ate r is
n e e d e d to u se a sin gle tran smitte r in a
SIL2 ap p licatio n , fo r e xamp le , as
sh o wn in
3
.
Th e th ird ap p ro ach in vo lve s d u p licat-
in g critical e le me n ts to ach ie ve gre ate r
Hard ware Fau lt To le ran ce (HFT). In
ABBs SIL p re ssu re tran smitte r, fo r e x-
amp le , a d iffe re n tial in d u ctive se n so r
p ro vid e s two in d e p e n d e n t sign als p ro -
p o rtio n al to in p u t p re ssu re an d a d u al
arch ite ctu re p ro ce sse s th e se sign als
in d e p e n d e n tly.
In
3
, th e co lu mn s n u mb e re d 0,1,2
re fe r to th e n u mb e r o f simu ltan e o u s
h ard ware fau lts wh ich th e d e vice can
to le rate . In cre asin g re d u n d an cy cle arly
h as a b e n e ficial e ffe ct o n SIL b u t at
th e co st o f so me d u p licate d h ard ware .
Th e stan d ard h as a lo o p h o le wh ich
allo ws su p p lie rs to claim a h igh e r HFT
if th e d e vice is p ro ve n -in -u se . Pro v-
e n in -u se imp o se s a sign ifican t b u r-
d e n o n th e su p p lie r wh o o fte n d o e s
n o t h ave acce ss to h igh -q u ality, lo n g-
te rm h isto rical d ata sh o win g d e vice
failu re s. With o u t su ch d ata, it is re c-
o mme n d e d th at safe ty tran smitte rs, fo r
e xamp le , h ave a HFT valu e o f 1.
It is p articularly imp ortant that software
failures be included in this SFF analysis.
As software in instrumentation gets
more and more comp lex, field failures
due to systemic software errors are in-
creasing. Therefore, any assessment of a
device must include the p otential soft-
ware failures and/ or have reliable soft-
ware diagnostics built-in to the device.
Understanding MTBF
Me an Time Be twe e n Failu re s (MTBF)
is d e fin e d as th e in ve rse o f th e Safe
Failu re Rate . Th e d ata is n o rmally
p re se n te d in te rms o f FITs, failu re s-
in time . Typ ical FIT d ata is e xp re sse d
in 10
-9
, o r th e n u mb e r o f failu re s p e r
o n e b illio n h o u rs u sage .
MTBF = 1/ (fo r 1o o 1 arch ite ctu re
1)
)
The re is ofte n a trade -off be twe e n SFF
and MTBF. For instance , one transmit-
te r on the marke t has a SFF of 96.7
p e rce nt and an rating of 963, while
anothe r has sp e cifications of 70 p e r-
ce nt and 490. The first achie ve s the 90
2
PFD failure rates
SIL PFD
1 0.1 < PFD <= 0.01
2 0,01 < PFD <= 0.001
3 0.001 < PFD <= 0.0001
4 0.0001 < PFD <= 0.00001
3
Safe failure fraction ratings versus SIL
SFF 0 1 2
< 60% SIL1 SIL2
6090% SIL1 SIL2 SIL3
9099% SIL2 SIL3 SIL4
> 99% SIL3 SIL4 SIL4
will p e rfo rm at th e re q u ire d le ve l.
Th is se p aratio n o f fu n ctio n s is mo re
th an ju st a p ractical co n ve n ie n ce ; it
carrie s le gal o b ligatio n s fo r b o th th e
syste m b u ild e r o r o p e rato r an d th e
safe ty in stru me n t su p p lie r.
To make th is re gime wo rk in p ractice ,
safe ty in stru me n t su p p lie rs to d ay mu st
fo llo w th e ru le s in th e siste r IEC
stan d ard #61508 Fu n ctio n al safe ty o f
e le ctrical/ e le ctro n ic/ p ro grammab le
e le ctro n ic safe ty-re late d syste ms an d
ach ie ve th e d e sire d SIL ce rtificatio n
fo r th e ir p ro d u cts.
Sister standards for safety
ABB is in th e in te re stin g p o sitio n o f
b e in g b o th an in stru me n t su p p lie r (e g,
safe ty p re ssu re tran smitte rs) an d a
syste m b u ild e r (e g, safe ty an d au to -
matio n fo r o il an d gas p ro je cts). Th o r-
o u gh kn o wle d ge o f th e ap p licatio n o f
th e IEC safe ty stan d ard s is cru cial in
main tain in g th e co mp an ys p o sitio n as
a safe ty le ad e r.
Th e IEC stan d ard s fo r th e se two d if-
fe re n t le ve ls o f su p p ly are su rp risin gly
similar an d can b e mu tu ally u n d e r-
sto o d b y a simp le ch an ge o f te rms:
Fo r safe ty in stru me n t e n gin e e rs th e
h azard co me s fro m with in th e co m-
p o n e n t itse lf in th e fo rm o f d e vice
failu re .
Th e p ro ce ss e n gin e e r p e rfo rms a
h azard an alysis wh e re as th e in stru -
me n t e n gin e e r p e rfo rms an FMEA
(Failu re Mo d e an d Effe ct An alysis).
Fo r safe ty in stru me n t e n gin e e rs it is
th e imp act o f a d an ge ro u s e ve n t o n
th e safe o u tp u t o f th e d e vice wh ich
mu st b e asse sse d .
En gin e e rs in b o th d iscip lin e s mu st
q u an tify th e like lih o o d o f th e ir re sp e c-
tive d an ge ro u s e ve n ts. Th e in stru me n t
e n gin e e rs calcu latio n s re su lt in a PFD
(Pro b ab ility o f Failu re o n De man d ).
Th e PFD valu e can b e d ire ctly map p e d
to a SIL le ve l acco rd in g to
2
. Fo r e x-
amp le , a SIL2 d e vice mu st fail le ss
th an o n ce o u t o f e ve ry 100 d e man d s.
Understanding failure rates
Th e simp le PFD valu e is a p o we rfu l
n u mb e r; n o t o n ly d o e s it d e te rmin e
th e marke t fo r th e d e vice b y virtu e o f
its SIL ce rtificatio n , b u t it also d e te r-
min e s th e co mp le xity an d h e n ce p rice
o f th e in stru me n t as we ll as th e co st
Safe instruments
Footnote
1)
1oo1 is explained lat er on in t he art icle.
ABB Review
p e rce nt SFF crite ria for single de vice
usage in SIL 2 ap p lications but has an
MTBF that is half of the se cond de vice .
What the use r ne e ds to unde rstand is
that safe ty transmitte rs are de signe d to
have a ve ry high re liability in te rms of
the ir main function but may be le ss
re liable from a p ure MTBF p e rsp e ctive .
A good rule of thumb for a safe ty
transmitte r, the re fore , is to sp e cify a
minimum of a 100-ye ar MTBF value .
Proof testing to maintain integrity in
operation
Th e se co n d te rm in th e PFD calcu la-
tio n , , re p re se n ts th e h o u rs b e twe e n
man d ato ry p ro o f-te stin g o f th e d e vice
wh e n in o p e ratio n . Th is is a lu xu ry fo r
d e vice su p p lie rs sin ce fre q u e n t te stin g
h as a b e n e ficial e ffe ct o n SIL. Op e ra-
to rs, h o we ve r, mu st b e ar th e b u rd e n
o f p ro o f-te stin g e ve ry su ch d e vice as
o fte n as se ve ral time s a ye ar a p art
o f th e life time o p e ratin g co st th at will
n o t go u n n o tice d at p u rch asin g time .
As a general rule, actuators such as so-
lenoid-op erated valves rep resent at
least 50 p ercent of the dangerous unde-
tected failures of the entire SIF loop .
The sensor accounts for ap p roximately
30 to 40 p ercent and the remainder is
attributed to the CPU and I/ O boards,
collectively known as the logic solver.
Th e re se arch an d d e ve lo p me n t e ffo rt
in ve ste d to ach ie ve th e lo we r failu re
rate s in ABB SIL in stru me n tatio n is
wo rth th e e ffo rt. Th e typ ically h igh
failu re rate s o f actu ato rs is an o p p o rtu -
n ity fo r se n so r an d lo gic-so lve r su p p li-
e rs su ch as ABB to re d u ce th e ir p ro d -
u cts PFD valu e s so th at th e SIL o f th e
e n tire safe ty lo o p can b e p re se rve d .
Lo we r PFD valu e s tran slate in to lo we r
co sts an d simp lifie d e n gin e e rin g fo r
e n d cu sto me rs b e cau se th e y will n o t
n e e d to b o o st SIL b y sp e cifyin g re d u n -
d an t tran smitte rs o r b y ch o o sin g mo re
e xp e n sive actu ato r valve s.
Au to matio n ve n d o rs h ave o n ly re ce n t-
ly starte d to e xp lo it fie ld b u s-b ase d
d iagn o stic cap ab ilitie s to o ffe r o n -lin e
p ro o f-te stin g. Su ch a te ch n iq u e e limi-
n ate s fie ld visits an d will mayb e o n e
d ay e ve n b e fu lly au to mate d . Th e
ABB Co rp o rate Re se arch Ce n te r in
No rway h as in ve stigate d th is te ch -
n iq u e fo r th e p ro o f-te stin g o f actu a-
to rs su ch as valve s b y e xe cu tin g a
p artial-stro ke o n ly, allo win g p ro d u c-
tio n to co n tin u e u n in te rru p te d . Fie ld -
b u s d iagn o stics carry stro ke te st d ata
to th e lo gic so lve r wh e re p o te n tially
d an ge ro u s failu re s can b e d e te cte d . In
th is way, th e y d e cre ase th e d e vice s
an d allo w o p e rato rs to wait lo n ge r b e -
twe e n man d ato ry fu ll sh u t-d o wn s fo r
valve te stin g. Th e re se arch ce n te r is
also in ve stigatin g th e u se o f n e w safe -
ty varian ts o f Pro fib u s an d Fie ld b u s
Fo u n d atio n to co mp le te th e p ictu re
fo r ro b u st safe ty asse t man age me n t.
Safety Instrument Portfolio
ABB sup p lies a range of safety p ressure
transmitters that use a variety of sens-
ing methods. ABB also offers a range
of temp erature sensors, p ositioners and
a flowmeter all classified to SIL2. The
AC800M-HI High Integrity SIL2 Safety
Controller and its associated safety I/ O
round off the comp anys safety p ortfo-
lio. These SIL classifications are award-
ed after assessment by accredited third-
p arty comp anies
4
, an effort which re-
quires ABB to p rovide thorough docu-
mentary p roof of comp liance.
Th e 2600T-Se rie s p re ssu re tran smitte r
5
h as mo d e ls ce rtifie d to SIL2. 37
h ave re ce n tly b e e n so ld to Stato il in
No rway. Oth e r cu sto me rs o f ABB SIL
in stru me n tatio n in clu d e Tracte b e l Gas
En gin e e rin g Gmb H (TGE), wh o h ave
p articu lar e xp e rtise in th e are as o f
sto rage , co n d itio n in g an d sh ip p in g o f
liq u e fie d gase s (LNG an d LPG) an d
p e tro ch e mical gase s.
A tool for optimizing safety design
Th e co mp le xity o f trad e -o ffs in vo lve d
in safe ty in stru me n t d e sign is mu lti-
p lie d wh e n an e n tire SIF is co n figu re d .
Th e se can b e in ve stigate d an d visu al-
ize d in th e ABB TRAC to o ls Trip Re -
q u ire me n t an d Availab ility Calcu lato r.
Th is was d e ve lo p e d b y Jo h n Hu n t an d
Ian Brad b y o f ABB En gin e e rin g Se rvic-
e s in th e U.K. TRAC is a PC-b ase d
so ftware to o l u se d to assist safe ty,
p ro je ct an d main te n an ce e n gin e e rs in
d e te rmin in g th e o p timu m d e sign co n -
figu ratio n an d p e rio d ic te st in te rvals
fo r safe ty in stru me n te d fu n ctio n s.
TRAC is u se d b y ABB e n gin e e rin g
co n su ltan ts an d h as also b e e n lice n se d
fo r u se b y e n d -cu sto me rs wo rld wid e .
Th e TRAC to o l p ro vid e s th e e n gin e e r
with a syste matic an d co n siste n t ap -
p ro ach to calcu latin g th e re q u ire d SIL
u sin g e ith e r Risk Grap h o r LOPA
(Laye r o f Pro te ctio n An alysis). TRAC is
p re -lo ad e d with b o th fie ld re liab ility
d ata an d th e man u factu re rs re liab ility
d ata, in clu d in g d ata fo r man y o f ABBs
safe ty in stru me n ts. All calcu latio n s
d iscu sse d so far in th is article are
u se d with in TRAC, p e rmittin g th e u se r
to fo cu s o n th e d e sign task.
Finding the optimum configuration
On e o f th e main b e n e fits o f TRAC is
allo win g p ro je ct e n gin e e rs to in ve sti-
gate vario u s re d u n d an cy sch e me s.
So me stan d ard s p re scrib e th e u se o f
re d u n d an cy as th e cu re fo r syste m re li-
ab ility, b u t d o n o t e xp lain th e q u an ti-
tative an alysis th is re d u n d an cy is
b ase d u p o n . Risk an alysis is b ase d o n
p ro b ab ility th e o ry an d can b e d e rive d
5
ABBs 2600T pressure transmitter is
certified to SIL2
4
ABBs 800xA HI safety system is certified
to the IEC 61508 and IEC 61511
safety standards
6
Simplified PFD formulae for redundancy
Architecture PFD
1001 / 2
1002
2

2
/ 3
2002 / 2
2003
2

2

Safe instruments
ABB Review
fro m se ve ral me th o d s. All me th o d s
re ly o n ce rtain ke y e le me n ts in o rd e r
to p ro vid e o b je ctive an alysis failu re
rate s, failu re mo d e s, d iagn o stic co ve r-
age an d co mmo n cau se d ata. Th e mo st
co mmo n arch ite ctu re s u se d in th e p ro -
ce ss in d u strie s are th e fo llo win g:
1oo1 One-out-of-One
Wh e n u sin g a sin gle d e vice , th e
safe ty is affe cte d b y th e d an ge ro u s
failu re s, th e re liab ility b y th e safe
failu re s.
1oo2 One-out-of-Two
With 1o o 2 vo tin g, if e ith e r tran smit-
te r fails, th e n th e p ro ce ss is trip p e d .
Th is in cre ase s safe ty (ve rsu s 1o o 1)
at th e e xp e n se o f re liab ility.
2oo2 Two-out-of-Two
With 2o o 2 vo tin g, b o th se n so rs
n e e d to fail in o rd e r to trip th e sys-
te m. Th is in cre ase s re liab ility at th e
e xp e n se o f safe ty.
2oo3 Two-out-of-Three
Th is arch ite ctu re is ve ry co mmo n in
th e p ro ce ss in d u strie s sin ce yo u
h ave ve ry go o d safe ty an d re liab ility,
b u t at th e e xp e n se o f ad d e d co st.
A set of simp lified equations has been
develop ed to p rovide a quick risk anal-
ysis based on a few key p arameters of
the device in question the safe failure
rate, and dangerous undetected failure
rate. The analysis typ ically will assume
the same MTTR (mean time to rep air)
and TI (test interval) values. The equa-
tions used are shown in
6
.
Th e go o d n e ws is th at th e d ata re -
q u ire d fo r th e calcu latio n s sh o wn
ab o ve is n o w p u b lish e d b y mo st majo r
ve n d o rs an d h as b e e n in clu d e d in th e
TRAC so ftware p ackage . Th is allo ws
th e u se r to p e rfo rm wh at-if an alysis, as
sh o wn in
7
, to assist se le ctio n o f vari-
o u s ve n d o rs an d / o r arch ite ctu re s.
Finding the optimum proof test interval
The tool rep resents one ap p roach to
calculating SIF p roof-test intervals. By
focusing on the relevance of the system
and consequence of failure on demand,
the tool p rovides a range of test inter-
vals. In many cases, this is likely to
p ermit an extension to existing inter-
vals. Where an integrity level is not de-
fined, test intervals may be justifiably
extended to align with the convenience
of a p lant shutdown or other insp ection
criteria such as electrical integrity or
simp ly just rep air on breakdown. TRAC
p rovides multip le solutions for testing
inp uts and outp uts within the bounds
of the required maximum and mini-
mum allowable p robability of failure on
demand. For each sp an of test intervals,
the cost of testing is calculated from
known annual testing costs. Results are
disp layed grap hically and a comp re-
hensive rep ort is issued in a fully trace-
able format
8
.
Robert Martinez
Billingtsad, Norway
Frank Fengler
ABB Automation Products GmbH
Minden, Germany
frank.fengler@de.abb.com
References
[1] IEC 61508 Funct ional safet y of programmable
elect ronic safet y- relat ed syst ems
[2] IEC 61511 Funct ional safet y Safet y inst rument -
ed syst ems for t he process indust ry sect or
[3] ISA Aut omat ion West 2004, Select ion of Safet y
Transmit t ers in SIS applicat ions, Michael Cush-
ing , ABB Pressure Product s
[4] Safet y Solut ions and Safe Net works Highlight
Hannover Fair, ARC Insight s, 28.04.2005
7
TRAC tool for safety function configuration
ABB Review Special Report
Automation Systems
March 2007
Editorial Council
Veli- Matti Reinikkala
Process Automation Division Head
Member of the Executive Committee
ABB Ltd.
Scott Spencer
Group Vice President
Head of Process Automation Marketing
Nils Leffler
Chief Editor
nils.leffler@ch.abb.com
Publishers office
ABB Schweiz AG
Corporate Research
ABB Review / REV
CH- 5405 Baden- Dttwil
Switzerland
Partial reprints or reproductions are per-
mitted subject to full acknowledgement.
Complete reprints require the publishers
written consent.
Publisher and copyright 2007
ABB Ltd. Zurich / Switzerland
Printers
Vorarlberger Verlagsanstalt GmbH
AT- 6850 Dornbirn / Austria
Layout
DAVILLA Werbeagentur GmbH
AT- 6900 Bregenz / Austria
Disclaimer
The information contained herein reflects
the views of the authors and is for infor-
mational purposes only. Readers should
not act upon the information contained
herein without seeking professional advice.
We make publications available with the
understanding that the authors are not
rendering technical or other professional
advice or opinions on specific facts or
matters and assume no liability whatsoever
in connection with their use. The com-
panies of the ABB Group do not make
any warranty or guarantee, or promise,
expressed or implied, concerning the con-
tent or accuracy of the views expressed
herein.
ISSN: 1013- 3119
8
TRAC tool for proof- test interval optimiza-
tion
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lor details, visit us at www.abb.co/controlsystes
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In stru me n tatio n sys-

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