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3BSE062589

ABB / PA / Control Systems


May 12, 2014 | Slide 1


Electrical Integration with System 800xA

Integrated Process and Power Automation
3BSE062589

ABB Group
May 12, 2014 | Slide 2

Outline
What is Electrical Integration?
ABBs solution: Integrated Process and Power Automation
Customer benefits
References

3BSE062589

ABB Group
May 12, 2014 | Slide 3

Outline
What is Electrical Integration?
ABBs solution: Integrated Process and Power Automation
Customer benefits
References
3BSE062589

ABB / PA / Control Systems
May 12, 2014 | Slide 4
What is Electrical Integration?
A hot topic Larry OBrien, ARC
3BSE062589

ABB Group
May 12, 2014 | Slide 5

What is Electrical Integration?

Electrical Integration is the integration of Process
Automation and Power Automation into one system


Process Instrumentation
Measurement and
control of pressure,
temperature, flow
Process Electrification
Monitoring and control
of motors, pumps,
fans

Substation Automation
Protection, monitoring
and control of
generators,
transformers,
switchgear
Power Management
Advanced control of
power distribution
Process Automation Power Automation
3BSE062589

ABB Group
May 12, 2014 | Slide 6

What is Electrical Integration?
Users of Electrical Integration
Power Generation
Power Consumption
Power
transmission
and distribution
Power Plants
Generate Power
Process Plants
Consume Power
3BSE062589

ABB Group
May 12, 2014 | Slide 7

What is Electrical Integration?
Objectives of Electrical Integration
Power Generation
Power
transmission
and distribution
Power Consumption
Power Plants value
optimized utilization of
generating capacity
Reduce auxiliary
systems energy
consumption

Oil & Gas want to
maximize production
P&P / M&M want to
manage electricity
usage
3BSE062589

ABB Group
May 12, 2014 | Slide 8

Electrical Integration
Traditional approach

Many protocols,
lack of global
standard
Separate system
for power
automation
Organizational
barriers among
process and power
department
Device specific
solutions for
integration into DCS
A lot of hardwiring
needed
Lack of information
from electrical
devices
3BSE062589

ABB Group
May 12, 2014 | Slide 9

Outline
What is Electrical Integration?
ABBs solution: Integrated Process and Power Automation
Full Plant Integration with System 800xA
Electrical Integration Based on Open Standards
Complete Portfolio from ABB
Customer benefits
References
3BSE062589

ABB Group
May 12, 2014 | Slide 10

Electrical Integration
Traditional approach


3BSE062589

ABB Group
May 12, 2014 | Slide 11

Integrated Process and Power Automation
Electrical Integration with System 800xA

Electrical
Integration
Based on Open
Standards
Full Plant
Integration with
System 800xA
Complete Portfolio
from ABB
3BSE062589

ABB Group
May 12, 2014 | Slide 12

Integrated Process and Power automation
Full Plant Integration with System 800xA

Common
information
management
Centralized
Historian and
Data Archiving
Common asset
management
Common
system
architecture
Common engineering
Common
operations
3BSE062589

ABB Group
May 12, 2014 | Slide 13

Integrated Process and Power Automation
Electrical Integration Based on Open Standards
System 800xA fully supports open standards for both
Process and Power Automation
Power Automation
IEC 61850
Process Electrification
Profibus / Profinet
Modbus / Modbus TCP
DeviceNet
Process Instrumentation
Foundation Fieldbus
Hart / WirelessHART
Profibus

3BSE062589

ABB Group
May 12, 2014 | Slide 14

Integrated Process and Power Automation
Electrical Integration Based on Open Standards

IEC 61850
IEC 61850 is a global standard for the design of
substation automation systems
Benefits
Provides interoperability between Protection & Control
IEDs (Intelligent Electronic Devices)
Open and flexible standard for future extensions
Future proof by choice of Ethernet based communication
for cost effective, fast and reliable data transmission
Endorsed by IEC and ANSI
3BSE062589

ABB Group
May 12, 2014 | Slide 15

Integrated Process and Power Automation
Complete Portfolio from ABB
Main Electrical
Contractor
Main Automation
Contractor
Integrated Process and Power Automation
Control
Systems
LV
Power
Distri-
bution
Intelli-
gent
Switch-
gears
Drives Motors
Safety
Systems
Telecom
Systems
Intelli-
gent
Field
Instru-
ments
Analyzers
Expertise and
Consulting services
Consulting
Services
HV/MV
Power
Distri-
bution
Bridging two worlds together with Electrical Integration
3BSE062589

ABB / PA / Control Systems
May 12, 2014 | Slide 16

ABB Group
May 12, 2014 | Slide 16
Integrated Process and Power Automation
Complete Portfolio from ABB
DCS
ABB is market leader in DCS with System 800xA, a
complete DCS intended for all types of industrial
automation
Substation Automation integration
ABB is market leader in products for substation and
distribution automation including native IEC 61850
Protection and Control IEDs
Process Electrification integration
ABB is market leader in products for process
electrification including low voltage switchgear, variable
speed drives and motor controllers
Project Execution and Services
ABB has experienced project execution capabilities within
power and automation for all industries, as well as a wide
range of product services for operations and maintenance
3BSE062589

ABB Group
May 12, 2014 | Slide 17

Outline
What is Electrical Integration?
ABBs solution: Integrated Process and Power Automation
Customer benefits
Benefits of Integration
Reduced Investment Costs
Improved Operator Effectiveness
Reduced Maintenance Costs
Increased Plant Availability
Reduced Energy Cost
References
3BSE062589

ABB / PA / Control Systems
May 12, 2014 | Slide 18
Benefits of Integration
Enable the power engineer
The Past - Expensive substation to DCS
interlock schemes
Hard-wired signals
Complex software gateways
Extra logic required when using
ModBus
Modbus is slow! 5 sec feedback!
The Present - Cost effective substation
to DCS interlock schemes
Less hard-wired signals; Ethernet
backbone instead
IEC 61850 broadcast messages
eliminate extra logic needed when
using ModBus

Relay A
Relay B
Direct Trip
Command
Shell Gumusut
Non-ABB DCS
ABB PMS
20 sec delay via OPC
Now hard-wired
3BSE062589

ABB / PA / Control Systems
May 12, 2014 | Slide 19
Benefits of Integration
Enable the power engineer (contd)
Better HMI than a typical SCADA
Online parameterization of IED logic
Modify protection schemes from
remote operations center
Enhanced Auto Transfer Systems
control
Online parameterization of Auto
Transfer logic
Immediate visibility on any bus
transfer or event
Alarming on events
Email & text message notification

Relay A
Relay B
Direct Trip
Command

3BSE062589

ABB Group
May 12, 2014 | Slide 20

Customer Benefits
Reduced Investment Cost

3BSE062589

ABB Group
May 12, 2014 | Slide 21

Customer Benefits
Reduced Investment Cost

Reduced system footprint with one integrated system
Reduced wiring with Ethernet based solutions
Shortened project execution and commissioning time by using
standardized control logic, libraries and testing
Reduced project risk by choosing ABB with complete portfolio,
expertise and experience in both power and automation
3BSE062589

ABB Group
May 12, 2014 | Slide 22

Customer Benefits
Improved Operator Effectiveness

Power group Process group
3BSE062589

ABB Group
May 12, 2014 | Slide 23

Customer Benefits
Improved Operator Effectiveness

Process Operator Power Operator
Same operator interface for process and power group
enables collaboration
Consistent operating philosophy reduces risk of errors
Common access point for both process and power
data provides faster error analysis
3BSE062589

ABB Group
May 12, 2014 | Slide 24

Adoption
High
High
Med
Medium
Low
Low
Value
Turbines
Compressors
Fans
Blowers
Mechanical
Equipment
Electrical
Equipment
Control
Valves
Centrifugal
Pumps
Field
Devices
Customer Benefits
Reduced Maintenance Costs

Extending Asset
Management into
electrical equipment
*Survey completed by ARC Advisory Group
Typical Asset
Management areas*
3BSE062589

ABB / PA / Control Systems
May 12, 2014 | Slide 25
Customer Benefits Reduced Maintenance Costs
Single strategy for asset management
Not just for smart instruments
Single view for all critical process and electric plant assets
Visibility
Common user environment for operations & maintenance
Troubleshoot problems more quickly
Relevant actionable data to prevent plant upsets and predict
equipment failure
CMMS Integration
Streamline maintenance activities up to 25% by reducing
paperwork and administration effort
Maintain only one interface to CMMS
Maintenance planning more efficient
Single source for maintenance analysis
Spend less time planning and more time doing

Process based
Asset Monitors
Instrumentation
Rotating equipment
Vibration
DCS controller
health
IT assets
Heat exchangers
Control loops
Electrical equipment
Asset Monitors
Transformers
LV circuit breakers
UMC 22 motor
starters
MNS iS LV
switchgear
Motors
Drives
Protective relays
(IEDs)
3BSE062589

ABB Group
May 12, 2014 | Slide 26

Customer Benefits
Reduced Maintenance Costs

3BSE062589

ABB Group
May 12, 2014 | Slide 27

Customer Benefits
Reduced Maintenance Costs

Process
Instrumentation
Substation
Equipment
Process
Electrification
Equipment
Common user environment for operations
and maintenance
Relevant actionable provided to the right
person including operators, engineers, and
maintenance personnel at the right time
Troubleshoot problems more quickly
3BSE062589

ABB Group
May 12, 2014 | Slide 28

Customer Benefits
Reduced Maintenance Costs

Reveal previously hidden critical plant
equipment status
Electrical device health information is lost
with legacy system integration methods
With IEC 61850 and open fieldbus
standards, the hidden critical plant
electrical equipment health is now revealed
3BSE062589

ABB Group
May 12, 2014 | Slide 29

Customer Benefits
Reduced Maintenance Costs

Maintain only one interface to CMMS
Maintenance planning more efficient
Single source for maintenance analysis
3BSE062589

ABB Group
May 12, 2014 | Slide 30

Customer Benefits
Increased Plant Availability

3BSE062589

ABB Group
May 12, 2014 | Slide 31

Customer Benefits
Increased Plant Availability
System 800xA is widely used as integrated or
standalone Power Management System
Power Management Systems are used for
industrial plants with:
In-plant generation
Critical Loads
Insufficient reliability of grid supply
Typical Power Management functionality:
Fast load shedding
Ensure at any time the availability of
electrical power to all critical loads in the
plant
Switching off non-essential loads in case
of a shortage of power in the plant
Typical response time: < 100 ms
3BSE062589

ABB Group
May 12, 2014 | Slide 32


ABB Group
May 12, 2014 | Slide 32
Customer Benefits
Increased Plant Availability
2.2 1.8 1.8 2.1
3.3
2.
50.1
1.5
7.2
5.7
MW MW MW MW
MW
MW
MW
Hz
kV
Generator trip
3BSE062589

ABB Group
May 12, 2014 | Slide 33


ABB Group
May 12, 2014 | Slide 33
Customer Benefits
Increased Plant Availability
0.0 1.8 1.8 2.1
3.3
2.
50.1
1.5
4.8
3.9
MW MW MW MW
MW
MW
MW
Hz
kV
Fast load shedding
Avoidance of black-outs with System 800xA
based Power Management Systems
Faster load shedding than hardwired with IEC
61850 high speed protocol
Quality monitored load shedding signals
Reconfiguration without rewiring
3BSE062589
Customer Benefits
Reducing Energy Costs
Improving visibility into power consumption
Understand and easily access power usage information
Explore energy saving opportunities
Enhance existing energy usage reduction program
Track and trend power consumption
An increase in power consumption can indicate
equipment malfunction and wear
Integrate equipment and systems to make energy
efficient decisions
Centralized control of power consumption
Plant personnel will have complete visibility and
control of a situation regardless of where a problem
originated (i.e. an electrical glitch, process control
problem, or a failing IT asset)
3BSE062589
Customer Benefits
Motivation for Reducing Energy Usage
Issues
7 15% of energy does not leave the fence
Increase in operating costs
Plant net and gross heat rates gradually deteriorate
CO
2
emission costs
Cap and trade in US and Canada
$15 to 30/ton of CO
2
?- emissions are no longer going
to be free
Defacto moratorium on new coal plant
construction?
Need to increase output of existing plants
Need to extend lifetime of existing plants
3BSE062589

ABB Group
May 12, 2014 | Slide 36

Integrated Process and Power Automation
Electrical Integration with System 800xA

Electrical
Integration
Based on Open
Standards
Full Plant
Integration with
System 800xA
Reduced Investment Costs
Improved Operator Effectiveness
Reduced Maintenance Costs
Increased Plant Availability
Reduced Energy Costs
3BSE062589

ABB Group
May 12, 2014 | Slide 37

Outline
What is Electrical Integration?
ABBs solution: Integrated Process and Power Automation
Customer benefits
References

3BSE062589

ABB Group
May 12, 2014 | Slide 38

Integrated Process and Power Automation
References

Global Installations across all Industries
Oil, Gas, Petrochemical
Power Generation
Metals and Mining
Chemical
Pulp and Paper
3BSE062589

ABB Group
May 12, 2014 | Slide 39

Integrated Process and Power Automation
REPAR Refinery, Petrobras, Brazil
Customers need:
Refinery process control and power management
Single plant interface, integrated operations and maintenance
ABB solution:
Full Plant Integration with System 800xA
Integrated Process Automation and Power Management System
Electrical Integration Based on Open Standards
IEC 61850 integration of ABB and Schweitzer Protection & Control
IEDs
Complete Portfolio from ABB
DCS, PMS, IEDs
Customers benefits:
30% less engineering hours due to reuse of engineering data
15% savings in installation time with standardization of
solution
20% savings in training costs with improved visibility of one
system
3BSE062589

ABB Group
May 12, 2014 | Slide 40

Integrated Process and Power Automation
Flasjo Hydro Power Plant, E.ON, Sweden
Customers need:
Hydro power plant process control and substation automation
High availability unmanned station with remote operations
ABB solution:
Full Plant Integration with System 800xA
Integrated Process Automation and Substation Automation System
Electrical Integration Based on Open Standards
IEC 61850 integration of ABB Protection & Control IEDs
Complete Portfolio from ABB
DCS, SAS, LV Switchgear, IEDs
Remote Diagnostic Services
Remote troubleshooting and fewer trips to site
Customers benefits:
Cost effective solution, short installation time
Standardized concept for coming hydro power renewals
Reduced maintenance costs with remote access to plant data
3BSE062589

ABB Group
May 12, 2014 | Slide 41


ABB Group
May 12, 2014 | Slide 41