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ABB
Review
The corporate technical journal
of the ABB Group
www.abb.com/abbreview
Operational profitability
page 9
Capital productivity
Special Report
page 44
Risk management
page 64
Automation Systems Global responsibility

page 85
a
Contents
ABB Special Report

Automation systems
Automation systems 41
Peace of mind
5 Increased productivity in cement with ABB’s System 800xA
ABB IndustrialIT
Building the bridge between traditional control and IT
Operational profitability Capital productivity

44
9 Age is no issue
Mastering the assets Evolution of automation systems upholds productivity of
ABB’s Asset Master software helps curb equipment failure
older plants
13 48
Remote services Integrated engineering
Revolutionizing support and service
Revolutionizing design and documentation in engineering
17
53
Winning the battle with downtime
Integrated electrical and automation systems
Streamlining maintenance with risk-based inspection
A key to reduced capital and operational costs
21
57
Drive monitor
Powerful renovation
The software with a finger on the system’s pulse
Rejuvenating a coal-fired power plant
25
61
Control loops – pleasure or plague?
Keeping control systems under control
Analytics in Shanghai
ABB’s Analytic Systems Integration Unit in Shanghai
30
Not on my watch
Power management system prevents costly shutdowns Risk management
35 64
Experience counts Process Analytical Technology
A papermaker who knows he can rely on ABB Integrated PAT solutions for the Life Sciences industry
38 68
Finding the right balance Flexibility guaranteed
Electrification solution for the pulp and paper industry System 800xA libraries – a unified yet flexible platform
2 Special Report Automation Systems

ABB Review
www.abb.com/abbreview
25
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
53
Global responsibility
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
61
Global responsibility for quality and safety
96
Safe instruments
Safer instruments mean safer processes
72
Special Report Automation Systems 3
ABB Review
Foreword
ABB Process Automation –

Focusing on customer needs
ABB is a global leader in the supply of electrical and auto- smoother start-ups. Through our global account program,
mation technologies. Our Process Automation team is we also develop customer-specific “best practices” to
charged with delivering products, services, and complete ensure consistent project delivery regardless of size, com-
industry solutions through a variety of channels. However plexity, scope or geographic location.
what we deliver is only valued if we can clearly demon-
strate how it meets the critical business needs of custom- Like ABB, most companies today are embracing a renewed
ers, in particular in the areas of operational profitability, commitment to social responsibility. Customer investments
capital productivity, risk management and global responsi- in our integrated safety and control systems help ensure
bility. safe and secure working conditions for employees, protec-
tion of the environment, and the re-use of installed assets.
Many customers would suggest that maximizing production This approach helps customers protect their reputation and
efficiency is the most important requirement of a process license to operate, while meeting ever more demanding
automation solution. To that end, our industrial business regulatory and compliance requirements. ABB’s commit-
units are constantly developing applications that allow ment to social responsibility reflects well on customers
plants or equipment to run at maximum output, consistently who share our high standards for business ethics, health
producing high-quality products. Our IndustrialIT solutions and safety, and community spirit.
integrate engineering, operations and maintenance activi-
ties on a common technology platform, thus improving Viewed collectively, the business needs of our customers
overall plant efficiency and safety. Our Asset Management are complex. Viewed individually, each one is yet another
and Performance Service solutions minimize downtime and opportunity to deliver proven solutions for power, pro-
help to reduce variable costs such as labor, maintenance ductivity and sustainability that help make the world a
and consumables. In this era of record energy consump- better place. Many of the products, applications and servic-
tion, our solutions for energy management help plant oper- es that fulfill these business needs are showcased in this
ators to reduce both cost and environmental impact. ABB Review Special Report. I hope you find the collection
of articles informative and interesting. Most importantly,
ABB customers expect a high return on their automation I invite you to explore the world of ABB Process Auto-
investments, and we offer many ways of improving the mation, and to learn of the many products, services and
productivity of capital. Our early involvement in projects solutions on offer to help improve your productivity.
helps to optimize engineering and design cycles, thus
lowering project costs while meeting or exceeding design
goals. Overall procurement and commissioning costs are
further lowered by customers who select ABB as their main
electrical, automation, analytic or instrumentation partner.
To ensure both performance and longevity for these invest-
ments, we offer industry’s most comprehensive lifecycle
management program.
Risk is a major characteristic of any process automation

project. Project inefficiency or poor product quality can
add cost, delay schedules, or increase project hazards. Veli-Matti Reinikkala
To reduce these risks, our Centers of Excellence develop Process Automation Division Head
tested, certified and reusable industrial applications for Member of the Executive Committee
repeatable performance, shorter project schedules and ABB Ltd

ABB Review
Automation Systems
IT
ABB Industrial
Providing the business value proposition for automation
Larry O’Brien, ARC Advisory Group
ABB introduced its IndustrialIT 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 Review
ABB IndustrialIT
Automation Systems
N owadays, end users are finding

that technology alone is no lon-
ger sufficient to justify automation
system. A powerful object-oriented
technology called Aspect Objects
underlies all of the IndustrialIT offer-
information management, and asset
optimization. System 800xA also pro-
vides a common operator environ-
purchases. Instead automation must ings and resides at the core of System ment for ABB’s entire portfolio of
provide solid business value benefits 800xA. Simply put, Aspect Objects safety and process control systems,
based on a combination of metrics, allow users to view any aspect of the providing access to information across
such as enhanced asset availability, automation scheme, from a pump or a the enterprise as well as context sen-
return on assets, reduced lifecycle valve to a process unit or pressure sitive decision and action tools that
cost, and many other strategic and transmitter, as a software object. Each allow the right users access to the
financial objectives 1 . IndustrialIT pro- object in the system has a number of right information at the right time
vides this value proposition with an attached aspects Factbox that can range from any point within the system.
open technology platform that pro- from integration to computerized
vides seamless access to data from all maintenance management systems
areas of the plant and the enterprise. (CMMS) and Enterprise Asset Manage- Capital deployment is
Therefore, ABB’s goal today is to ment (EAM) systems to schematic reduced through planned
show the bottom line economic im- drawings and trending information.
pact and improved business perfor- Aspect Objects provides the key real-
upgrades for installed
mance that can be obtained through time linkage between equipment and systems and the use
implementation of IndustrialIT solu- applications. of Overall Equipment
tions.
800xA supports ARC’s Collaborative Effectiveness tools.
The following article is an executive Automation vision
summary of an ARC Advisory Group A key aspect of ARC’s vision for Col- In the next phase of their evolution
report1) on ABB’s IndustrialIT architec- laborative Process Automation Systems process automation systems will be
tural concept. (CPAS) includes a single, unified envi- considered the sentinel of plant per-
ronment for the presentation of infor- formance. They will continue to facili-
800xA is core of the IndustrialIT mation to the operator, as well as the tate process control but will also be-
offering ability to present information in con- come the primary source of manufac-
At the core of all IndustrialIT solutions text to the right people at the right turing data and information for Col-
is the System 800xA Extended Auto- time from any point within the system. laborative Manufacturing Management
mation control system2). Extending the System 800xA provides these func- (CMM) applications all within a robust
core of System 800xA hardware and tions with a single window environ- environment. Similarly, a key strength
applications are ABB and third party ment for information access and con- of System 800xA is its ability to ex-
products that have been tested and text sensitive decision and action tend its reach beyond the traditional
certified (IndustrialIT Enabled3)) to ver- tools, and builds on a common envi- functions of the Distributed Control
ify proper operation with an 800xA ronment for engineering, operations, System (DCS) to include functions
1 Core business values 2 Empowering the knowledge worker
Footnotes
1)
The full, 32 page article can be found on www.abb.com/industrialit
2)
www.abb.com/product/us/9AAC115756.aspx?country=US (October 2006)
3)
This symbol on products from ABB and its strategic partners means a product has been tested and certified for compliance with IndustrialIT standards for information,
integration, and architecture.

ABB Review
ABB IndustrialIT
Automation Systems
3 Extended automation
Infrastructure Equipment Process Control Energy Control
Maintenance Operations Production Engineering

System Servers
Safety Management
ABB OCS Batch Management Infomation Management

3rd Party System 800xA
Controllers
Controllers Hardware Controllers
Variable Speed Drives Production Intelligence
Fieldbus Devices
Intelligent
Devices Alarm Management
Motor Control Center

Software
Applications
CMMS Integration
such as production management, safe- asset utilization rate. A recent ARC Factbox Aspect Object technology
ty and critical control, advanced con- survey conducted with 107 operations
trol, information management, smart and management personnel – 86 per-
instrumentation, smart drives and cent of which came from the process The following extract has been taken from
motor control centers, asset manage- and hybrid industries , showed a defi- “The ABCs of IndustrialIT ABB Review
ment, and documentation manage- nite shift toward making return on 1/2002, pages 6–13.
ment capabilities. assets (ROA) the primary criterion in
justifying process automation. Aspect ObjectTM technology associates
information with the plant and business
Over US$ 20 billion or ABB offers a path to reduced TCO entities (the objects) it belongs to, by orga-
almost 5 percent of through reduced engineering and nizing these objects to mirror reality and
production in the process design costs from integrated front end by providing powerful functions for naviga-
engineering tools, standardized work- tion and searching. Expanding further, the
industries is lost to flow processes around the ISA 95 IndustrialIT concept defines the collection
unscheduled downtime. standard and standard ERP/CMMS of information required to support each
connectors. Capital deployment is plant component as an Aspect Object –
reduced through planned upgrades containing all the characteristics, or As-
Reduced total cost of ownership and for installed systems and the use of pects of the device. Aspect Objects can
enhanced asset utilization Overall Equipment Effectiveness also be things such as finished products,
The three core areas where IndustrialIT (OEE) tools. Maintenance costs can be raw materials, sales and manufacturing
provides business value are: reduced by integrating operations and orders. An electric motor for example
Increased productivity maintenance data, through the inte- could be represented by an Aspect Object
Reduced total cost of ownership gration of control systems with ERP containing all the real-time information
Enhanced safety through reducing systems, and by embedding operator connected with it. This might include
risk and providing a high level of knowledge about maintenance into design drawings, control diagrams, main-
security. the process automation system. Daily tenance information, location, quality infor-
operating expenses can be reduced by mation and configuration information. It is
The value proposition of an automa- offering contextual data access, reduc- important to realize that an Aspect is not
tion system rests in its ability to pro- ing cycle times, and consolidating just the real-time information connected
vide enhanced asset utilization and multiple data sources. with a particular Aspect Object; it also
reduced total cost of ownership defines a set of software functions that
(TCO). Companies are in business to Increased productivity not just about create, access and manipulate this infor-
make money through adding value. cutting costs mation.
The amount of profit resulting from In most cases, manufacturing assets
this endeavor is directly related to the are capable of performing to design

ABB Review
ABB IndustrialIT
Automation Systems
specifications. Reliability and utiliza- ABB’s approach to plant maintenance System 800xA High Integrity is a
tion, however, are suffering from con- is to provide an environment where IEC 61508 and IEC 61511 compliant
strained human performance. Accord- information is transparently accessible Safety Instrumented System (SIS) that
ing to ARC, over US$ 20 billion or to users in both the process control spans the safety loop, including Safety
almost 5 percent of production in the system and the maintenance system Integrity Level (SIL) rated controllers,
process industries is lost to unsched- environments, regardless of where the field devices, I/O modules, and field
uled downtime. Up to 78 percent of information has originated. This is actuators. Embedded safety and con-
that is readily preventable. Human consistent with ARC’s view that infor- trol are within the same architecture
error, primarily operator error, is re- mation should be provided in context providing a common high integrity
sponsible for 40 percent. This can so the maintenance personnel have system environment for production
be addressed by using both the opera- access to all the information they control, safety supervision, and pro-
tors and the automation more effec- need when they need it, regardless of duction monitoring. This architecture
tively. its source or location. provides the option of combining
control and safety functions within the
The biggest change in plant perfor- Increased safety and security has direct same controller or keeping control
mance improvement for the 21st cen- impact on profitability and safety functions separate within
tury and a key vehicle for reducing ARC believes that end users must the same system. With safety and pro-
this unplanned downtime will come take an integrated approach to plant cess applications executing within the
from the empowerment of the knowl- safety, plant security, and risk reduc- same system environment, and even
edge worker. Manufacturing will un- tion. Through its approach to the within the same controller, System
dergo fundamental organizational integration of control and safety sys- 800xA offers safe, instant interaction
changes because of operators becom- tems, ABB provides enhanced plant between applications.
ing knowledge workers empowered security, and reduced risk through an
with information 2 . This proliferation integrated approach to project man- ABB’s positioning of IndustrialIT
of information is causing organization- agement where it can serve as the around the three primary domains of
al structures to flatten, pushing down main automation contractor (MAC). reduced cost of ownership, increased
the authority and responsibility asso- Unscheduled downtime – unexpected productivity, and reduced risk is a
ciated with the distribution of infor- stoppages resulting from equipment good fit with this increased focus on
mation. A higher level of coordination failure, operator error, or nuisance business value. ABB also has ad-
at lower levels is also required. trips – is the nemesis of all manufac- vanced capabilities in products, servic-
turers. Providing a path toward better es, and vertical industries to help end
ABB’s IndustrialIT solutions enable safety and security also means pro- users realize the business value and
knowledge workers in several key viding a path toward increased reli- increased performance potential of
ways, but probably one of the most ability. automation. In terms of offering a high
important factors include providing degree of functionality and a wide
information in context. Another im- array of advanced applications, ABB
portant factor includes providing a Maintenance is one of is very strong and has a lot to offer.
unified platform for plant and asset the most significant and The future success of the company
maintenance management that also depends largely on its ability to suc-
automates the transactions between
untapped areas of cost cessfully provide its customers with
the automation system and computer- savings in plants today, sustained and measurable benefits
ized maintenance management sys- and also one of the most from automation that provide a path to
tems (CMMS), also known as Enter- continuous improvement for business
prise Asset Management (EAM) plat- overlooked. performance and profitability.
forms 3 .
Implementation of an integrated con-
Maintenance is one of the most signif- trol and safety system, such as the
icant and untapped areas of cost sav- integrated critical control capabilities
ings in plants today, and also one of of ABB’s System 800xA High Integrity
the most overlooked. According to (see next paragraph), allows users to
DuPont, for example, maintenance is significantly reduce risk and realize
the largest single controllable expen- the benefits of an advanced strategy
diture in the plant, with maintenance for critical condition management Larry O’Brien
budgets accounting for around two- (CCM). Aside from the safety aspect, Research Director, Process Automation
thirds of annual net profit. According ABB reduces risk by providing a ARC4) Advisory Group,
to Dow, the cost of unnecessary main- single point of responsibility through Dedham, MA, USA
tenance is about the same size as the its MAC capabilities. On the software
total plant profit. Shell Global Solu- side, the company has embedded Footnote
tions estimates that about 63 percent functionality such as secure design 4)
“Founded in 1986, ARC Advisory Group is a
of maintenance labor results in no practices, patch programs, audit trails, research and advisory firm in the manufacturing and
action at all. and advanced access control. supply chain sector. www.arcweb.com

ABB Review
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 ships were to seafarers in the

15th century, the computer was
to information processing in the
computer programming by more than
a century; John von Neumann, who
proposed storing a program as elec-
research organizations throughout the
US. In time, this evolved into a world-
wide network – the Internet. Taking
20th century. From number crunching tronic data; and Alan Turing, who advantage of networking technolo-
to problem solving, it has become an believed that an algorithm could be gies, it is now possible to create richer
indispensable tool in the ever-increas- developed for almost any problem. and more powerful applications that
ing complexity of today`s work envi- enable organizations to achieve higher
ronments. Today, large organizations expect to operational efficiency.
examine and monitor the status of
The history of computing is peopled even the most remote outpost at the Each progression in the evolution
with the most picturesque characters: push of a button. Networks make of information technology has been
Charles Babbage and his “Analytical this possible. It was in the 1970s the result of a timely idea. The focus
Engine”; Ada Byron, who anticipated that ARPANET was set up to connect today is on integrating disparate tech-

ABB Review
Mastering the assets
nologies and systems to achieve the tuning, diagnostic alerts, asset moni- The tiers provide extensive scope,
next level in industrial automation. toring, calibration management and from an “electronic screwdriver” at
integral work order processing. Final- one extreme to a full device manage-
Creating Asset Master – ly, it needed to be scalable. The appli- ment tool installed on the common
a complete asset management tool cation had to focus on specific instru- network using a central database at
Every year, heavy industries spend mentation needs for device manage- the other. Customers can start with a
billions of dollars on maintenance; ment, while supporting direct inte- small maintenance based application
yet, equipment failure is the principal gration into large scale process auto- and grow it into a larger control sys-
cause of production losses. There mation systems such as 800xA. Thus tem using the same configuration data
is now a wide appreciation that the instrumentation and automation users and navigation methods for both.
development of new monitoring alike could benefit from a common
technologies is critical to reducing set of engineering resources and com- Named Asset Master, the software
downtime and containing cost. Most ponents. application for Tiers 3 through 5 is a
importantly for industrial work prac- single tool for all instruments, inde-
tice, employing asset management will pendent of the manufacturer of the
impel a shift in work culture, from Today, large organizations device or the communication protocol
routine and reactive maintenance to expect to examine and (eg, HART, PROFIBUS, or Foundation
proactive maintenance. Complete Fieldbus).
asset management in industrial plants
monitor the status of
is an emerging opportunity and a even the most remote Asset Master Architecture
present challenge, as changing cus- outpost at the push of Asset Master is based on the 800xA
tomer needs tend to raise the bar in System and makes use of common
innovation. a button. features and components. It can be
upgraded by using existing 800xA
The first step in defining Asset Master Most of these desired features for components such as audit trail, cali-
or “must have” features was to identi- Asset Master were already present in bration management, maintenance
fy specific industry needs: The appli- ABB’s 800xA System and thus, it pro- trigger, etc. 1 shows the 800xA Sys-
cation needed to be capable of man- vided the perfect platform for creating tem architectural concept. The goal
aging all areas of field instrument Asset Master. By concentrating on is to reuse as many components as
engineering, commissioning, and providing a scaled down version of possible.
maintenance. It had to support ABB this functionality the precise needs
and third party devices. It needed to of instrumentation users could be The functionality of Asset Master will
provide easy access for online and achieved. A six-tiered strategy was be synchronized and expanded with
offline device configuration, para- under taken for supporting a number each release of 800xA. The initial re-
meter setting, online monitoring and of use cases Factbox . lease of Asset Master, scheduled for
early 2007 will run on a stand-alone
1 800xA software architecture concept
Factbox Six-tiered approach to asset
standalone tool basic components management use cases
DTM
DTM EDD
EDD
DTM
DTM EDD DTM and EDD
DTMEDD
EDD Tier 1: Device configuration – PC –
additional specific DTMs or aspect systems
based setup tool, factory configured
devices, and local device Human-
Machine Interface (HMIs)
Fieldbus
other Tier 2: Device configuration – Hand-
Builder
AIP OPC Audit Trail Valve application held configuration of ABB and third-
PROFIBUS/ Calibration
Server Assistant monitoring aspect party devices and hand-held calibrator
HART
systems Tier 3: Configuration and visualization –
Aspect System
800xA based stand-alone PC
configuration and visualization tool (base
offering)
Aspect
Aspect Integrator Platform (AIP) Tier 4: Calibration – Device
Directory
management calibration software
(option to base offering)
Tier 5: Asset optimization – Asset
PROFIBUS HART FF monitoring and reporting (option to base
Local Local Local offering)
Communication Communication Communication Tier 6: 800xA – automation system
Driver Driver Driver (upgrade from base offering + options in
Tiers 4 & 5)

ABB Review
2 Asset Master maintenance workplace
PC. It will employ a new Asset Master to cell phones and pagers will also ration of the connected fieldbus de-
workplace derived from the existing be supported. The 800xA includes all vices. A search function simplifies
maintenance workplace. of these optional features and pro- efforts in identifying all fieldbus
vides them unaltered for use by Asset devices connected to the modem,
Instrument connections with Asset Master. adapter, or linking device.
Master will be made in support of two
primary use applications: The Asset Master Workplace display
point-to-point access for bench Every year, heavy indus- environment focuses on maintenance
work configuration (HART via tries spend billions of needs and is comprised of an alarm
modems, PROFIBUS via adapters, band that identifies asset condition
and Foundation Fieldbus via ABB’s
dollars on maintenance; events organized by asset type (pres-
LD800HSE) yet, equipment failure sure, flow, etc.), a browser for orga-
multiplexer access for online is the principal cause of nizing and selecting assets and their
network configuration. displays or data functions, and a
production losses. viewing area to see the selected dis-
The Mobility hand-held calibrator for play or data 2 .
integrated calibration is an optional Asset master functionality
extra. In support of asset optimiza- Asset Master runs on Windows XP This workplace reduces the time it
tion, interfaces to asset condition from a single PC workstation, and takes to comprehend the state of all
monitoring and Computerized Mainte- provides concurrent connections with plant assets. Asset monitors are pro-
nance Management System (CMMS) HART, PROFIBUS, and FOUNDATION vided to identify not only the fault,
are also available as optional offer- Fieldbus devices. Software installation but also the probable cause and the
ings. is straightforward, usually taking less suggested corrective action. Asset con-
than 2 hours. Support for HART mo- ditions can trigger a cell phone mes-
Considering the rise in transfer of dems and PROFIBUS adapters goes sage to designated personnel. Graphi-
digital information over cellular net- beyond earlier online 800xA capabili- cal based DTMs monitor and config-
works, an option for SMS messaging ties to provide offline bench configu- ure HART and PROFIBUS devices to

ABB Review
improve plant operation and produc- nance and asset optimization informa- day. Therefore, implementing Asset
tion. FOUNDATION Fieldbus device tion. Real-time monitoring and alarm- Master creates a substantial savings
and network configuration is integrating of asset Key Performance Indica- potential.
ed with the LD800HSE linking device tors (KPI) facilitate fast, reliable im-
for setting up and monitoring the Link plementation of corrective actions. Asset Master can provide another sig-
Active Scheduler and function block Asset Master collects, aggregates and nificant benefit by ensuring industry
applications. Device calibration notic- analyzes real-time plant asset infor- compliance. For instance, pharmaceu-
es and asset conditions can be used mation to provide advanced warning tical units, subject to rigorous Food
to trigger a work order submittal to a of degrading performance and/or im- and Drug Administration (FDA) regu-
Computerized Maintenance Manage- pending failure. Asset Master’s report- lations, rely on the trustworthiness of
ment System (CMMS) such as MRO ing features provide visualization of electronic records generated/managed
Maximo or SAP / PM that can then be current health conditions, while its by critical systems. A recent FDA reg-
tracked through completion from the analysis features provide the ability to ulation, 21 CFR Part 11, covers elec-
Asset Master workplace. drill down to the root cause of failure. tronic records and signatures that
Integration of disparate CMMS, DMS affect production, quality and distribu-
Because Asset Master uses a stream- and Fieldbus engineering tools pro- tion of drugs in pharmaceutical units.
lined version of 800xA, it can easily vides users with a single view, leading With integration of Mobility Device
integrate into larger 800xA systems. to quick and efficient assessment of Management System (DMS), Asset
This allows a site to start small with maintenance needs. Master can provide users with FDA
Asset Master and grow over time into regulation 21 CFR Part 11 – enabled
a larger 800xA system. calibration solutions. In an industry
Customers can start with where data integrity is critical to
Key benefits a small maintenance product quality and/or public safety,
In the area of Fieldbus Device Man- systems must be overall compliant
agement, Asset Master provides signif-
based application and with FDA regulations. Integrating DMS
icant benefits. Primarily, it offers a develop it into a larger in the control system offers versatile
single tool to configure and diagnose control system using the plant life cycle management and orga-
multi-vendor devices, thus reducing nization allowing the user to derive
capital expenditure on tools and train- same configuration data maximum value from plant assets.
ing and removing the user’s burden and navigation methods
of selection. Reusing several 800xA award-winning
for both. features resulted in reduced develop-
The full value of intelligent field de- ment time for Asset Master and an
vices, that provide critical information Included standard with ABB manufac- end-to-end Asset Management Tool
on their own health and the health tured instrumentation are highly inte- that assures compliance with industry
of processes and equipment around grated and comprehensive asset moni- regulations. Even now, the combina-
them, can be realized only when used tors that enable Asset Master to not tion of intelligent field devices and
in combination with asset optimiza- only identify faults but to show proba- asset management software is setting
tion software. Asset Master offers im- ble cause and suggested corrective new standards for what can be ex-
proved productivity through choice of actions. This can reduce the mean pected and accomplished from the
devices that best fit the application, time to troubleshoot and / or repair control room. This growing trend in
independent of fieldbus-type. the fault leading to improved produc- using Asset Optimization will most
tivity. likely accelerate in the future, fueled
Asset Master reduces configuration by the need for output improvement
time by using pre-configured field In his book on predictive mainte- and cost reduction.
device objects with extended func- nance, Keith Mobley [1] points out
tionality to access device data, asset that in the US alone, every year, up-
information and documentation. wards of $ 200 billion is spent on
It also enables faster commissioning plant equipment and facilities mainte-
through certified devices and ap- nance. Every year, ineffective mainte-
proved field device libraries. nance management results in a loss of
more than $ 60 billion. Thus, mainte-
It is in the area of Asset Optimization nance can represent 15 to 60 percent Eric Olson
that Asset Master provides tangible of the cost of goods produced, de- ABB Inc.
economic benefits by reducing main- pending on the specific industry. In Warminster, PA USA
tenance costs over a plant’s life cycle an oil refinery, for example, the fail- eric.olson@us.abb.com
and thus boosting the bottom line. ure of a single valve during peak
hours can result in a loss of hundreds
Independent of asset type, Asset Mas- of thousands of dollars. A one per References
ter provides a single interface for en- cent decrease in productivity can re- R. Keith Mobley: An Introduction to Predictive
gineering, notification of plant mainte- duce output by hundreds of barrels a Maintenance. Butterworth-Heinemann, 2002.

ABB Review
Remote services
High tech means high service performance
Gordon Cheever, John Schroeder
“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:

ABB Review
Remote services
W ith an installed base of more

than $100 billion worth of auto-
mation products and systems world-
types of products, this can be a com-
plex undertaking.
Remote troubleshooting
Remote troubleshooting provides
expert on-demand, diagnostic remote
wide, ABB is constantly working on Remote service benefits support assistance in the event of a
ways to improve the way these sys- A well-executed remote service offering specific problem or failure. A de-
tems are supported. Remote services can reduce unnecessary maintenance mand-driven connection to the drive
use existing and cutting edge technol- and downtime, improve production effi- equipment is initiated to begin the
ogies to support field engineers, irre- ciency, track causes of failures, provide troubleshooting process.
spective of location, in ways only root cause data and fault diagnosis and
dreamed of five years ago. The Inter- recommend actions. It can provide pre- Periodic maintenance
net, together with advances in com- dictive notification of impending fail- Periodic maintenance provides a man-
munications and encryption tech- ures allowing proactive instead of reac- aged monitoring service for collection
niques, has contributed enormously tive corrective actions. Finally, it can of equipment health information four
to this. Remote service developments allow remote specialists to apply their times per year. Skilled support special-
are a direct result of clients’ changing expertise to any factory in the world ists provide expert data analysis based
needs. ABB has been told clearly in 24 hours per day, 7 days per week. on established equipment benchmarks.
almost every industry it serves, that it
must continue to improve the return ABB’s Remote Service business pro- Continuous monitoring
on assets of the systems it delivers. vides predictive and diagnostic capa- Continuous monitoring provides con-
This does not mean customers want bilities serving all aspects of a plant – tinuous monitoring of key parameters.
less support, but rather more support automation, equipment per formance, It automatically sends a message to
at lower costs. Remote services are equipment health, mechanics, electri- an ABB monitoring center when para-
designed to maximize knowledge bas- fication, electronics, and production meters exceed limits. ABB specialists
es in the most cost-effective manner. to provide a complete solution. analyze the alarm and remotely access
The result should ensure that the best the device to further diagnose the
knowledge is in the right place, at the Three levels of remote monitoring issue. Corrective action recommenda-
right time, to support the clients’ as- service are available to align with cus- tions are provided to the customer if
sets. With a large number of different tomer needs: required.
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 Call center

Analysis & feedback layer
Communication layer
Internet, modem, direct line, etc
Connection layer
Propulsion Asset Web-based On-line Remote Remote

predictive optimization maintenance parts drive robot
maintenance management monitoring services
software
Marine IndustrialIT enabled Control systems Instruments and Drives and motors Robotics
products and systems low-voltage
products

ABB Review
Remote services
Two types of alarms are generated: Remote paper plant support reached with a combination of auto-
Predictive alarms: Device has not ABB provides remote services to a matic and manual processes.
yet failed but key parameters North American paper manufacturer
indicate that a problem may occur. that produces high performance liner- Remote power utility support
Reactive alarms: A problem has board. The remote service includes A major power utility producer in the
occurred and needs to be monitoring Control Loop and Quality United States recently experienced an
diagnosed. Control System (QCS) performance. issue that was preventing a startup.
ABB’s QCS solution is designed spe- Using their support line subscription,
Asset Optimizer as a key cifically for the pulp and paper indus- they called ABB for technical support
component try and is designed to measure and late on a Friday night. The caller
The Asset Optimizer, from ABB’s In- control the weight, moisture and cali- feared he would not get results at that
dustrialIT product portfolio, takes re- per (thickness) of the linerboard. hour, and when he was told someone
mote services a step further. The asset would return his call shortly, he felt
monitoring software acquires and ana- The remote service provides monitor- certain his fears would be realized.
lyzes asset status and condition infor- ing of the health of QCS System’s
mation. Powerful analysis algorithms scanners and sensors, the PID control
developed from ABB’s deep process loops, as well as the quality of the ABB holds the view that
and maintenance knowledge, provide product. If potential problems are technology for technolo-
predictive and proactive information indicated (by monitor “trips”), ABB’s
and alarming functions. Once an remote monitoring center is alerted.
gy’s sake is not always
alarm is generated, ABB’s remote These alarms often occur before a fail- the best solution.
monitoring engineers are notified. In ure has even taken place.
addition to the alarm, the Asset Opti- Imagine his delight when an ABB Ser-
mizer also provides important data The remote service has provided sig- vice Engineer (SE) returned his call
related to the issue for ABB’s remote nificant value to this customer. The within 30 minutes. The SE immediate-
expert to analyze and determines the remote monitors recently sensed ably proceeded to solve the problem.
root cause of the problem. On-site normal changes in a device that was There was no waiting until the next
operators and maintenance personnel not scheduled for immediate mainte- business day – no waiting for an engi-
can also be notified when an abnor- nance. The device was replaced dur- neer to fly to the site!
mal condition has occurred that ing a scheduled production stop.
requires some form of maintenance When the process came back up, all This ABB customer had been resetting
action. signals were normal. This paper plant several modules. One had continued
was able to save approximately ten to report an error. By utilizing contin-
hours of unscheduled downtime by uous monitoring, the service engineer
Advances in technology predicting when the device was about determined that the module had to be
are changing the way to fail, and changing it at the most reloaded, which he did remotely.
cost-effective time – before an un-
firms approach the planned stoppage costing tens of The service engineer utilized ABB’s
support of installed thousands of dollars in losses could Remote Diagnostic Services (RDS)
equipment, as well as occur. technology to optimize the power
utility producer’s assets in real-time.
helping clients improve Remote robot support
their return on assets. When an issue arises concerning an The module was successfully reset.
installed robot, the on-site plant engi- Delays and uncontrolled maintenance
neer calls ABB’s global robotic expert costs were avoided, while the startup
In addition, the Asset Optimizer can center. The plant engineer then cre- stayed on schedule.
be directly linked to most computer- ates a direct link between the center
ized maintenance management soft- and the installed equipment, but only Remote condition monitoring
ware systems for automatic work or- after ensuring all local safety require- ABB holds the view that technology
der generation. This feature provides ments are in place. Off-site experts for technology’s sake is not always the
a powerful, integrated solution con- review the equipment, diagnose the best solution. When it comes to vibra-
necting site management, operations, problem and either take direct action tion analysis in condition monitoring,
maintenance, and ABB’s remote ser- or provide instructions to the site en- for example, the company balances its
vice engineers allowing seamless gineer, who can then solve the prob- services to provide a cost-effective,
communication and fast, efficient lem. tiered approach. This means that an
actions. appropriate technical solution is deter-
The robot can also diagnose the prob- mined based on the consequences of
Remote services at work lem itself, and then call ABB’s global the asset failing and/or its cost. In the
The following examples illustrate how Robotic Expert Center for support. following, the case is considered of a
remote services in use today are giv- However, this raises safety concerns at simple low-cost motor in a non-critical
ing customers more value at less cost: the site. A balanced compromise is application that is best supported

ABB Review
Remote services
when data is gathered manually. Vibra- ule before it became a costly issue. quality, improved maintenance plan-
tion data is collected using small hand- Had the primary communication mod- ning, and increased uptime.
held devices. This data is then loaded ule failed, the redundant module
onto a PC where a software applica- would have been unavailable and Conclusion
tion “decides” whether the vibration production would have ceased. ABB’s Remote Service business pro-
data is within specification. If not, the vides predictive and diagnostic capa-
system will automatically upload the bilities serving all aspects of a plant –
data to global ABB condition monitor- ABB must continue to automation, equipment performance,
ing experts where another more in- improve the return on equipment health, mechanics, electri-
depth software application screens it fication, electronics, production, and
for recommendations. It then passes
assets of the systems it quality to provide a complete solution
the final data and pre-analysis to dedi- delivers. This doesn’t for our clients’ needs.
cated vibration experts. A final review mean customers want
is done, and recommendations or work The primary benefits of Remote Servic-
orders are sent back to the local site. less support, but rather es are that they increase asset availabil-
In general, the level of automation for more support at lower ity and improve production efficiency.
this process is based on asset costs In addition, they maximize operations
versus human intervention costs at the
cost. and maintenance effectiveness.
client’s site. The systems for high-cost
critical assets automatically and contin- Instead, WKE was notified in a timely Remote Services can greatly contribute
uously monitor vibration data and pro- manner, was able to schedule mainte- to the operational excellence and
vide specific analysis and work inter- nance on the failed redundant unit financial performance of a customer
vention 24 hours a day. during routine maintenance, and a plant. The combination of powerful
costly stoppage was avoided com- predictive and diagnostic analysis
Remote power plant support pletely. Production capacity was along with experts available 24 hours
Kentucky’s primary energy services ensured and maintenance costs kept per day, 7 days per week can provide
provider is Western Kentucky Energy, low through remote continuous moni- a highly effective means to remain
or WKE. In a recent pilot program, toring. competitive in the marketplace.
WKE’s Green Station in Sebree, Ken-
tucky, (USA), utilized asset optimiza- Remote site asset monitoring enables
tion to provide diagnostic service for optimized control system performance Gordon Cheever
their Harmony process control system through continuous retrieval and eval- ABB Automation Technologies
(Harmony Continuous Monitoring). uation of system performance indica- Wickliffe, OH, USA
Asset monitors installed on-site sent tors against established norms. If there gordon.r.cheever@us.abb.com
critical asset data to the ABB monitor- are on-going issues, remote diagnos-
ing center around the clock. tics will catch them. Coupled with John Schroeder
automated incident reporting, remote ABB Automation Technologies
Remote diagnostics recently detected monitoring provides reduced mainte- Westerville, OH, USA
a failed backup communication mod- nance cost, enhanced production john.schroeder@us.abb.com

ABB Review
Winning the battle

with downtime
Tony Musgrave
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.

ABB Review
P lant engineers fight a continuous

battle with downtime. Although
key contributors, maintenance and
equipment that make up a plant is
variable. However, this fact is seldom
reflected in the inspection routines
This accumulated knowledge and ex-
perience helps engineers to decide
what equipment needs to be inspect-
repairs are not, however, the only applied across the inventory of equip- ed and when, as well as to establish
cause for concern; increasingly, it is ment. Risk-based inspections focus where failure would be least accept-
the threat of business interruption, the inspection and maintenance effort able and cause the most problems.
with its effect on output and profit- on those areas where the risk and its This makes it easier to see where
ability. The viability of a process, potential effects are greatest. effort has to be focused in order to
even the business itself, may be on maximize the return. It facilitates the
the line as a result. The prime objectives of an RBI pro- optimization of examination intervals
gram are to: whilst at the same time identifying
ABB Eutech1) has developed a Risk Focus effort on identifying and re- equipment for which non-invasive ex-
Based Inspection (RBI) method that ducing the safety and business risks. aminations would be equally effective.
enables companies to substantially Achieve increased plant availability
increase plant reliability, reduce the by ensuring that outages only take
number of plant failures and cut the place for essential inspections. Average inspection inter-
time re-quired for regular inspection/ Reduce the maintenance costs vals were increased by
maintenance. associated with unnecessary or
excessive dismantling and
between 35 and 57 per-
Recent results with four customers in preparation. cent, with an average
the chemical and petrochemical indus- Improve safety by getting rid of increase of 44 percent.
try provide compelling evidence of hazards associated with preparing
major savings. The total cost of infor inspections.
spection, for example, could be re- Up until now, ABB’s experience has
duced by 49 to 80 percent. Average RBI is becoming the preferred tool by been mainly with pressure vessels.
inspection intervals were increased by which “good engineering practice” is However, exactly the same approach
between 35 and 57 percent, with an measured. Its predictive approach is is adopted when assessing risks for
average increase of 44 percent. And designed to eliminate excess and in- rotating equipment, critical instrumen-
more than half the plant equipment adequacy by concentrating inspection tation and structures.
could be removed from the invasive effort on real risks 1 . Use of RBI has
inspection programs. shown to be effective in reducing the The company’s RBI approach relies
number of unforeseen breakdowns. on harnessing company and consul-
The bottom line is that RBI reduces tants’ expertise as well as the use of
downtime, planned or unplanned, for The ABB approach to RBI sophisticated software tools.
a saving in maintenance costs. The ABB’s RBI process is built around an
time and capacity/availability that is asset care strategy that is designed to ABB has refined its proven RBI ap-
released as a result has a direct, posi- monitor the plant throughout its life- proach into an efficient, streamlined
tive effect on a plant’s output. cycle. This involves the acquisition of solution called Risk Based Inspec-
detailed knowledge and requires a tion+© 2 . The result of experience
The principles of RBI good understanding of the behavior gained through hundreds of projects,
RBI is a knowledge-based method that of every component in the plant unit focuses on delivering tangible
uses risk as a basis for prioritizing and der its current duty conditions. Multi- results by:
managing an inspection program. In disciplinary in its approach, it looks at
this definition, “risk” is seen as the parameters such as the design/con-
1 RBI risk matrix: moving the operating risk
result of the probability of future fail- struction quality, inspection/mainte-
envelope to a safer region
ure and the likely consequence of that nance history, and the service condi-
failure. tions, including normal and abnormal
Likelihood
d
excursions. The review identifies all
Generally speaking, the level of risk failure mechanisms and associated b c
associated with the different pieces of risks.
Factbox Typical recent results
Post RBI
Study A B C D a
Average inspection interval Consequence

before/after RBI study (months) 31 / 44 No data 54 / 85 48 / 65
a No special care required
Vessels moved to
b Hazard study
non-invasive inspection 16 out of 26 76 out of 157 90 out of 179 41 out of 82
c Periodic inspection
Reduction in inspection costs 58 % 49 % 61 % 81 %
d Full registration procedure

ABB Review
Accumulating comprehensive RBI delivers for Victrex plant. The general rule was that an
knowledge of the risks associated Victrex manufactures PEEK™ polymer, annual increase of 100 tons in output
with specific plant assets. a high-performance thermoplastic always required an investment of
Significantly reducing the total cost with exceptional chemical, wear, elec- $ 1.5 million.
of inspections. trical and temperature resistance. It is
Achieving longer intervals between used in critical applications in the in- In recent years output has been raised
inspection/maintenance turnarounds dustrial, automotive, electronics, med- from 1000 tons per year to 2000 tons
and reducing the time needed for ical, aerospace and food industries in two jumps of 500 tons, first in 1996
them. around the world. and then again in 2000. In each case
Ensuring much improved equipment almost $ 10 million was invested in
availability and reliability, and mini- The company is actively expanding new plant 3 .
mizing unforeseen breakdowns, its markets for PEEK polymer through
resulting in more uptime. intensive marketing, customer-focused Saving time, saving cost
Building greater confidence in service and a commitment to product The inspection and maintenance
equipment integrity. quality. Victrex is in the fortunate po- routines were a prime target for close
Providing an established path to all sition of enjoying very high demand examination. It was seen that time
necessary regulatory approvals. for its product. Its major challenge is and cost savings could make a vast
to increase production while control- difference to output, efficiency and
An outstanding example of the suc- ling overhead and investment costs. profitability of the plant.
cess of Risk Based Inspection+ imple-
mented in close partnership with a Working with ABB, Victrex engineers Before RBI the inspection regime was
customer is a project ABB undertook were aiming to break out of the prescriptively invasive on all items,
recently for Victrex plc, a UK polymer vicious loop that had always linked regardless of the risks associated with
producer. higher output to investment in new them. It is a fact that, very often,
extensive inspection during the shut-
down periods reveals no deteriora-
tion. However, there are occasions
2 Inspection life cycle database
when unexpected problems are
found, and these can lead to un-
ABB RBI+ planned repairs that increase the out-
age time.
Identify
Auditing All inspection and maintenance work
deterioration
on the main pressure vessels must
mechanisms
comply with Pressure Systems Safety
Regulations 2000. These look mainly
at how the safety performance and
Materials/NDT Training condition of the vessels reduce work-
New assets expertise
place risks as far as is reasonably
practical.
Data
Risk
collection & Defect
analysis As a Victrex engineer puts it, “The
analysis assessment total cost of inspection includes de-
Registration commissioning, decontamination and
Design Operational
assessment preparation for internal inspection.
expertise knowledge
Fitness All this time and effort just to find
for purpose that, more often than not, everything
Reduction assessment
Repairs & is OK! This led us to question our
of
modifications approach.”
actions
Existing assets
Independent It was this questioning that steered
Inspection Maintenance
design review the company toward a knowledge-
technology expertise
based approach to understanding the
behavior of the plant.
Develop
Execution of Asset life
inspection
inspection planning The RBI objective was to raise plant
plans
availability from 80 to 85 per cent –
from 290 days to 310 days per year –
ABB inspection service
which is the “world-class standard” for
Registration Inspection life cycle database Support similar batch specialty chemical pro-
cesses.

ABB Review
It was concluded that the nine days. The necessary en-

3 The Victrex plant
main contribution to increas- gineering and maintenance
ing plant availability would work was completed in four
come from a reduction in the days. The total cost of the
annual shutdown time. This exercise was half the amount
would need to be cut from budgeted.
35 days to 21 days.
The next shutdown period,
The potential financial bene- a little less than a year later,
fit of saving a large amount was cut from 35 days to
of downtime was estimated 20 days. The team expects
to be almost $ 10 million. shutdowns to be kept to this
Such an amount would result level in future years as some
from an improved gross mar- of the equipment gets older
gin and reduced short-term and wear and tear increases.
investment needs.
Besides the welcome time
None of this means that saving it provides, RBI has
future plant expansion is met and exceeded expecta-
ruled out, but Victrex immediate pri- ough analysis of the causes of lost tions. During a recent period of high
ority was to get the most return from output in the last 12 months, provided demand, the gross margin has been
its existing facility before embarking the basis for the knowledge base on improved by more than $ 9 million
on further major investment. which the RBI plan would be devel- over eighteen months of operation
oped. and other savings on capital invest-
For both ABB and Victrex there were ment and associated depreciation ex-
some essential steps in ensuring that ceed $ 3 million. Year on year shut-
RBI delivered the desired benefits. For Victrex, a UK polymer down savings are running at almost
Above all else there was the need to producer, the potential $ 100,000. Victrex engineers admit that
harness all existing in-house knowl- their initial desire to apply RBI was an
edge and experience and link it to
financial benefit of reduc- act of faith. They saw the opportunity
ABB expertise. As a starting point, the ing downtime through RBI and believed that the goals would be
in-house team members were to pool was estimated to be achieved, but they had no previous
all their knowledge and experience. experience to refer to. As Andrew
This data, both qualitative and quanti- almost $ 10 million. Anderson, Engineering Manager of
tative, together with historical records Victrex says, “The past experience,
of previous inspections and a thor- A full understanding of the results of professionalism and expertise of ABB
past inspections of pressure vessels were vital elements in steering the
during shutdowns was vital, since pre- work forward and in providing the
Factbox ABB Risk Based Inspection+©
paring for and carrying out invasive confidence in the achievability of our
in brief
inspections accounts for much of the objectives.”
time and effort involved in a shut-
What equipment should be inspected?
down. Knowing and understanding The Victrex experience shows quite
Where would failure be unacceptable?
the failure mechanisms each item is clearly that Risk Based Inspections
Where should effort be focused?
susceptible to, and where to look for can provide the benefits businesses
Which techniques should be used?
them, helped the team decide on the need to save on preventive mainte-
How can the examination intervals be
adequacy of non-invasive inspection. nance while minimizing the risks of
optimized?
This proved to be a major benefit. failure.
Benefits
Thoroughly gathering and assessing
Increased knowledge of the risk of salient historical data, plus the use of
operating assets ABB advanced software tools, enabled
Significant reduction in the total cost of the team to develop an inspection
inspection routine that prioritizes and responds Tony Musgrave
Longer turnaround intervals, and to risks and foreseen failure scenarios. ABB Eutech Limited
reduced turnaround durations It also minimizes the risk of unexpect- Warrington, UK
Improved equipment availability and ed failure. tony.musgrave@gb.abb.com
reliability, helping to maximize uptime
Increased confidence in equipment Having carried out the full review and
Footnote
integrity created an RBI program, the results 1)
ABB Eutech is the process solutions center of
Established path to regulatory approval have proved immediate and impres- excellence within ABB’s petroleum, chemical, life
sive. The first shutdown to be affect- science and consumer goods industries business
ed, in October 2001, required only area.

ABB Review
Drive monitor
Embedded product intelligence that enhances lifecycle
management and process performance in drive systems
Maciej Wnek, Michal Orkisz, Jaroslaw Nowak, Stefano Legnani
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 drive’s history, all from a remote computer. Drive performance monitoring
provides also deep insight into the process status – useful extension in analyzing the
Operational profitability.

ABB Review
Drive monitor
R eal plant systems comprise a wide

variety of assets. Some are
straightforward, simplistic even, while
tion line, which contains many assets.
The second aspect is the availability
of data: from “what’s already there”
would differ according to their impor-
tance.
others are “intelligent,” capable of to dedicated measuring systems that A scalable system is not the same
self-diagnosis or even self-correction. detect vibrations, current, corrosion thing as a combination of different
All of these assets need careful moni- etc. The third aspect relates to in- approaches that address different
toring. Large and critical assets often creasing levels of knowledge content aspects of lifecycle management.
come with their own supervisory con- and diagnostic functions: at one ex- To be efficient, a tool must guarantee
trol systems, but all of the assets in a treme having a simple limit threshold, full data interoperability, single data
process chain are information provid- at the other, having advanced lifetime entry points, and unified interfacing,
ers – either directly, via in-built sen- prediction algorithms. usage and reporting. Multiple systems
sors, or indirectly, by reporting on can be combined in an IT integration
other assets in the chain. project, but only a scalable tool can
An efficient lifecycle provide true maintenance optimiza-
Cost-effective data collection management system tion.
and processing
An efficient lifecycle management
requires scalable tools In short, individual assets must be
system requires scalable tools that can that can be adapted to assessed to determine the level of
be adapted to the nature of an asset, the nature of an asset, its investment that can be justified by
its value, status, and general mainte- their individual roles in a process.
nance policy. The first aspect to be value, status, and general
considered is the comprehensiveness maintenance policy. A good condition assessment system
of the system: whether it be a single is:
asset (eg, a drive), or a whole produc- expandable, to accommodate single
To target low tool costs one has to or multiple asset objects
concentrate on scalability and config- able to apply rules of various com-
uration flexibility. Similar assets plexity to the assets – vibration-
1 MV drive – an asset with a broad technology
should be treated similarly, but with based, temperature-based, electrical
span and a rich information source
individual attention dependent on test-based, operation data-based,
their context in the system. For exam- statistics- and history-based etc.
Java/.Net ple, two electric motors might be able to acquire data from various
identical, but if one is running a venti- sources, eg, drive systems, control
lation fan of low importance and the systems, vibration measuring tools,
Si Cu other a critical fume-exhaust fan, their manual entries, and the asset itself.
maintenance programs would be simi- ABB has used this methodology in
lar, but the level of investment in each the development of its Asset Opti-
Assembler
3 DriveMonitor – Analyzing the system’s heartbeat. Drive information can be utilized on various
diagnostic levels – from the converter unit to the process section
2 The DriveMonitorTM design principles
DriveMonitor Unit
Industrial PC
Router
VPN Firewall
Ethernet
TCP/IP
Optical Fibers
NDBU 95
ACS drivers
1 ........... 5

ABB Review
Drive monitor
mization/Asset Monitors concepts What should be done to the asset in DriveMonitor: embedded intelligence,
and DriveMonitor is a part of this order to maintain the highest per- scaleable and secure
truly scalable solution 1 . formance and the lowest costs. The DriveMonitor system consists of a
When should this action be taken? hardware- and a software layer 2 . The
ABB Drives – assets as “knowledge hardware layer is a properly inter-
containers”. Ideally the asset should be intelligent faced industrial PC that is factory in-
ABB MV Drives focuses attention on enough to provide this information to stalled in the most powerful new ABB
product design and development, but the operator. Alternatively, the intelli- MV Drives (it can also be offered as
also on configuration and optimiza- gence can be embedded as the asset an upgrade to existing models). The
tion in relation to customer applica- extension – intelligence that utilizes software layer automatically collects
tions. A quick look “under the hood” fully the amount of data processed in and analyses selected drive signals
of a drive unit will immediately show the drive. and parameters. The DriveMonitor
that the technological complexity of hardware is based on an industrial PC
this “torque delivery plant” ranges platform to provide the expected lon-
from copper bars to electronic circuit In order to keep tool gevity and remote accessibility. Virtual
boards. Its software ranges from as- costs down, maintenance Private Network (VPN) solutions are
sembler code to the newest high-level used for remote access to ensure high
languages. To obtain the highest pos-
systems should be flexible security.
sible performance from such a device and able to accommodate
over its entire lifetime requires some a wide range of asset Scalability – the biggest challenge
attention. However, drive units, such The DriveMonitor software layer is
as the MV Drive from ABB, are huge types. extremely flexible with respect to the
banks of data, recording information configuration of diagnostic rules, the
relating not only to the drive convert- The DriveMonitor system is designed range of the assets with which it can
er performance, but also to the driven to meet these requirements. On the be used, its alarm and reporting func-
equipment, and even to the whole one hand it provides continuous mon- tions, and its data intake sources.
downstream production process. Effi- itoring and analysis of the drive state Being compatible with ABB’s Asset
cient use of these drive data is the and operation, supports root-cause Monitor family, DriveMonitor opens
first step towards the lifecycle man- analysis (RCA) and helps to follow the door to the whole ABB Asset Man-
agement – at first for the converter predictive maintenance paths. On the agement portfolio, with Asset Opti-
itself, ultimately for the whole drive- other, it provides a platform upon mizer and other Asset Monitors as
powered process. which to offer the customer unique optional extensions. DriveMonitor can
extension features that, by utilizing be easily integrated into automation
Efficient lifecycle management drive signals, allow the operator to systems using the ABB 800xA platform
A pragmatic approach to lifecycle visualize the whole shaft state along (other systems can be connected
management issues should answer the with process-related KPI’s, etc. through OPC1) servers). The Drive-
following questions: Monitor is designed to be used with a
single drive, and with large systems.
There are possibilities for expansion
to include other measurements such
Extended support information facilitating root-cause analysis
as corrosion, vibrations, additional
temperature sensors, etc. It provides
millisecond-based sampling rates with
year-based scheduling, event-driven
actions and alarms, and more. The
various DriveMonitor components can
be distributed to different computers.
For instance, several DriveMonitor
units can be configured in parallel to
cover larger installations and the re-
sults can be brought to a central con-
trol room PC for operator conve-
nience.
Application area
The basic function of the DriveMoni-
tor is to “watch” the converter part of
Footnote
1)
OPC-OLE for Process Control

ABB Review
Drive monitor
a drive shaft system 3 . It continuously

DriveMonitor – shaft-line overview
monitors the drive status and responds
when that status changes. Changes in
drive status can be caused by drive SCALABLE
faults (unexpected drive stoppages),
alarms (signals crossing threshold val-
ues), user-defined parameter changes,
and higher level, DriveMonitor-gener-
ated application-specific alarms.
ABB MV Drives focuses

attention on product
design and development, Plant Personnel
Pager
but also on configuration Asset e-mail
Cell Phone
Monitors
and optimization in relation
to customer applications.
With extra diagnostic packages, Drive- Drive Monitor
Monitor can follow other shaft train
components such as the main circuit
breaker, the transformer, and the driv-
en machine. At the highest level, spe-
cialist packages directly related to
specific application areas (such as
rolling mills, water pumps, and com-
pressors) can be integrated into the
system. This kind of expansion can be for the controlling purpose by AC800M no hardware investment, drive data is
done at any point in time depending units. In this way, a high added value mapped against traditional process in-
on the customer’s needs. It is also is obtained at low investment cost. All formation from the control platform –
possible to incorporate extra measure- results are integrated into the 800xA and all this is enabled by systematic
ments that go beyond the drive sig- Workplace panel giving the operator and coordinated development of the
nals. DriveMonitor-based diagnostic visually compatible status information ABB Asset Management platform –
routines are valuable extensions to – not need to learn yet another plat- both from the product and the system
plant-level Asset Management pro- form for condition monitoring as it is sides.
gram such as ABB Asset Optimization typically the situation in industrial
solution. The DriveMonitor block is an plants. Concluding remarks
easy fit to already installed ABB con- ABB process automation offers com-
trol platforms and on the other hand TM plete systems for the plant asset man-
can be a good start for plant Asset
DriveMonitor continu- agement that are in all respects com-
Management solution. ously monitors the drive patible with ABB’s product portfolio –
status and responds generating high level benefits at low
Oil and gas – Ras Laffan pumping investment costs. 1+1 can equal 3 or
station when that status changes. even 5 in this case.
The pumping station consists of 27
pump units using, in total, more than Rolling mills – Seeing the process
19 MW of power delivered by ABB “heartbeat” Maciej Wnek
electrical motors and ACS6000 drives. ABB Drives are very powerful and Michal Orkisz
All drives are supervised by the moni- configurable units in a process. Their Jaroslaw Nowak
toring package, but as an extension, status is not only converter-related, ABB Corporate Research
the data from the ABB AC800M con- but reflects several parameters that Krakow, Poland
trollers that control the pump line reflect the process status. These para- maciej.wnek@pl.abb.com
operation are processed by the diag- meters include shaft torque, phase michal.orkisz@pl.abb.com
nostic package. Without requiring current and phase voltages. These jaroslaw.nowak@pl.abb.com
additional investment in hardware or data – as provided by the drive unit
measuring devices, the system watch- and analyzed by the DriveMonitor – Stefano Legnani
es the status of the motors and the can return valuable process status in- ABB Medium Voltage Drives
pumps’ temperatures, operating con- formation regarding process outliers, Turgi, Switzerland
ditions and vibration levels processed process drift and changes. Again, at stefano.legnani@ch.abb.com

ABB Review
Control loops –
pleasure or plague?
A plant floor view within the process industry
Alexander Horch
Control loops are a vital part of the The availability and effectiveness of a Performance monitoring of closed
process industry and are especially control system is essential for loops – or Control Loop Condition
important when it comes to quality, operating the process safely and at Monitoring (CLCM) as it is also known
economy and safety. In fact, a maximum performance, ensuring – is used to automatically assess
significant portion of incorrectly tuned quality of production and its controller performance. In this article,
automatic control loops can actually profitability. Supervision and ABB’s control loop condition
decrease production performance improvement of controller monitoring technology is reviewed.
rather than improve it. performance is therefore vital and
important.

ABB Review
C ontrol loops are an intrinsic part

of any automation system. It has
been estimated that control loops have
The need for CLCM?
Assessment of control loop behavior
is as old as controller design. In the
CLCM in industry
The chemical, petro-chemical and
pulp and paper industries were the
an asset value of $ 25,000, with a cost design phase, the designer usually first to apply CLCM methods and
distribution as shown in 1 . According creates a controller that satisfies some have, over the years, built up consid-
to a recent editorial from the Hydro- given performance specifications. erable experience. More recently,
carbon Processing Journal [1], “With- Unfortunately, these performance
out properly tuned control loops to specifications often cannot be evaluat-
minimize variability, and updated pro- ed using measurement data obtained
2 Loop ranking overview for a typical plant in
cess models used by the advanced from normal plant operation.
the process industry.
controls to reflect real constraints and
business objectives, substantial bene- In helping to resolve this issue con-
fits are lost”. In other words, “include siderable research has been carried
control loops in asset management”. out to develop a holistic and non-in-
vasive methodology that can automati- 16 %
Automated CLCM is highly attractive cally assess controller performance. 28 %
in most plants because there are sim- An overview of ongoing research is
ply too many control loops to be presented in [3].
maintained by one service engineer
on a regular basis, ie, at least every 6%
32 %
six months. Another reason why many
industries are interested in CLCM is its
Automated CLCM is
18 %
inherent non-invasiveness. highly attractive in most
plants because there are
CLCM works like a doctor’s stetho-
scope: it obtains a diagnosis by pas- simply too many control Good Fair
sively listening to the process. Typi- loops to be maintained by Poo Open-loop
cally, no more information than stan- Excellent
dard DCS tags – setpoint (SP), process
one service engineer on a
regular basis, ie, at least
SP, PV
variable (PV), controller output (CO)

etc. – is required. In a typical produc- every six months.
tion plant in the process industry, for
example, there may be up to several
OP
thousand control loops. 2 shows a The most obvious and serious control
typical and important loop perfor- loop problem is a persisting oscilla-
mance ranking result, including typi- tion. Reasons are manifold: bad con-
SP, PV
cal data for each category. troller settings; external problems;

valve friction; equipment failure; or
process-related reasons. Irregular de-
1 Cost distribution of a control loop.
OP
viations from targets are more difficult

to analyse. Luckily nowadays, oscilla-
tions and poor performance can be
SP, PV
12 % 10 % automatically detected – with help, for

example, from what is known as the
8%
Harris Index [2]. However, the main
challenge of diagnosing bad perfor-
OP
26 %
12 % mance remains.
CLCM typically focuses on basic con-

SP, PV
8%
trol loops that are vital in achieving
24 %
the targeted product quality and plant
performance. However, in situations
OP
where highly advanced control loops

Sensor are used, more advanced supervision
Control valve functionality is needed. Advanced
SP, PV
Commissioning control (eg, a model-predictive con-

Share of DCS troller) relies heavily on the assump-
Installation tion that the underlying basic control
Engineering loops perform satisfactorily. CLCM
OP
Maintenance ensures this requirement.

ABB Review
there have been successful applica- ABB has adopted this idea and inte- havior are very common. These oscil-
tions in power plants. The increasing grated both functionalities into what it lations can be automatically detected
number of academic research groups calls the OptimizeIT Loop Performance by ABB’s AC800M controller. Not only
and the increasing interest from differ- Manager (LPM) tool [5]. this but the AC800M controller can
ent automation system vendors is an- overcome the sticking valve move-
other indication of the usefulness of What’s on offer from ABB ment by adding pulses to the manipu-
CLCM. ABB offers CLCM functionality on dif- lated variable so the valve moves to
ferent levels of it’s IndustrialIT automa- the desired position [6]. 5 shows a
tion palette 3 . typical measurement signal (PV) in a
CLCM includes single- control loop exhibiting stick-slip and
loop analysis (bottom-up) OptimizeIT Loop Performance Manager the corresponding AC800M functional-
as well as plant-wide (LPM) ity.
ABB’s OptimizeIT Loop Performance
analyses (top-down). Manager (LPM) is a general and pow- The controller can detect sticking
ABB is first to offer this erful tool for controller performance valves and apply a stiction compensa-
condition monitoring. It combines tor algorithm to guarantee best possi-
superior combination. both control loop assessment and ble controller action until the next
controller tuning functionality, and valve maintenance.
This interest is also an effect of the runs with any automation architecture
more general trends affecting asset via OPC data connectivity 4 . The lat-
management. These trends have est version also includes a Plant-wide
CLCM is able to detect
been recently published by the ARC Disturbance Analysis module which loop performance
group [4]: has proven to be able to locate plant- deficiencies and can
Deliver recommendations, not only wide disturbance root causes very
pure information. successfully. contribute to substantial
Extend the usage of current assets gains once the appropri-
(no trend to replace current LPM’s control loop auditing not only
equipment). indicates the best and worst perform-
ate maintenance actions
Provide tight integration with the IT ing loops in a plant section, but it also have been taken.
environment. gives detailed analyses on how to re-
Reduce plant staff and increase move identified problems. These System 800xA: Asset Optimization and
competitiveness by creating a new problems include discrepancies in the control loop asset monitoring
maintenance paradigm. final control element, external distur- ABB’s 800xA Asset Optimization Sys-
bances, and controller tuning. tem includes fully automatic loop
Modern CLCM tools strive to support monitoring functionality via a so
these trends. In fact ARC recommends Controller hardware: ControlIT AC800M called “Control Loop Asset Monitor”.
the combination of control loop con- On the field device level, some basic By that the detection and diagnosis of
dition monitoring with a controller functionality exists for control loop control loop problems is fed into the
tuning tool. condition monitoring. For example, asset optimization data handling of
oscillations due to valve stick-slip be- the 800xA system [7]. Messaging, con-
3 Automation architecture indicating controller condition monitoring 4 ABB Loop Performance Manager (LPM): loop auditing window.
functionality (red arrows).
800xA System 800xA Asset OptimizeIT Loop

Optimization Performance Manager
Plant network
Plant
Information
Management
System (PIMS)

ABB Review
nection to the computerized mainte- 5 Oscillation detection and stiction compensation function overview in the 800M controller.
nance management system (CMMS),
The process value exhibits typical stiction behavior.
and access to historical data and other
real-time plant information helps the Advanced PID controller module Enable
user trace problems and initiate cor- Setpoint
Stiction
rective actions. compensator
PID Algorithm
Industrial applications AO
Output
Without any doubt, industries experi-
Oscillation
ence various control-loop related Process value
detector
problems. These problems may vary
Sluggishness
depending on the industry in ques- Output if
detector !
tion. oscillations
sluggish control Process valve at
are detected risk of stiction
According to a recent
editorial from the Hydro-
carbon Processing Jour-
loops, and experiments verified the One important point is the ability to
nal, “Without properly diagnoses. The subsequent improve- classify CLCM results by the current
tuned control loops to ments are obvious from the data col- load situation in the power plant. Con-
lected later. troller behavior is typically a function
minimize variability, and of the load (eg, high, low, start-up,
updated process models Diagnosis of controllers
used by the advanced in power plants
ABB’s CLCM has caught
CLCM-related problems in power
controls to reflect real plants are very similar to those in oth- the attention of various
constraints and business er industries. Some aspects, however, industries, and many are
do differ, such as the total number of
objectives, substantial control loops is somewhat lower than starting to apply such
benefits are lost”. in the chemical industry. This allows techniques.
greater sophistication when it comes
A simple example is to compare the to the configuration and tuning of load change) or of other properties like
high-precision position controller in a each of the loops. Cascades, feed for- raw material type etc. Modern CLCM
disc drive with a surge tank level con- ward and more advanced control log- methods do consider such conditions.
troller in a paper mill. Obviously, ics are also more common and CLCM
both controllers share the same task needs to take such configurations into Diagnosis of control-relevant
but their respective benchmarks account. disturbances in cold rolling mills
should be set on two different In the rolling mill industry,
scales. a few highly sophisticated
control loops are needed
6 Improvement of controller performance after application of CLCM
Consequently, some of the for tension and thickness
with subsequent maintenance.
control performance monitor- control. However, the appli-
ing methodology would fit before after cation of standard CLCM
the first application, some of methods in the rolling mill
it the other. Since control per- 20 industry is perhaps not as
formance monitoring tradi- straightforward as in the
tionally originates from the chemical industry, as recent
16
process industry, most estab- applications of these meth-
lished methods focus on the ods have produced results
Tag number
problems that are typically 12 that are difficult to interpret.

encountered in this industry.
8
On the other hand, where
Diagnosis of controllers in the CLCM functionality has been
(petro-) chemical and pulp and specially designed for rolling
4
paper industry mill applications, the results
6 shows a subset of data be- have been very encouraging.
fore and after a performance 0 To be more specific, CLCM
improvement initiative in a 0 500 1000 1500 2000 functionality has been suc-
pulp mill. CLCM methods Samples (s) cessfully designed to diag-
detected oscillatory control nose and remove periodic

ABB Review
7 ABB OperateIT screen for the diagnosis of periodic disturbances.
disturbances which are predominant in Conclusions ABB’s research and product variety
rolling mills [9], and a typical automat- CLCM is inherently a passive and auto- has enabled a flexible application of
ed diagnosis screenshot is shown in 7 . matic technique which has caught the CLCM across many different indus-
attention of many industries. The ben- tries. These applications have been
Beyond single-loop controller condition efits gained by removing control per- adapted so that the existing hardware
monitoring at a customer site is used. CLCM can
CLCM is able to detect loop perfor- The benefits gained by be applied to any process architecture
mance deficiencies and can contribute regardless of whether ABB’s 800xA
to substantial gains once the appropri- removing control perfor- System or a third-party DCS is in-
ate maintenance actions have been mance bottlenecks and stalled.
taken. However, there are cases
where the plant is not properly opti-
performance degrada-
mized even though the controllers tions due to bad control
are performing well. In such cases, it are substantial.
is highly probable that the current
controller structure is not sufficient. formance bottlenecks and perfor-
A systematic and fast way of assessing mance degradations due to bad con-
the controller landscape and the pre- trol are substantial. So much so that Alexander Horch
vailing automation infrastructure is by more and more industries and compa- ABB Corporate Research,
using a benchmarking service provid- nies are starting to apply such tech- Ladenburg, Germany
ed by ABB [10]. niques. alexander.horch@de.abb.com
References
[1] Kane, L. A., “Include control loops in asset management”, Editorial of Hydrocarbon Processing, June 2003, p. 128, 2003.
[2] Harris, T. “Assessment of control loop performance”, In “The Canadian Journal of Chemical Engineering”, Vol 67, pp. 856–861 (1989).
[3] Horch, A., Dumont, G., International Journal of Adaptive Control and Signal Processing, Special Issue on Control Performance Monitoring, Eds., Vol. 17, No. 7–9,
September-November 2003.
[4] ARC Advisory Group, “Real-time Performance Monitoring Strategies for Asset Optimization”, ARC Strategies, July 2004 (www.ARCweb.com)
[5] ABB (2005). “OptimizeIT – Loop Performance Manager Version 2.0. User’s Guide.” ABB Advanced Control Solutions, www.abb.com ’ Products & Services ’ Systems
and Industry Solutions ’ Chemicals ’ Advanced Control ’ LPM.
[6] Hägglund, T. (1997). “Stiction compensation in control valves.” In European Control Conference, Brussels, Belgium.
[7] ABB (2005). System 800xA Asset Optimization, www.abb.com ’ Products & Services ’ ABB Product Guide ’ Control Systems ’ 800xA ’ Asset Optimization
[8] ABB (2005). System 800xA Information Management, www.abb.com ’ Products & Services ’ ABB Product Guide ’ Control Systems ’ 800xA ’ Information
Management
[9] ABB (2005), “AdviseIT for Cold Rolling Mills”, Brochure, Ref. No. DEPI/BM_0105_EN., www.abb.com/metals
[10] ABB (2005). “ABB Service Guide”. www.abb.com ’ Products & Services ’ ABB Service Guide
[11] Horch, A., Hegre, V., Hilmen, K., Melbø, H., Benabbas, L., Pistikopoulos, S., Thornhill, N., Bonavita, N., “Root Cause”. ABB Review 2/2005.
Additional reading
ARC Advisory Group, “Applying OpX to Control Loops increases ROI”, ARC Insights, October 2002 (www.ARCweb.com).

ABB Review
Not on my watch
How ABB’s Power Management System prevents multi million dollar shutdowns
Otto van der Wal, Per Erik Holsten
Energy is vital for industries to operate. Many of ABB’s 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
T he situation in nearly any black-
out is almost always the same:
one part of a system fails forcing
public electricity supply is unreliable or non existent meaning they must rely nearby equipment to absorb its load.
heavily on their own generation capabilities. An unscheduled trip in, for exam- This equipment is then pushed into
ple, a refinery or a liquefied natural gas (LNG) plant due to a total loss of pow- an overload mode causing it in turn to
fail. These multiple failures snowball
er could result in several days of lost production. When translated, this repre-
and a large area ends up in the dark
sents a value exceeding $-10 million. with potential dire consequences
including potential loss of life, loss of
Because of this dependence on electricity and the volatility of energy costs, production and damaged equipment.
combined with a growing environmental consciousness and more stringent
legislation, efficient energy management is becoming ever more important. It is imperative that process upsets
and shutdowns are avoided as they
will have a negative effect on the fi-
ABB’s IndustrialIT Power Management System (PMS) is a family of unique
nancial, environmental and social per-
solutions that ensure reliable and stable energy supply for energy-intensive formance of a company. Power sup-
industries. The PMS balances energy demands with the available energy ply reliability and power quality affect
supply, thus preventing disturbances or even blackouts in operations. both throughput and safety; therefore
Furthermore, it enables a company to control its energy costs, to enhance avoiding black-outs and power distur-
safety, and to mitigate environmental and health impacts. bances are of substantial value to any
process plant. Equipment must be
monitored continuously to ensure op-
timal performance and stability over
time. The extremely fast dynamic
properties of the electrical process re-
quire quick response times – of the

ABB Review
Not on my watch
order milliseconds – to prevent pro- [1, 2], which is designed to monitor, functions for power generation, distri-
tection relays from issuing trip com- control and protect all sections of a bution and supply in industrial plants.
mands leading to a domino effect in process plant. This common IndustrialIT Such broad functionality is partially
terms of equipment overload. platform provides control functions, represented by modules commonly
and a flexible and well organized sin- used by the industry under different
Inefficiency isn’t just costly in terms gle-window interface that allows oper- names1).
of excessive fuel consumption; high ators to work efficiently. In addition,
emissions can rack up the cost still advanced functions such as intelligent
further. Solutions that help lower op- alarm filtering, consistency analysis By checking the open/
erating costs while reducing environ- and operator guidance help reduce the close positions of critical
mental impact are sorely needed by need for operator intervention and,
industry. more importantly, these functions can
circuit breakers in the
prevent incorrect interventions. electrical network and
One such solution, ABB’s IndustrialIT using its internal “knowl-
Power Management System (PMS), The importance of systematic operator
helps achieve stable operation where- training in a realistic setting is increas- edge” of the electrical
by the electrical plant as a whole can ingly acknowledged as a prerequisite network topology, the
withstand larger disturbances from to reach operational best in class tar-
within or from outside the plant. This gets. The IndustrialIT Training simula-
Network Determination
application package contains not only tor can be integrated with a multitude function can determine
the traditional SCADA functionality of process and electrical simulators. network contingencies.
but also a full complement of electri- Because it runs on the IndustrialIT
cal solutions including Power Control platform, the PMS can be conveniently
and Load Shedding, two major func- deployed in the integrated Training In addition to the traditional functions
tions that are described in details in Simulator, where control strategies – of supervisory control and data acqui-
this article. such as load shedding priorities – and sition (SCADA), the system offers:
“what-if” simulations can be tested SCADA electrical functions:
A common platform for process control, prior to deployment 1 . – Generator control including inte-
safety, power generation and utility gration with the governor and
control PMS main functions excitation controller.
The PMS is based on ABB’s Industrial The PMS provides an integrated set of – Circuit breaker control including
IT Extended Automation System 800xA control, supervision and management integration with protection relays,
event monitoring, time synchroni-
zation with 1ms resolution. Syn-
chronization between two electri-
Factbox Network Determination
cal islands must be performed and
checked by the PMS before a cir-
The Network Determination function is an The electrical network matrix is a square
cuit breaker is closed. The gener-
important supporting function for the Power matrix with same number of columns and
ators used for synchronization can
Control, Load Shedding and Synchronization rows. Each column and row represents a
be selected manually or automati-
functions. (main) bus bar in the electrical network. The
cally. This is performed by the
cells in the matrix represent circuit breaker
positions which are the connections between
synchronization function.
By checking the open/close positions of
the (main) bus bars.
– Transformer and tapchanger
critical circuit breakers in the electrical
network and using its internal “knowledge” of
control: the mode control func-
the electrical network topology, the Network The Network Determination function tion changes the control mode
Determination function can determine calculates the electrical network contingen- of tap-changers, governors and
network contingencies. cies from this matrix – it calculates a “re- excitation systems according to
duced” network matrix. The number of rows the status of the electrical net-
The PMS uses sophisticated matrix in this reduced network matrix is equal to the work 2 .
calculations to determine electrical network number of sub networks (or network islands) – Motor control including integra-
contingencies. Network contingencies must in the electrical network. The reduced net- tion with motor control centers,
be calculated in a matter of milliseconds after work matrix is used by: Power Control to time synchronization, automatic
a circuit breaker position has changed and calculate imported and generated power and sequential re-start and re-accelera-
are therefore determined by complex logics. balance loads in sub networks; Load Shed- tion release after load shedding or
To give an idea of the complexity and size of ding to calculate imbalances between avail- under-voltage.
the necessary logic, an electrical network able and required power; Synchronization to Network Determination: This and
with one grid connection and eight check which power sources (grid and gener- the mode control function are
generators has 2(1+8) – 1 possible network ators) are available to achieve synchroniza- important supporting functions for
contingencies. tion. the Power Control, Load Shedding
and Synchronization features. See
Factbox .

ABB Review
Not on my watch
Power Control including tie-line tion will interface with the Load shed- the difference in [Hz] is converted into
control, peak shaving and load shar- ding function (see Peak Shaving be- an active power unit [MW].
ing. low) to shed sufficient non-critical
Load Shedding including both fast, loads. In case of power flow control, the
slow and frequency based. power working point at the exchange
Active Power Control point is subtracted from the power
Both Power Control and Load Shed- As part of Power Control, the Active setpoint.
ding are described in greater detail in Power Control module performs fre-
the following paragraphs. quency control and active power flow PI control
control at an exchange point with the The input to the PI control element is
Power Control grid. It monitors the actual network power mismatch. The output of the
The objective of the Power Control configuration and sends an active control element increases/decreases
function is to maintain stable opera- power setpoint to the participating as long as there is a mismatch at the
tion. It does this by sharing active and generators to: input of the PI control element.
reactive power demand among differ- Maintain the bus bar frequency at a
ent generators and tie-lines in such a pre-defined value if that particular Participating factor
way that the working points of the network is isolated. The operator can assign a participat-
generator sets are as far as possible Or maintain an active power flow ing factor to each generator. This de-
from the border of the individual between a particular network con- termines to what extent the generator
PQ-capability diagrams so the plant nected to the grid. will participate in power control. To
can withstand bigger disturbances 3 . decide on the most suitable participat-
Active Power Control Aspect decides ing factor, the operator can look at
if frequency control or power flow calculated factors based on the avail-
The importance of sys- control is applicable. This decision able control margins. There are partic-
tematic operator training depends on the actual network con- ipating factors for active power con-
in a realistic setting is in- figuration. This means no operator in- trol and reactive power control.
teraction is required after a network
creasingly acknowledged configuration change. Power setpoint per generator
as a prerequisite to reach A power setpoint can be set to keep
The active power setpoints are sent to the generator at a desired spot in the
operational best in class the participating generators, ie, the generator capability curve without
targets. generators that act in Governor Auto- affecting the frequency/voltage or
mode. active/reactive power flow control.
In the following paragraphs, the con-
trol strategies contained within the Power mismatch Reactive power control
overall Power Control package are In the case of frequency/voltage con- The Reactive Power Control module is
described. trol, the working point, taken from the Object Control Aspect for voltage
the bus bar, is subtracted from the set- control and reactive power flow con-
Tie-line control point. In case of active power control, trol at an exchange point with the
The Tie-line control function, which
is part of Power Control, optimizes
1 What is needed for an efficiently operating plant.
the power exchange with the Public
Power Company (PPC) to an adjust-
able setpoint based on contractual
Users
obligations, such as the maximum 15

minutes peak value used in Europe. ...
Utility Operator Process Operator Maintenance Manager
It works as follows: the PMS measures
the imported (or exported) power, or
the transmitted power between differ- Visualization, Interaction
ent locations, by counting pulses from
IndustrialIT
energy meters. From these measure- Power Mode Load Re-acc.

Synchr.
ments, a sliding 15 minutes power Control Control Shedding Re-start
demand forecast is calculated. When
power demand tends to exceed con- Object monitoring, control and protection
tracted electricity import limits or a
setpoint specified by an operator, the
PMS will initially try to increase in-
Plant
Power Generation Production Inventory,

plant generation to avoid exceeding
and distribution Process Shipment
the contractual obligations. If this is
not possible, the Tie-line control func-

ABB Review
Not on my watch
grid. It monitors the actual network (measured value) is minimized by the quency threshold. Frequency Load
configuration and sends an reactive AVR control of the participating gener- Shedding is usually used as an inde-
power setpoint to the participation ators. Control parameters as gain and pendent back-up system for fast
generators and/or transformer to: time integration are adjusted in such load shedding
Maintain the bus bar voltage at a a way that the transformer control Slow Load Shedding is used when
pre-defined value. Maintain a reac- prevails. an overload has occurred. For ex-
tive power flow between a particu- ample if a transformer is loaded at
lar network and the grid, or another Load Shedding 120 percent, switching off some
network. The PMS Load Shedding function loads to bring the transformer back
Maintain the powerfactor at the ensures the availability of electrical to its nominal load is by far the best
exchange point. power to all critical and essential solution. The system advises the
loads in the plant at all times. Load operator which non-critical loads he
The Reactive Power Control Aspect shedding is achieved by switching off can switch off. This manual effort
decides if voltage control or reactive non-essential loads when there is a must be done within a specified
power flow control is applicable de- shortage of power generation capacity period of time otherwise the system
pending on the actual network config- in the electrical network of the plant. will do it automatically.
uration. This means that no operator – Peak Shaving is another type of
interaction is required after a network There are four different types of load slow load shedding and occurs
configuration change. shedding: when the following situation aris-
Fast Load Shedding is based on es: if in-house generation is maxi-
The reactive power setpoints are sent electrical energy balance mized but it seems highly proba-
to the participating generators and calculations. As soon as one or ble the 15 minutes sliding maxi-
transformer. more electrical islands are detected mum power demand will exceed
(using network determination the contracted maximum value,
Also a reactive power setpoint can be software), the system calculates if then some of the low priority
set to keep the generator at a desired there is enough electrical power loads are shed. Manual Load
spot in the generator capability curve available in every individual island Shedding is mainly used when
without affecting the voltage and/or to power the loads. If not, any one of the afore-mentioned condi-
reactive power flow control. existing demand surplus is shed. tions for Slow Load Shedding
The shedding process is dictated by occurred but operations did not
Reactive power control in cooperation priority tables, which are based on allow the system to shed auto-
with transformer control the operational conditions of the matically.
A transformer is used for main control process.
when it participates in voltage control Frequency Load Shedding (or back- How much to shed?
or reactive power flow control. Trans- up load shedding) uses a frequency The ABB system is fast because it
former control maintains the voltage drop as an input to activate load doesn’t wait for a decrease in frequen-
or reactive power flow at a desired shedding. Activation of an actual cy before it starts to shed loads. In-
setpoint and the remaining mismatch shed command can be based on a stead, its decision to shed – as well as
between setpoint and working point frequency decay or by passing a fre- how much should be shed – depends
2 Generator Capability diagram with working point and mode selections.

ABB Review
Not on my watch
3 Single Line Diagram indicating that four motors have been shed after 4 Graphical presentation of the accumulated effect of shedding the
a generator trip. loads assigned to the 20 load shedding priorities.
on the balance between the amount Plant start up: the PMS will ensure in a short space of time just by ensur-
of power generated and consumed in the power system capacity is not ing greater efficiency of power gener-
every island. To execute load shed- violated at any time by holding load ation, import and usage under varying
ding within 100–250 ms of a distur- start commands until the system can operating conditions.
bance, however, many calculations provide the power required to start
must be done in advance. a particular load. This helps get the The investment can easily be justified
plant safely on stream as quickly as in both green and brown field plants,
Deciding how much power should be possible. and several examples of recent instal-
shed depends on the number of prior- All phases of plant operation: the lations exist around the globe. The
ities used, the size, in MW, of the load PMS will control generators and same system is used for both electrical
shed groups, and the availability of transformer tap-changers to ensure and process control allowing cost re-
system measurements. stable power system operation, as duction in training, spare parts and
well as monitoring and controlling maintenance.
ABB’s load shedding set-up is very active and reactive power exchange
flexible because an operator can adapt with the public grid. The general
(online) the priority of the various workload and number of inter-
plant loads to the process operating ventions from the operators are
conditions and the electrical network 4 . reduced. Otto van der Wal
Also at the moment the system deter- Maintenance planning: ABB A.S. Norway
mines the shedding order, it considers comprehensive data are recorded otto.wal@nl.abb.com
how much spinning reserve is avail- and aggregated on the condition of
able. To utilize this reserve, the system the electrical assets. The appropriate Per Erik Holsten
can, and will if necessary, change the ABB Industrial IT Asset Monitors ABB A.S. Norway
operating mode of a generator. can monitor this data automatically, per-erik.holsten@no.abb.com
and the responsible people are
The coordination between load shed- notified when actions must be References
ding and re-acceleration is also impor- taken. The ABB Industrial IT Asset [1] Taft, Mike W., “IndustrialIT System 800xA, Extend-
ing the reach of automation to achieve continuous
tant. Re-acceleration is disabled when a Optimizer workplace provides the
productivity improvements”, ABB Review 1/2004,
load shedding action is required, and is overview of equipment health and
pp 32–37.
immediately restarted once the condi- the base information needed to plan [2] www.abb.com/automation
tions for load shedding have vanished. maintenance campaigns.
Summary The PMS can also be part of a broader Footnotes

1)
The PMS benefits are clearly visible electrical system delivery from ABB. Electrical Control System (ECS).
2)
Electrical Integrated Control System (ELICS).
during: In certain industries such as chemical, 3)
Integrated Protection and Control System (IPCS).
The plant definition phase: the im- petrochemical, cement and steel, en- 4)
Power Distribution Control System (PDCS).
proved system stability allows tight- ergy costs represent approximately 5)
Load Management System (LMS).
er dimensioning and thus reduced 30 to 50 percent of the total produc- 6)
Electrical Network Monitoring & Control System
costs. tion cost. ABB’s PMS can pay for itself (ENMCS).

ABB Review
Experience counts
Mondi Packaging Frantschach can rely on ABB
Marja-Liisa Parkkinen
T he Mondi Packaging Frantschach

1 Factbox mill has three paper
machines, the PM 6, 7 and 8, that pro-

duce approximately 250,000 tons of
sack and kraft paper per year. The
wire width of the PM 6 is 490 mm
and the sack paper produced covers
60-125 grams per m2. With a speed of
920 meters per minute, the PM 6 is
one of the fastest sack paper
machines in the world. The PM 8 also
produces sack paper and has a wire
width of 510 mm and a speed of
830 meters per minute, while PM 7
produces kraft paper of 30–150 grams
per m2 with a speed of 350 meters per
minute. The Frantschach mill also
produces approximately 50,000 tons
of unbleached market pulp per year,
and uses spruce and pinewood as
the raw materials. Franz Maischberger
2 is Head of the Project Department
responsible for Electrical, Process

Control and Process IT. He has been
working at the mill for 29 years; his
passion for stable state-of-the-art tech-
nology is one of the reasons for Frant-
schach mill’s position as a technologi-
cal forerunner. Mr Maischberger says
that “the mill’s strengths lie in: quality;
Research and Development; employee
skill; two highly efficient sack paper
The 125 year old Mondi Packaging Frantschach mill sits in the Lavant Valley machines; and just-in-time delivery”.
amid the breathtaking beauty of the southern Austrian Alps. Three paper Its outstanding approach to sack
machines produce approximately 250,000 tons of sack and kraft paper per paper production sets the standard for
year. Frantschach’s high quality pulp and paper are used to produce high many other Mondi sack paper mills.
quality end products. Producing pulp for the Melitta coffee group as well as
luxury paper bags based on its kraft paper, the mill’s overall export rate is End products
Frantschach’s sack and kraft paper
more than 80 percent of production. Quality is the key factor and to maintain
goes under the brand name of
such high quality, the company’s strategy is to modernize continuously to “ADVANTAGE”. Sack paper needs to
ensure it has the most up-to-date technology. And helping Frantschach in this be of the very highest quality when
task is one of its many long-term partners, ABB. one considers that some customers fill
them with 25 or 50 kilos of cement,
producing some 4,000 sacks per hour!

ABB Review
Experience counts
Frantschach enables customers to berger, “We work alongside customers Secondly, the company identifies best
achieve this by paying special atten- worldwide to achieve world grade practices in its production processes
tion to factors such as printability, quality. We want to be our customers’ and is constantly accumulating experi-
strength, energy absorption and po- preferred, long-term partner.” The ence through its “Knowledge for Pro-
rosity1). Very few sack paper produc- same attitude emerges when Mr. Mais- duction” continuous learning system.
ers are able to meet such quality chberger refers to suppliers. He pre- Each shift worker logs information on
requirements. The world-renowned fers major, global suppliers who, in any incidents or problems, as well as
coffee filter brand, Melitta, acquires the long run, provide high quality. the related actions and solutions. This
Frantschach’s unbleached pulp. Other means that all experiences related to
special pulp grades produced by the the process are available online
mill are used in the production of
Quality is a key factor – around the clock.
isolation material for transformers. to maintain such high
Meanwhile the luxury paper bags quality, the company’s The third factor concerns health and
used in many shops are based on safety. Mr. Maischberger says that
Frantschach’s kraft paper. strategy is to modernize “safety, health, environmental friend-
continuously to ensure it liness and a zero rate of accidents
Quality is the key factor that embraces are our working environment goals”.
end products, the paper production
has the most up to date “This is a question of attitudes rather
process, the pulp mill process, the technology. than techniques,” he continues. As a
woodyard process as well as the staff’s result of this ambitious program, safe-
know-how. According to Mr. Maisch- Basis for high quality ty performance has developed signifi-
Several factors have contributed to cantly over the last few years.
the mill’s reputation as a high quality
pulp and paper producer. First of all, ABB – a long-term partner
1 The 125 year old Mondi Packaging
the company’s strategy is to continu- Equipment and PCs bearing the ABB
Frantschach mill sits in the Lavant Valley
ously modernize to ensure it has the logo can be found all over the mill.
amid the southern Austrian Alps
most up-to-date technology. This is The second generation of Manufactur-
helped by the fact that it has reliable ing Execution Systems (MES) solutions
long-term partnerships with major – the equivalent of Collaborative Pro-
P&P industry machine, and equipment duction Management (CPM) – have
and system suppliers. The Frantschach been deployed in production planning
mill is currently reconstructing its and optimization, production tracking
wood yard and raw material mixing and quality management 3 . Three
at a cost of approximately 20 million quality control systems delivered by
euros. ABB perform online quality control on
Factbox Mondi Packaging
The Mondi Packaging Frantschach is Mondi Packaging Frantschach mill has won
member of the Mondi Packaging Group, a several awards in recent years because of its
leading European paper and packaging attention to quality and innovation. In partic-
2 Franz Maischberger is Head of the Project (P&P) company. It is active in the bag and ular it has won countrywide environmental
Department responsible for Electrical, flexibles business and has more than 100 improvement and innovation awards.
Process Control and Process IT production facilities worldwide.
Taking care of the environment
The Mondi Group is owned by the Anglo The nearby town of Frantschach-St. Ger-
American Group. Mondi operates worldwide traud has some 3,000 inhabitants, and the
and is principally involved in producing paper, area is renowned for skiing in winter and its
packaging solutions, coating and business hiking and biking routes in the summer. Envi-
paper. In 2005, it employed 16,278 people ronmental issues are therefore of great im-
with sales totaling 3,092 billion euros. portance to Mondi Packaging Frantschach
and due to solid technology improvements,
Mondi Packaging Frantschach GmbH is waste water figures have dropped to an
located in the Lavant Valley in Austria and 1,500 Inhabitants Equal Value, while SO2
was founded in 1881. It is responsible for all emissions have tumbled from 1,800 mg/m3
R&D within the Mondi Packaging Paper to 40 mg/m3. In 1998 the mill was certified
Division. The mill employs more than 500 according to the Environmental Management
people and in October 2006, it celebrated its System ISO 14001.
125th anniversary.

ABB Review
Experience counts
PM 6, 7, 8 and the flash dryer 4 , while ABB in 2002 to cover the production investment decisions – improved pro-
ABB’s Automation System, which scheduling of the flash dryer, paper cesses, quality and better customer
already covers the paper machines, machines, winders and rewinders as service – have all been borne out.”
the pulp mill and the power plant, has well as warehousing and logistics. A similar system, based on this Frant-
just been upgraded and extended to According Mr. Maischberger, “Our schach template, was successfully in-
now cover the wood yard. experience of ABB’s earlier systems stalled at the Mondi Packaging Dynäs
was decisive in our decision to pur- mill in May 2006.
CPM chase another CPM solution from
Approximately 10 years ago, ABB them, as well as the financial aspect. Enterprise integration the key
delivered an MES system to the Frant- The applications were designed as to success
schach paper mill. Some years later it multi-mill solutions, possibly covering A fully integrated mill means that
was decided to install a new system similar mills belonging to Mondi Pack- every aspect of the mill can be con-
because (a) the original MES system aging in the future.” trolled. The wood yard was modern-
was nearing the end of its lifecycle ized and is also controlled using the
and (b) Frantschach mill’s corporate control system delivered by ABB.
structure changed when it became a The company identifies
member of the global Mondi Packag- best practices in its pro- The original pulp mill control system
ing Group. For these reasons, the mill was delivered between 1996 and 2000
decided to acquire new production
duction processes and is and was upgraded in 2006 to include
planning, production tracking and constantly accumulating the latest advanced features of the
quality management systems from experience through its current system. This system comprises
12 ADVANT AC450 controllers and
“Knowledge for Produc- 16,000 input/output points gathering
3 The second generation of MES solutions
tion” continuous learning information on processes, with about
20 operator workstations. The paper
have been deployed in production planning system. mill system is based on ADVANT
and optimization, production tracking and
AC460 technology which operates all
quality management
A template solution, a proto system three paper machines on one Distrib-
based on ABB’s IndustrialIT CPM solu- uted Control Network. Therefore sit-
tion, was created as a first step. IT ting in a conference room, for exam-
specialists from the Frantschach mill ple, an operator can connect online
and ABB’s Helsinki base worked to- to the pulp and paper mill processes
gether to install the new system. Even and simultaneously display the contin-
though it was based on a standard uous cooking process, paper machine
CPM solution, many customized fea- operation and QCS in real time.
tures were incorporated to ensure that
it fitted perfectly into the mill’s pro- Access rights are set up so that each
cesses. A challenging additional as- user gets the required information for
pect was the linking of the ABB-CPM timely and informed decision-making.
solution to a centralized SAP system In the same way, online history data
built simultaneously. The system now is made available immediately. This
supports 70 concurrent users. fully integrated solution is helping to
improve the productivity of the entire
A fundamental new feature of the mill.
4 Three ABB quality control systems perform
template/proto solution is the Capa-
online quality control on PM 6, 7, 8 and the
bility to Promise (CTP) feature, which
flash dryer
gives a 100 percent assurance online
to customers that Mondi Packaging
Frantschach is able to deliver the right
quality at the right time. Another
unique feature, the integrated plan- Marja-Liisa Parkkinen
ning functionality, enables paper ABB Finland
producers to forecast the amount of marja-lissa parkkinen@fi.abb.com
pulp needed for paper and market
pulp production and to balance this
Footnote
with the planned production of bulk 1)
Printability, strength, total energy absorption and
pulp.
porosity are the most important quality features
in sack paper. Frantschach has a quality control
The project was called SPARK 2, and system for every paper machine; these ADVANT
lasted three years. Mr. Maischberger 1190 systems have been controlling basic paper
said that “the reasons underlying our properties for many years.

ABB Review
Finding the right

balance
Electrification solution for the pulp
and paper industry
Marja-Liisa Parkkinen, Juha Willman
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.

ABB Review
Finding the right balance
A total electrification solution cov-

ers basic and detailed engineer-
ing, supply site management, supervi-
Neplan network calculation program
to carry out the electrotechnical
dimensioning of a network. This pro-
ployed. The use of larger units has
meant that optimal voltage levels have
had to increase. For example, 690 V
sion, erection and commissioning of gram can model all the central elec- has replaced, to a large extent, the
the entire electrical solution. ABB’s trotechnical parameters, and it helps 400 V value which was very popular
long-term and extensive experience in engineers find the most reliable as a low voltage. Due to its greater
such electrification projects for the dimensioning of an entire network stiffness it can also replace, or at least
pulp and paper industry enables the for various normal and abnormal situ- partly, 3 kV and 6 kV as a motor volt-
company to implement an electricity ations. age. In electricity distribution, a volt-
distribution plan for a complete pulp age of 33 kV has often replaced lower
or paper plant based on relatively lim- distribution voltage levels.
ited initial data. At the very least this
ABB’s extensive experi-
initial data should include lists of con- ence in electrification Compatibility
sumers and a plant layout. However, projects enables it to As a rule, a new electrical system is
in reality consumer information at the related to an already existing system
beginning of a project can be ex- implement an electricity but it has limitations or requirements
tremely limited. In such cases ABB’s distribution plan for a imposed on it by the older system.
experience in various types of pulp However, the new system creates its
and paper plants can be exploited by
complete pulp or paper own preconditions for future plant
complementing the initial data with plant extensions. For this reason, the most
experimental data from other projects probable scenarios for future exten-
of similar types. In addition, other Energy efficiency sions should also be taken into con-
technical matters related to the pro- In addition to purchasing costs, other sideration when designing a new
cess in question, including power factors which can optimize overall network. In other words, the future
stations, should be considered. costs should be considered during the extendibility of a plant depends to a
design phase. Energy costs and losses, large extent on the basic decisions
Network calculations for example, are increasing all the made in the current design.
Good basic skills acquired from work- time and in the future their share of
ing with electrical systems, together the total costs will be even more sig- To successfully implement large sys-
with an advanced network calculation nificant. With this in mind, ABB has tems, the quality of electricity and the
program ensure a network configura- dedicated much R&D towards improv- compatibility of the equipment and
tion in which margins are managed, ing the efficiency of various apparatus systems are of the utmost importance.
unnecessary over dimensioning is and decreasing their losses. Compatibility is partly an equipment-
avoided and solutions that are techni- related factor but it can also be affect-
cally the simplest are obtained. In Total losses are not only positively ed through different constructive solu-
some cases the network dimensioning affected by the most constructive tions of the systems to be used.
is checked by using operational solution for an electricity distribution
modes which are very different from system, but also through basic choices As to the compatibility of the net-
one another. From the point of view such as the voltage levels used. The works in pulp and paper plants, har-
of dimensioning, situations in which recent tendency towards larger units monics from loads and voltage drops
the network is at its weakest – includ- in pulp and paper plants is noticeable resulting from the starting process of
ing isolated operation – form the most in the processes themselves and in the motors are the most important factors.
challenging situations. ABB uses the single units of process equipment em- These should also be taken into ac-
Network analysis – Harmonic spectrum Network analysis – Network impedance Z(f)
1.5 1.5
1.2
1.0
0.9
Z/ohm
U%
0.6
0.5
0.3
0.0 0.0
0 5 10 15 20 25 27 0 200 400 600 800 1000 1200
f/fn f/Hz

ABB Review
Finding the right balance
Substation
Plant Network
Power
Transformers
Power Distribution
Control
High Current
Process Control Busbars
Process Controller High Voltage

Fieldbus Switchgear GIS
Medium Voltage Protection

Switchgear Relays
Field Instruments
Sectional
Drives Generator/Motor
Excitation
Frequency
HCC
Converters
Links
Low Voltage
Distribution
Switchgear
Transformers
Low Voltage Motors

Medium Voltage Motors
count in network calculations in addi- motor appears to be the only limiting tions, including ”load shedding” and
tion to loading and short-circuit cur- factor. Motor starting is an especially ”islanding”, can be modelled and the
rents. By modelling a network accu- demanding operation in an isolated operational values can be accurately
rately, it is possible to ensure (a) suf- network if the motor is large com- determined.
ficient margins for different design pared to the generator. In this situa-
parameters even in the most difficult tion the dynamic behaviour of the The said optimized criteria are also
situations and (b) sufficient compati- generator and the excitation system included in project-related standards
bility for different parts of the net- should also be considered. In short, and guidelines – such as design and
work. However, significant cost differ- the optimal choice and dimensioning dimensioning instructions – which are
ences may arise between various solu- of the starting arrangements of motors created together with the customer.
tions. By optimally proportioning the has an important effect on costs and These standards and guidelines take
immunity levels of the equipment and availability. into account ABB’s extensive experi-
the amount of interferences generated ence in the pulp and paper industry,
in the network, significant savings can There are techniques available that the advantages of modern solutions,
be obtained when compared to gener- almost completely eliminate the large the results of network modelling and
ous over-dimensioning. Unnecessary harmonic currents currents created the customer’s knowledge of local
over-dimensioning of the quality of by motors in the network. However, conditions to give the best possible
electricity causes extra investment their elimination is not always the end result.
costs. most optimal solution. In the end cor-
rect reactive power compensation and
The voltage drops that occur during harmonic filtering have the most sig-
the starting process of a motor no lon- nificant effect on costs.
ger represent a limiting factor for the
motor size because of modern tech- Implementation design
niques. As effective starting methods The application design process also
are now available, the under-voltages uses network modelling. It gives basic
encountered during motor start-up values for dimensioning parameters Marja-Liisa Parkkinen
can always be adjusted to acceptable and determines different solutions for Juha Willman
levels. However, these requirements relay protection. In addition to basic ABB Automation technologies
should be checked in all switching protection functions, such as short-cir- Helsinki, Finland
situations where start-up is required. cuit and earth-fault protection, differ- marja-liisa.parkkinen@fi.abb.com
In fact, the normal operation of the ent kinds of advanced protection solu- juha.willman@fi.abb.com

ABB Review
T he construction and modernization
Peace
of cements plants is, in many
ways, very similar to other industries.
Cement customers and producers aim
to produce a high quality end product
efficiently using the most cost effective
of mind
means possible, while at the same
time minimizing overall environmental
impact.
Global players in the cement industry

Enabling increased productivity and comprise companies such as Holcim
(Switzerland), Lafarge (France) and
profitability in the cement industry with Heidelberg (Germany) as well as a
ABB’s System 800xA number of small local companies. The
majority of cement projects, including
Heikki Tanskanen, Alfredo Zeta
complete new plants as well as re-
vamps and modernizations, usually
occur in developing countries and
emerging markets – including Asia
and the Middle East. This is no sur-
It is no secret in the cement business – as with many other indus- prise because booming and emerging
tries – that basic automation solutions are fast becoming a com- economies are usually accompanied
modity product. However many “patchwork” automation systems by a need for new buildings, bridges
exist either because plant managers have had no choice but to and other infrastructure.
buy the equipment they need from various suppliers or the overall
concept was never properly considered or thought out to begin Challenges facing the cement customer
Each project is unique in its complexi-
with. In many cases, the end result is a poor unsatisfactory work-
ty and is heavily dependent on local
ing solution. conditions. Not many people realize
that the cement manufacturing pro-
This is where ABB Process Automation and its family of Industrial- cess is in fact a chemical process
IT®
System 800xA products and solutions stand out and differenti- which is fully dependent on the quali-
ate themselves. ABB uniquely identifies itself not only as an auto- ty of local raw materials and their in-
mation product supplier, but also as: a manufacturer and supplier; herent natural variations. The cement
manufacturing process is also de-
an engineering, commissioning, services and support partner; and
manding in terms of energy consump-
a cement process specialist. This “single point of responsibility” is tion and environmental consider-
what cement customers are looking for in a competent automation ations. Cement production demands a
partner. sound automation solution which can
deal with these variations at a mo-
ments notice, and adapt to it’s “new
conditions” as efficiently as possible.
In addition, an automation solution
can only be successful when the cli-
ent’s automation partner and supplier
fully understand the complexities of
the cement manufacturing process,

ABB Review
Peace of mind
and has the experience necessary to applications based on four decades of and communication for application
realize these unique solutions. experience exists. System 800xA em- development with drag-and-drop facil-
braces the principles of open, real- ities 1 . It provides a complete set of
What is common to all cement manu- time networking with its unique inte- operator functions, realistic process
facturers, as well as to most indus- grated object oriented system environ- displays with graphic elements and
tries, is the necessity for operational ment for operations, control and engi- faceplates, superior trending capabili-
excellence, productivity and profit- neering, and provides a scalable solu- ties, intelligent alarm and event han-
ability, minimized environmental im- tion that spans and integrates loop, dling with remote messaging, report-
pact, global and local competence, re- unit, area, plant and inter-plant con- ing, as well as integrated drawings
sponsibility and support, all of which trols. and wiring diagrams.
can be summed up as risk manage-
ment and minimization. Building a The System 800xA Minerals Library, Such features give ABB the unique
brand new greenfield cement plant is for instance, includes pre-engineered advantage of being able to handle
clearly a major undertaking but the modular objects containing control very complex projects, from turnkey
modernization of an old plant to the logic, human machine interface (HMI) new greenfield plants to those that
latest standards, production and effi-
ciency levels while it is still in opera- 1 Modular automation
tion1) demands a whole different set
of skills and competences for the sup-
plier and partner.
ERP
Business
This is where ABB shines and stands Management
out as the leader in the field. ABB’s
Minerals Business Unit, based in Swit-
CPM
zerland and with worldwide responsi- Process Optimization
HMI
bility for all cement customers and Information Management
Product on Support
projects, has clearly established itself
as the industry leader in automation
solutions.
Controller Controller Controller
ABB’s distinctive approach
ABB’s cement organization has been
serving customers since the 1960s,
Interface Interface Interface Interface Interface Interface
and during this time it has amassed a Sensor/ Control MCC Drives Power Peripheral
wealth of experience. One of the Actuator Loops Distribution Control
main reasons the company has always

provided world class automation solu-
tions to its customers is because it is
2 IndustrialIT System 800xA in the Cement and Minerals industry
also the developer and manufacturer
of the full range of products that it
supplies. All automation related hard- Thin Clients for Process Control e-commerce clients Business/ERP-System
ware, software, tools and engineering

Intranet or
as well as service and support are Internet Infrared
RMP KM/LIMS
provided to its customers’ base world- Firewall
Process Portal Clients Engineer
E0/LM Scanning
Thin Client Thin Clients
Router Thin Clients System
wide via ABB without the involvement
of external third parties. ABB’s pro- Shared
Printer
cess knowledge, built into standard
packages, libraries and automation Client/Server Network (TCP/IP)
solutions for the cement industry, has Process Portal Expert Optimiser /
KM Knowledge Manager /
OPC Servers LIMS Laboratory/
been continuously evolving since the RMP/
Information Management/
Server
Server
1960s. Today, this knowledge is fully MB 300
Control Network (Ethernet)
implemented and standardized in
Process Portal Grinding
ABB’s IndustrialIT® (IIT) System 800xA AC400
AC800M
Autolab
MP200
platform. S100 I/O Profibus/Foundation Fieldbus/
Infrared X-ray
Scanner
Advant Fieldbus 100 Ethernet/TCPIP Press
Profibus ABB
For the cement industry, for example, Profibus
a suite of re-usable objects for control AC800M
S800 I/O S800 I/O AC 6 Laser granulometer
Field Universal Insum
S400 I/O Remote I/O Drives Autolab
Devices Motor MCC
familiy Controller
Footnote
1)
Stringently planned and minimized downtimes are Optional redundancy for any OCS component available
essential.

ABB Review
Peace of mind
need revamping and modernizing the project was ensured with solid solutions are also provided that cover:
under severe time, budget and sched- engineering foundations, consistent the raw materials needed (RMP-Raw
ule constraints 2 . The advantage for methods and the use of standard Material Preparation); optimization
the customer is long term supplier libraries which comprised ABB’s years (EO-Expert Optimizer); labs (Auto-
commitment and the assurance that, of process experience with similar Lab); knowledge management (KM-
as its business evolves, its automation projects. Knowledge Manager); and dispatch. In
partner, ABB, can always provide a addition, electrification to automation
professional, reliable and compatible Holcim Settat not only has ABB’s lead- to integrated ERP systems and non-
solution to the existing, older technol- ing automation solution, but it will ABB products are also covered.
ogies installed in the plant. also benefit from advanced energy
monitoring and reduced consumption, Pure automation, in the traditional
Holcim (Maroc) Settat plant environmental management and pow- sense, is greatly expanded with IIT to
Holcim’s new Settat cement plant (see er monitoring. On top of this, the include CPM (Collaborative Produc-
title picture) is located south of Casa- company will profit from ABB’s pro- tion Management) 3 and ERP (Enter-
blanca in Morocco. At the end of 2004, duction information management and prise Reporting Systems) as well as
Holcim decided to establish a com- optimization capabilities. Finally, the access and control of substations,
plete cement factory by adding a new overall automation solution will be power distribution, MCCs, generators,
cement grinding plant and a clinker combined into one system at the main quality and laboratory systems, expert
production line. Operation of the plant and remote quarry, all using the and optimization systems as well as
grinding plant was scheduled for the same design and application princi- business systems including SAP. This
third quarter of 2006, and the clinker ples, thus simplifying overall opera- also includes the seamless integration
production line is expected to be in tion and maintenance. of industry standard technologies like
full operation by the end of 2007. The TCP/IP, Fieldbus/Profibus and others.
main quarry is located 25 km from the ABB – more than just automation In addition, ABB’s turnkey solutions
main plant and provides the raw mate- As a leading provider to the cement can also include full electrification,
rials for the process. A railroad links industry, ABB takes on the sole re- cabling, sensors, motors and drives,
the two locations. sponsibility of providing quality prod- lighting, fire and video systems as
ucts, solutions and standards, and the well as the installation and commis-
ABB engineered, supplied, installed means for increased productivity and sioning of all items provided.
and commissioned the complete sys- efficiency while always considering
tem – including electrical distribution the customer’s Total Cost of Owner- ABB has installed automation systems
– within the planned but very de- ship (TCO) and environmental impact. for over 500 production lines, 30 in the
manding short construction schedule. Because of proven methods, modules, last three years alone. The company’s
The IIT 800xA based solution was im- technologies and platforms, planning installed base and advanced automa-
plemented in a step by step fashion, and experience, ABB’s automation so- tion solutions save customers over
thanks to its plug and play functional- lutions are in a class of their own. 1 100 million per year on energy costs
ity. Software compatibility throughout More impressively, complete turnkey alone. Four decades of experience
combined with its ability to develop
and manufacture the full range of auto-
3 CPM solutions for the cement industry
mation products it supplies means ABB
can take sole responsibility for com-
Economic Process Optimization
Performance Indicators
plete automation solutions. ABB prod-
SAP
Thermal Energy Electrical Energy
Production Performance
Costs MM/SD PP-PI PM ucts are complemented with the com-
pany’s skills, which are in turn trans-
Information
ferred to local teams and partners to be
Expert Optimizer Raw Mix Preparation Knowledge Manager Dispatch used in the industries and markets they
Automation
Kiln Optimization Stockpile Blending Production Information Mngt
Solutions
serve. Customers therefore have peace
Mill Optimization Raw Mix Proportioning Production Accounting of mind in the knowledge that, as their
own businesses grow, ABB’s automa-
Alternative Fuels Raw Mill Optimization SAP Integration
AutoLab
tion solutions will grow with them.
LIMS Quality
Set Points Process Data Management Robotics
Raw Data
Process Control
Heikki Tanskanen
Alfredo Zeta
ABB Switzerland Ltd
heikki.tanskanen@ch.abb.com
alfredo.zeta@ch.abb.com

ABB Review
Age is no issue
Evolution of automation systems to improve return on assets
Mark W. Taft
“Naturally, ABB’s 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 ARC1) believes that
ABB is performing this task at a level that exceeds the industry norm.” says Larry
O’Brien, ARC’s Research Director for Process Industries, when commenting on ABB’s
control system evolution strategies.
R ecent investments in “greenfield”

plants with state-of-the-art tech-
nologies have primarily been directed
range can be gained through im-
proved maintenance techniques in
such plants.
Aging workforce
A massive turn-over of intellectual
talent in process manufacturing plants
towards facilities located in the devel- Increase personnel productivity. Pro- is projected in the next 5–10 years.
oping world. To remain competitive viding real-time access to relevant There is an urgent need to capture
the “brownfield” manufacturing sites information facilitates empowered that experience and knowledge and
of North America and Europe must decision-making and action, en- make it available via the automation
significantly improve their ROA (re- abling cost and productivity advan- and information management systems
turn- on assets). tages, which is vital to the business to the operations, engineering, and
process improvements necessary to maintenance personnel of the future.
Nurturing brown fields for green bucks achieve greater ROA. Much data is already being collected
This challenging global environment via the applications running in the
is driving the owners of “brown field” Integration failed in the past existing automation and peripheral
plants to search for competitive ad- In the last decade, billions of dollars systems on the plant floor. However,
vantages in the extended use of auto- were spent on new ERP (enterprise it is not accessible as knowledge in an
mation. Several strategies can be ad- resource planning) systems. The intent integrated, contextual fashion to those
opted: was to integrate the business world people who need it, when they need
Reduce unplanned downtime. The with the manufacturing process. In it.
ARC Advisory Group has estimated most cases the basic ERP implementa-
this to represent two to five percent tion projects overwhelmed the organi- Aging automation infrastructure
of current production. zation and integration was never real- Morgan Stanley estimates the value of
Implement reliability centered ized. Further business process im- installed automation systems in pro-
maintenance techniques to reduce provements and the implementation of cess manufacturing facilities that have
costs and optimize maintenance best-in-class processes require close reached the end of their lifecycle to
practices. The maintenance budget integration of plant floor automation be $ 65 billion. Plant floor installations
in a typical chemical plant is esti- with business systems. A renewed at- are a collection of aging, disparate
mated to be two thirds of net profit. tempt to harness the substantial im- and loosely or non-connected sys-
According to a US Federal Energy provement available through informa-
Management Program Report, sav- tion integration will drive automation Footnote
ings in the double-digit percentage investments over the next decade. 1)
ARC DCS Worldwide Outlook, September 2005

ABB Review
Age is no issue
tems. These “closed” systems are a been a formidable challenge, which class products, applications and ser-
barrier to integration. Manufacturers has led to the development of System vices from ABB and IndustrialIT certi-
require a migration plan to help them 800xA. fied supplier-partners with existing
remain competitive. At issue is the automation installations – regardless
massive investment that has been of the original system’s origin – to
made, both intellectual and capital. ABB’s pledge of “evolu- create an extended automation envi-
Automation users understand the need tion through enhance- ronment. The 800xA system supports
to balance the benefits of moderniza- total plant management and control,
tion with the requirement to achieve
ment” ensures that new removing the barriers of traditional
highest possible return on existing in- advances in automation distributed control systems.
vestment. Many migration solutions systems technologies
require extensive rework, automation Evolutionary customer benefits
application redevelopment and dis- strengthen, rather than Whether a customer-owner’s original
ruptive “rip and replace” of existing compromise prior auto- system nameplate says Advant, DCI,
system content just to return function- Freelance, INFI 90, Master, Melody,
ality to current levels of performance.
mation investments. MOD 300, Satt, Symphony, or that of
This approach sacrifices the experi- a competitor, it can and should be
ence and knowledge automation own- System 800xA extends the reach of used as the foundation on which to
ers have accumulated in their applica- traditional automation systems beyond build a System 800xA installation 1 .
tions. So how can these companies process control, to achieve the pro- This evolutionary approach offers
upgrade their systems while preserv- ductivity gains necessary for manufac- many fundamental deliverables to
ing this knowledge? turers to succeed in today’s business. ABB’s customer-owners.
This scope is accessible from a single
The answer is automation evolution! user interface that presents informa- By combining new System 800xA
tion and provides interaction in a con- applications supporting asset optimi-
Evolution vs. migration text appropriate to each user’s respon- zation, information and production
ABB’s IndustrialIT System 800xA Ex- sibility. Extended Automation objects management and ERP integration with
tended Automation software facilitates created within System 800xA provide existing systems, new productivity
the addition and integration of the a foundation for the efficient develop- potential may be achieved.
new capabilities to prior generation ment and continuous improvement
automation systems. ABB’s pledge of The reuse of intellectual investments
“evolution through enhancement” of production applications with a pre- in existing systems via direct re-host-
ensures that new advances in automa- dictability unattainable by other auto- ing of applications, or via application
tion systems technologies strengthen, mation offerings. translation tools and services reduces
rather than compromise prior automa- risk, and shortens implementation
tion investments. Automation system The system’s architecture is built upon schedules and “switch-over” time.
evolution is a process of simple, grad- ABB’s patented Aspect ObjectTM tech- Engineering efforts focus on improve-
ual advancement to a highly integrat- nology2). Aspect Objects relate plant ment rather than recreating functional-
ed, extended automation environ- data (aspects) such as I/O definitions, ity that already exists.
ment. The task of merging disparate engineering drawings, graphics,
control system families into a cohesive trends, etc., to specific plant assets
modern automation system, while pre- (objects). This unique architecture lets Footnote
serving customer investments, has customer-owners integrate best-in- 2)
See also ABB Review 1/2002 pages 6–13.
1 An 800xA evolution builds on existing architecture 2 ORLEN is Central Europe’s largest refiner of crude oil and ethylene

ABB Review
Age is no issue
System 800xA Process Portal supports stallation and provides the foundation son to seamlessly and effortlessly con-
standard displays, faceplates and op- for the addition of other System 800xA nect Process Portal to the existing
erating philosophies from prior gener- capabilities. system, and have operators view the
ation “Operator Station” products to old system as well as the new, on one
maintain a familiar operations envi- ABB’s tested and proven evolution common platform – a very real invest-
ronment. The knowledge that opera- project execution services and proce- ment savings.”
tors, engineers, and maintenance per- dures ensure low-risk, cost-efficient
sonnel have gained through use of and predictable results for every evo- PKN ORLEN is Central Europe’s largest
their existing system will provide a lution step. Detailed evolution plan- refiner of crude oil and ethylene.
foundation for improvement. Training ning services provide a well thought 2 ORLEN’s first blending control and
can be focused on learning new capa- out execution plan for predictable optimization system was successfully
bilities of the system. performance throughout the step-by- commissioned in 1998. Adding new
step evolution program. controllers and operator stations to
the existing MOD 300 system extend-
The reuse of intellectual ABB’s product life-cycle support poli- ed the DCS. On-line and off-line opti-
investments in existing cy provides predictable support for mization and planning functions were
installed products, and a commitment valuable extensions.
systems via direct re- to provide functional replacement
hosting of applications, products to keep the plant running.
By evolving an automation
or via application trans- This policy allows customer-owners to
installation in a step-wise
evolve their system in a step-wise
lation tools and services fashion with the confidence that the fashion customer-owners
reduces risk, and short- foundation will be supported, and
address their business
available for production over the
ens implementation planned evolution period. needs in a time frame
schedules and “switch- appropriate to their invest-
over” time. Project briefs
When Molson Brewery in Canada, ment appetite.
needed to expand and upgrade their
By evolving an automation installation 20 year old Network 90 system, Ever- “ABB systems protect our investment
in a step-wise fashions customer-own- est Automation helped them evaluate very well. There are many examples
ers address their business needs in a all options. Molson chose to extend in the company where we started
time-frame appropriate to their invest- their existing system by adding System from a very small, single node and
ment appetite. For example, the addi- 800xA Process Portal because of the then migrated to huge control sys-
tion of Asset Optimization capability many benefits it offered, such as per- tems. This is a good example of step-
to an existing installation provides the sonalized workspaces and views that by-step evolution. The ABB system is
opportunity to mine the intelligence provide better visibility into their pro- well suited to this approach,” said
of existing HART field devices to im- cess, remote device configuration ca- ORLEN’s Manager of Process Auto-
plement asset monitors. The asset pability and continued use of their mation, Waldemar Nagórko. “We
monitors facilitate a move in mainte- original system investment. achieved all our targets with our ABB
nance strategies to a reliability cen- control system upgrade; optimal use
tered approach. The new software According to system integrator Joe of more components, optimized costs,
runs in concert with the existing in- Sollazzo, this solution “allowed Mol- elimination of re-blends, very good
3 Tissue-making machine 4 Alunorte plant in Brazil

ABB Review
Age is no issue
prediction and control of more prod- of CMPC Tissue’s Puente Alto Mill. Alunorte further enhanced its automa-
uct properties resulting in reduced “We never have the opportunity to tion by adding System 800xA when it
production costs and reduced give- change everything at once. The ability began its second and latest expansion
aways.” to make incremental improvements project. The Extended Automation
over time is very important. This is system utilizes fieldbus communica-
CMPC Tissue SA is a leading partici- the way you protect your investment tions (both Profibus and Foundation
pant in the pulp & paper market ac- and your company. From the begin- Fieldbus), as well as ABB’s Real Time
tive in over 50 countries on five conti- ning, ABB has met all our require- Production Intelligence (Real-TPI)
nents. To meet its ongoing goal of ments.” software. This expansion will allow
constantly improving efficiency by Alunorte to produce up to 99 percent
utilizing the most advanced control of the operational time, slashing
technologies, the company recently
Incremental additions and downtime to just one percent making
upgraded its more than ten year old functional extensions have the plant the largest, most efficient
control system in the Talagante mill delivered dramatic pro- alumina production facility in the
located in Chile. world when installation is completed
ductivity improvements for in 2006.
CMPC’s Talagante mill had been oper- ABB automation custom-
ating successfully with an ABB Master “The ABB system has helped Alunorte
system. CMPC decided to reduce
ers, while building upon reach production goals since start-up.
maintenance costs by combining a the value of the baseline If the DCS can give you good data,
new mill expansion with the evolution capital and intellectual you can change the data into informa-
of the existing system. Cost was fur- tion. If you have the power of infor-
ther reduced by the re-use of existing investment they made in mation you can change everything,
applications. The mill expansion was their original systems. but you need the right tool to make
directly integrated with the existing the change. Alunorte drives for im-
systems via evolution to System provement and ABB is one of the
800xA. Alunorte, in the Pará state in Brazil, most important partners in our efforts
is presently one of the five largest to increase of production capacity,”
“ABB’s Investment ‘enhancement alumina refineries in the world 4 . said Jorge Aldi, Process & System
through evolution’ control system It began its production with two lines Development Manager, Alunorte.
upgrade strategy gave us the possi- in 1995, utilizing ABB’s Master tech-
bility of maintaining, or ‘porting-over’ nology. When a third line was added Conclusion
a whole engineering process, rather in 2003, the Master technology was As illustrated above, incremental addi-
than having to start over,” says evolved to fully integrate with an tions and functional extensions have
Sr. Reinaldo Uribe, Project Manager Advant control system for all lines. delivered dramatic productivity im-
provements for ABB automation cus-
tomers, while building upon the value
5 Evolution architecture.
of the baseline capital and intellectual
investment they made in their original
Common System Applications systems. Planning is a key component
Operator Workplace Remote Clients
to a successful step-wise evolution
Maintenance Workplace
Manager Workplace
program 5 . That’s where a collabora-
Plant Network/Intranet/Internet
Workplaces tive effort between ABB and custom-
System Servers Router/Firewall er-owners to map out the best strate-
gies will help to minimize production
losses, and maximize the benefit of
Control Network
each increment of the program. ABB’s
overall goal is to mitigate risk, while
800xA System Harmony System
AC800M Control Control extracting maximum value from our
customer-owners’ automation system
investments.
Rack I/O
Variable Speed
Drives
Harmony INFI 90
Fieldbus High Speed Controllers
Linking Devices
(FF HSE/HI, PB DP/PA)
S800 I/O
MCC Mark W. Taft
Process Automation
Wickliffe, OH, USA
mark.taft@us.abb.com

ABB Review
Integrated engineering
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
T he engineering of a process plant

starts with a conceptual design
phase known as FEED (Front End
coms, electrical systems and analytics
are increasingly important and could
be within ABB’s scope of delivery.
produce more and better documenta-
tion. More demanding customers insist
on handover of a high-quality engi-
Engineering and Design). In this neering database along with their pro-
phase, the description of the material All large projects have a common cess plant including systems to keep
flows through the equipment are need to manage complexity. For a this data synchronized with plant
defined. This is typically performed plant with tens of thousands of instru- changes so that the database stays
by an EPC (Engineer, Procure, Con- ments, a huge volume of inter-related “as-built”.
struct) Company. The EPC uses design information must be managed. This
tools to model the process layout in information originates from diverse Progress in IT is allowing project
all dimensions and other tools to sources; from people working in sepa- engineering partners to upgrade their
model the physical properties of the rate teams; in separate companies, of- own tools and add features to cope
process, such as temperature and ten on separate continents; each with with these new challenges. A central
pressure. Once the overall design is their own set of specialized tools. prerequisite for this is the ability to
complete the detail design and pro- exchange data with globally distribut-
curement processes can begin. The engineering challenge 1: ed teams, and to manage, with full
Globalisation of engineering traceability, the evolution of this data
The project then enters the detailed The traditional model of the project throughout the lifetime of the project.
engineering phase where the EPC pro- engineering lifecycle as described To support these requirements, engi-
duces piping and instrument diagrams above is being challenged by the in- neering and design tools are becom-
(P&ID) using 2D computer-aided de- tense competitive pressures of global- ing data- rather than document-orient-
sign software. Instrumentation engi- ization. ed with the drawing document with
neers use design tools to specify the rendered from this data. Data is also
details of each sensor and actuator on Shorter delivery schedules force proj- being increasingly standardized in
the P&ID. In parallel, the control engi- ect engineering partners to work in neutral formats promoted by organiza-
neers develop the control strategy new ways and break the traditional tions such as the IEC (International
drawings which show how the devic- linear engineering model in order to Electrotechnical Commission).
es need to work together in real time allow more tasks to be performed in
to control the process. The safety parallel. Cost pressures force the proj- As the world’s largest process auto-
system undergoes a similar process ect engineering partners to outsource mation and electrical supplier, ABB is
resulting in the specification of cause more tasks to high-efficiency engi- investing in tools, methods and stan-
and effect matrices to define the inter- neering centres. More stringent safety dardisation strategies which are trans-
lock logic. and environmental regulations are forming the shared data from an engi-
forcing project engineering partners to neering burden into a high-value asset
The output of this phase is the starting
point for ABB’s own technical activi-
ties which, in the case of automation
1 Plant engineering lifecycle phases and deliverables
includes hardware engineering, appli-
cation software, and Human Machine
Process
Interface (HMI). The control system Flow
Cable Instrument BPCS SIS / F&G
Schedule Index Specifications Specifications
engineers use the company’s own pro- Diagrams
Piping & Electrical Instrument Control System
gramming and system configuration Instrument
Equipment Piping Line
Panel Data Architecture
Cause &
Index List Effects
tools, such as those included with Diagrams Schedule Sheets Diagram
800xA Engineering Studio. The main Process Equipment

Piping Lighthing
Instrument
Logic
Data Data Spec
project deliverables for detailed auto- Tie-Lines Plans Diagrams
Sheets Sheets Sheets
mation and electrical engineering are Vessel Site Plot Civil Structural Equipment Piping
Area Instrument
IO
Classification Location
shown on the right-hand side of 1 . Sketches Plan Plans Plans Plans Plans
Plans Plans
Loading
Piping
Single Line Logic
Double JB Layouts
Once designs are agreed, projects Lines
Diagrams Definition
FEED
enter a manufacturing and testing
PDS MCC Installation Graphics
phase, typically culminating in the RFQ 3D Model Layouts Details Development
Factory Acceptance Test (FAT) fol- Motor
Detailed Wiring
lowed by shipment and installation Design &
Control
Diagrams
Schematics
including a Site Acceptance Test Engineering
(SAT). After acceptance the system is Fabrication Switchgear Loop

Architectural Line-up Diagrams
& Testing
handed over to the client for commis- Civil
Process Systems
sioning leading to operation and on- Piping
Installation & HVAC Load
Commissioning Calcs
going maintenance. Rotating Equipment
Structural Operations & Power
Control Systems Maintenance Load
There are many variations of the Electrical Tabulation
above process. Functions such as tele-

ABB Review
for both project engineers and end- of new products and services such as field instrument (sensor element or
customers. The financial return from asset management. valve) through to the connection to
this effort is high as automation engi- the control system. This data is either
neering typically accounts for half of The engineering challenge 3: obtained from other design sources e.
the total control system package, and Integrate automation and instrumenta- g. P&IDs, or entered during the de-
electrical engineering for more than tion design sign process. Outputs from the system
one third of the total electrical pack- There are a number of instrumenta- include instrument schedules; hook-
age. Effective execution of engineer- tion design software packages on the up details for purchasing and installa-
ing impacts on the project schedule, market. These packages attempt to tion; panel designs; cabling details
costs and on ABB’s perceived capabil- centralize plant instrumentation de- and alarm data. All these are very rel-
ity to deliver such projects to a grow- sign information so that it can be easi- evant to ABB’s project engineering
ing global market. ly accessed, manipulated and updat- processes. The data flows are summa-
ed, thus ensuring consistency across rized in 3 .
The engineering challenge 2: the different instrument tasks and de-
Delivering the digital asset liverables. All such packages address These packages may also have mod-
For end-customers, effective manage- the project lifecycle information re- ules or interfaces that facilitate valve
ment of engineering information is quirements from early conceptual de- and orifice plate calculations. They
vital for the safety and maintenance sign and engineering to construction, enable significant parts of the control
of the plant over its lifetime. For pro- maintenance and decommissioning. system to be automatically configured,
cess industries, sources estimate that The commonly used packages include allow the telecommunications system
the value of well-managed electronic Intergraph’s SmartPlant® Instrumenta- to be engineered and also enable in-
engineering data is approximately tion (SPI) and Innotec’s Comos® PT. terfacing with maintenance, calibra-
two percent of the total cost of the Currently SmartPlant® Instrumentation tion and purchasing systems.
plant. (formerly INtools) has a dominant po-
sition worldwide, particularly with the ABB is working together with Inter-
A large part of this engineering infor- major EPCs, while Comos PT’s market graph and Innotec looking at ways of
mation is design data for tens of thou- is mainly European, but growing. making instrumentation design data
sands of instruments and their input/ available to all the engineering part-
output (I/O). For a process plant, in- These packages use a database to ners and their systems. The three key
strumentation is about 10 percent of hold all data related to the design of technologies being used to achieve
the capital expenditure (CAPEX) but the instrumentation system – from the this are:
about 20 percent of the operational Shared type-libraries and a mecha-
expenditures (OPEX). Engineering nism for mapping between these
2 Extract from an ARC insight document
companies eager to win contracts fo- types
Oct.28, 2004
cus on reducing the former, but it is Vendor-neutral XML-based format
OPEX which most affects the opera- From an operations perspective, for data exchange to preserve object
tor’s bottom line. engineering & design tools relationships
coupled with information Web services communication for
It should therefore be no surprise that management solutions form the open transport between vendors’
basis of lifecycle engineering.
end-customers are pushing for greater systems
Having this data available
standardization and improved han-
greatly reduces plant downtime,
dling of process engineering informa- improves plant performance, and The first result of these efforts is real-
tion, as recommended by industry assists in better plant revamp ized as a shared type-library for S800
consultants ARC in a recent report 1 . planning. and S900 I/O hardware and ABB’s
Process Engineering Tool Integration
The call for greater inter-op- (PETI) application software,
erability and for vendor in- as discussed in the following
3 Plant instrument engineering data inputs and outputs
dependence of engineering sections.
design data is a frequent re-
quest in many areas other INPUTS OUTPUTS Shared libraries: Accelerating
than process design. In de- Process Data Instrument Lists and hardware engineering
vice communication, for ex- Process Line specifications In order to help instrumenta-
Information Alarm Schedules
ample, the data handled is 3D Model Cabling Details
tion and hardware design en-
real-time instead of design P&ID Data SPI I/O Termination Details gineers to use the SPI pack-
DATABASE
Supplier Instrument Marshalling Panel Design
data, but the underlying is- age efficiently, a set of defini-
Specification Sheets Measurement Ranges
sues are the same. For ex- Electrical System and Units tion files has been developed
ample, vendors who acted Instrumentation Loop Drawings by ABB to represent the most
Hook-up Drawings
early to embrace open field- Hook-up Equipment BOMs common 800xA hardware
bus standards had a sales Termination Drawings components. Once imported
Cable and Core idents
advantage As the technology into SPI, these libraries can be
opened the door for a range used to create objects such as

ABB Review
I/O modules. The SPI user can drag commissioning can be automatically PETI offers two different ways to
and drop the desired I/O module type written back to the SPI database, access the engineering database. A
onto the project window. The field maintaining this as the “master”. stand-alone import/export utility can
signals can then be allocated to the I/ be used by the EPC to export the data
O channels and automatically cross- An open approach: Neutral format for as a file for subsequent import by the
wired to the field terminals and IS data exchange and web services control system engineer. Alternatively,
barriers as required. Drawings may The project engineering partners use a a web service can be used to extract
then be generated from the SPI system wide variety of tools with incompati- data and transfer it electronically. In
showing the correct termination num- ble data representation. As these tool either case the data is transferred in
bers, terminal layout, cable and core providers release new versions, for- CAEX format.
numbering etc. mats from earlier versions become ob-
solete. Preserving the design data Integrated Tools in Use:
S800 and S900 I/O definition files are across tools and across the decades of Experience from Projects
available for download by third par- a process plant’s lifecycle is the moti- The PETI package has been used suc-
ties from the Intergraph website, or vation for using a standard format cessfully on one recent chemical and
for ABB users only, from ABB’s inter- based on XML to represent design pharmaceutical project in the UK, and
nal SolutionBank. data. The CAEX standard XML-based is currently being used on several oil
format originated within ABB. It is and gas projects in Norway and the
The expanded SPI Reference Explorer now an approved DIN standard and UK.
folder in /4 shows some of the de- currently under review by IEC. This
fined combinations of S800 I/O mod- ultra-flexible format is used within UK ChemPharm and O&G
ules and termination units. The “My PETI to represent plant design data In the UK ChemPharm project, the
List” option allows a subset of I/O for bi-directional transport between ABB hardware design engineer
modules and bases to be defined for the engineering system and 800xA, as worked within the EPC’s offices using
use on a particular project, thus aiding shown in 5 . their SmartPlant® Instrumentation sys-
design standardization. tem to design the I/O and controller
cabinetry supplied by ABB. The hard-
4 ABB S800 Hardware type library for SPI
800xA has, from its inception, used wired I/O system adopted was S900
the idea of type libraries to define fre- and a significant amount of Founda-
quently used objects within the auto- tion Fieldbus instrumentation was also
mation project’s applications. These used, particularly for control valves.
libraries have been developed for a The SPI was used to generate “strip”
number of industrial sectors e.g., drawings, showing all terminations
chemical and pharmaceutical, oil and and interconnecting wiring and pneu-
gas, utilities and for common func- matics. These were used in conjunc-
tional areas such as field devices, tion with externally-prepared standard
equipment modules and safety appli- panel designs to build the 12 panels
cations. required. The same documentation
was used for inspection and testing.
The extensive use of type-libraries is a No other detailed design documenta-
key element in automating the generation was required.
tion of application objects which are
based on information from the engi- 6 shows one of the completed panels
neering database system used by the with examples of the SPI documenta-
Instrumentation and Control System tion used. A similar approach is now
Hardware Engineers. ABB’s Process being used for two UK based oil and
Engineering Tool Integration gas projects but with the
(PETI) provides a mechanism 5 Data Transport using CAEX between SmartPlant and 800xA
ABB hardware design engi-
to map interconnections be- neers based in the ABB
tween SPI instrument entities SmartPlant ® offices and working on the
and the 800xA aspect object Instrumentation EPC’s SmartPlant® Instru-
types. Instrument tags created 800xA mentation system. These
in SPI are used to auto-create systems will remotely use
Web Service Type
the corresponding objects Mapping terminal server technology
within the 800xA control and DB Import / to maintain system security.
Automation
Export Utility
Solution
functional structures. The SPI CAEX Library
property is then used to set (DIN-44366) Norwegian oil and gas
attribute values in 800xA. BP has been supportive in
Process Engineering Tool Integration
Once the object has been cre- CAEX the use of PETI on the Val-
ated, changes made to param- (DIN-44366) hall project based in Norway
eters during installation and and have guided ABB in ex-

ABB Review
tending PETI to support an online ver- modify alarm settings as a single specified and capable of fulfilling its
sion of their alarm response manual shared dataset, allowing the master process line function. A similar level
(ARM). The ARM data is centralized in engineering database to be kept “as- of responsibility with respect to
SPI but will be shared with operator built” throughout the lifetime of the switchgear, cabling and the electrical
graphic displays on ABB’s 800xA sys- plant. instrumentation engineering applies if
tem. PETI enables experienced opera- the electrical package is included
tors and process engineers to view End-customers are also interested in within ABB’s scope.
and, if the security level permits, the ability for 800xA operators to ac-
cess SPI loop drawings, instrument
specifications and other documents di-
Progress in IT is allowing
6 Completed cabinet with an example
rectly via the operator workplace. project engineering part-
of wiring diagrams automatically
generated with PETI
These documents, which are relevant ners to upgrade their own
to operations and maintenance func-
tions, are rendered live from the SPI tools and add features to
database server, where they can readily cope with these new
be maintained “as-built”. Some exam-
ples of this 800xA Workplace integra-
challenges.
tion are shown in the screenshots in 7 .
In addition to these engineering re-
One outcome of these projects has sponsibilities come the added data
been a refinement of engineering management tasks related to purchas-
work-flows between customer, EPC, ing, installation, commissioning and
ABB and other package suppliers. documenting all these devices.
Early agreement between all parties
on standards to be used for libraries The data integration approach de-
and data transfer between systems is scribed here is a key enabler for ABB
essential. in this strategic role. Instrument lists
will no longer be issued to the MAC by
SmartPlant integration: An enabler for a the EPC. Effective execution requires
main automation contractor that this interface be automated, and in
In some large contracts, the automa- addition end-customers will expect that
tion vendor has a expanded role typi- a MAC contractor’s database will be
cally known as “Main Automation fully integrated with other design data-
Contractor” (MAC). In this role, ABB bases, for example P&IDs and 3D plant
can be additionally responsible for the models. Use of SPI as the instrumenta-
instrumentation scope, creating the in- tion and panel design tool will help
strument list from the received P&IDs minimize the risks of taking the MAC
and ensuring each instrument is fully role. The SPI database has out-of-the-
box synchronization with P&ID, Elec-
7 PETI screenshot (top left) and workplace integration of SPI with 800xA trical and 3D design, and because of
the PETI interface also with 800xA.
The systems businesses within ABB

already function as system integrators.
Using this new technology ABB can
additionally develop the MAC role to
become the data integrator. The engi-
neering database system will deliver
advantages for both the owner/opera-
tor and ABB during the plant lifecycle.
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

ABB Review
Integrated electrical
and automation systems
Tom F. Nestli, Peter Tubaas
As process plants get larger and more complex, tween the process control and the electrical consumers
automation systems must handle an ever-increasing and actuators. ABB takes responsibility for all these
number of signals. At the same time, the number of systems and their integration. By letting ABB handle the
electrical consumers increases, making an electrical integration and all the interfaces, customers benefit from
control system essential. The electrical control system is faster project execution, reduced re-engineering, higher
an automation system in itself providing an interface be- quality, and higher operational efficiency.

ABB Review
E lectrical systems are clearly a core

part of any process plant, provid-
ing electrical energy to drive motors,
Europe, and the largest construction
project that Norway has ever seen.
encompassing subsea control process-
ing, complex LNG processes, and stor-
age and loading of the final products.
energize heaters, power lighting and
auxiliary equipment. The electrical
No system is more critical No system is more critical to the pro-
system is invariably complex, relying to the processing plant cessing plant than the combined safe-
on thousands of components and kilo- than the combined safety ty and automation system. The num-
meters of cabling. The complexity of ber of signals running through the
the system increases with the size of and automation system. Snøhvit process is enormous; the Pro-
the process plant. Such large process cess Control and Data Acquisition
plants are reliant on automation sys- Soon, gas from the Snøhvit field, ap- (PCDA) system has to handle more
tems to operate efficiently and safely. proximately 140 kilometers offshore in than 30,000 signals simultaneously. An
These automation systems will typical- the Barents Sea, will be flowing into unscheduled halt in production is ex-
ly respond to tens of thousands of sig- the gas processing plant for treatment tremely expensive. Therefore, ABB’s
nals in a quick, predictable and reli- and shipping to the global LNG mar- control systems are constructed and
able manner. The seamless integration ket. The core products of the plant will tested to provide the highest level of
of the electrical and automation sys- be liquefied natural gas (LNG, 5.67 bil- security and minimal downtime.
tems are highly desirable in a process lion m3/year), liquefied petroleum gas
plant, a benefit recognized by ABB at (LPG, up to 250,000 tonnes/year) and
the Statoil Snøhvit – or Snow White – condensate (up to 900,000 m3/year).
The hot exhaust gases
liquefied natural gas (LNG) plant. All products will be exported by ship. from the gas turbines are
Here, the Electrical Control and Super- used to provide heat for
vision System (ECSS) communicates Snøhvit is the first development in the
with a wide range of equipment and Barents Sea. The oil and gas fields were the parts of the process
ensures a stable power supply to the discovered in the early 1980ies. Com- that demand high temper-
LNG facility. bined with the adjacent Albatross and
Askeladd fields, Snøhvit contains more
atures.
Snøhvit than 300 billion m3 of natural gas. Gas
The Snøhvit field – named after the will be extracted from the seabed using The philosophy of process plant own-
fairytale character snow white – was subsea equipment, which are operated ers in general, and Statoil in particu-
discovered more than 20 years ago. remotely from Melkøya. The subsea lar, is to provide its operators with a
The road to develop this gas field has control system was delivered by ABB in “single window” into the plant. ABB’s
been long and winding, but the proj- the UK (now Vetco Aibel). The topside 800xA Extended Automation system
ect is finally close to production start. of the subsea control system, which is provides this facility and was, there-
It is planned to go on-line during the an integrated part of the overall Safety fore, chosen for the Snøhvit project.
summer of 2007. and Automation System (SAS), was
delivered by ABB in Norway. Plant power demand
The past few years have turned the Complexes for liquefied natural gas
uninhabited island of Melkøya 1 , not Complete control of the plant require a reliable and stable energy
far from the town of Hammerfest, into Snøhvit is an extremely complex in- supply. Most LNG plants are, howev-
the largest building site in Northern stallation. The process is extensive, er, situated in areas in which the pow-
MS Nordlys, one of the ships of Hurtigruten – The Norwegian coastal 1 Map of northern Norway.
ship operator – entering the port of Hammerfest.

ABB Review
er supply is either unreliable or non- rated for 145 kV, and medium voltage any one time – more than the plant’s
existent. The Snøhvit plant is no ex- switchgear of the UniGear ZS1 type, automation system. The ECSS provides
ception and must, therefore, rely on rated for 6.6 kV and 11 kV. Also in- a wide range of functions, enabling a
its own power supply. cluded are optical arc detection sys- stable power supply to the plant, low-
tems to provide early detection and ering operation costs and reducing
quick protective action of switchgear emissions, while at the same time in-
Snøhvit contains more to extinguish arcs. Further, MNS type creasing safety.
than 300 billion m3 of switchgear is used at low voltage lev-
natural gas. Gas will be els of 400 V and 690 V. Some 500 cu-
The past few years have
bicles supplying power to about 2,500
extracted from the seabed consumers are included at these volt- turned the uninhabited
using subsea equipment, age levels; of which some 600 con- island of Melkøya, not far
sumers are Insum starters (intelligent
which are operated motor starters) and 75 consumers are from the town of Ham-
remotely from Melkøya. variable speed drives of ACS 800 type. merfest, into the largest
ABB’s protection and control unit
To meet the power demand, the Snøh- (REF542) is used throughout the plant
building site in Northern
vit plant contains a 1.65 TWh power to provide the highest level of security Europe, and the largest
plant with five gas turbine-driven gen- and selective protection actions in the construction project that
erators of about 50 MW each. These event of a fault in the power system.
power the large refrigeration compres- Norway has ever seen.
sors of up to 65 MW, driven by vari- Electrical control and supervision
able-speed electrical motor, that are system An important part of the ECSS is the
required to liquefy gases. The hot ex- The complex nature of the electrical Power Management System (PMS)1).
haust gases from the gas turbines are system requires an automated ECSS. Since a relatively small fault may lead
used to provide heat for other parts of This system is required to unite the to a cascade of equipment shutdowns
the process. This set-up saves energy thousands of motors, switches, con- that could affect a large part or the
and provides about ten additional up- tactors and circuit breakers, and to entire plant, faults must be handled
time days per year due to the much minimize the effects should a fault quickly and appropriately to avoid a
higher availability of electrical drivers develop. A single unscheduled shut- domino effect. ABB’s PMS is also
(as compared to gas turbine drivers). down for the entire plant is extremely based on the 800xA Extended Auto-
expensive. mation system and is designed to
The Snøhvit plant not only includes its monitor, control and protect all sec-
own power station and large compres- The ECSS is at the heart of the electri- tions of a process plant. It includes
sor drivers, but also a large distribu- cal system and communicates with the functions such as:
tion network with several thousand vast range of ABB products using seri- Supervisory control and data acqui-
relatively small electrical consumers. al links and Ethernet. It is also linked sition (SCADA), including generator,
A large variety of ABB electrical com- with the automation system and other circuit breaker, mode and motor
ponents are included in ABB’s deliver- third-party deliveries. The system con- control
ies to the plant. These include high sists of 48 AC800M controllers. The Power control, including tie line con-
voltage switchgear of the EXK-0 type, ECSS processes some 44,000 signals at trol, peak shaving and load sharing
An ABB engineer taking an overview of the plant at Melkøya Two ABB engineers discsussing the plans for the day at the LNG plant in
(Photo: Peter Tubaas, ABB) Melkøya (Photo: Peter Tubaas, ABB)

ABB Review
Load shedding, including fast, slow and reliable operation of the electrical power grid, it soon became of interest
and frequency based load shedding, system. to study the dynamic behavior of the
as well as manual load shedding entire plant – including the gas tur-
Main electrical vendor approach bine generator sets – and its connec-
In the past, oil companies and engi- tion to the grid. ABB has performed a
ABB can draw on more neering, procurement and construc- dynamic stability study that was used
than 50 years of experi- tion (EPC) contractors have very often to set and adjust the parameters of the
ence with automation purchased different types of equip- power management system, as well as
ment (eg, transformers, high voltage the dedicated generator control algo-
and electrical systems switchgear, medium voltage switch- rithms. This ensures not only stable
to optimize their inte- gear and low voltage switchgear) un- operation of the process plant, but
der separate contracts. Project risks also ensures that the process plant
gration. can be reduced, however, by includ- contributes to the stability of the
ing most of the electrical equipment northern Norwegian power grid – as
Probably one of the most important and systems – as well as engineering required by the grid operator.
and most frequently relied upon parts – under one large contract. The result
of the PMS is the load shedding func- is lower costs and faster project exe-
tion, which helps ensure that the con- cution with safer systems that are fully
Complexes for liquefied
sequences of any one fault in the integrated and interoperable. Safety is natural gas require a reli-
electrical system has the smallest pos- improved during installation and com- able and stable energy
sible impact on the functioning of the missioning since project co-ordination
plant. ABB has delivered and commis- is more easily achieved with only one supply. Most LNG plants
sioned more than 30 PMSs worldwide, contractor. are, however, situated in
demonstrating that the PMS substan-
tially improves plant uptime, efficien- Statoil recognized the merit of such
areas in which the power
cy and reliability. an approach and merged all purchases supply is either unreliable
of high voltage, medium voltage and or non-existent.
The ECSS not only provides an inter- low voltage switchgear, as well as the
face between the process plant’s auto- ECSS, for the Snøhvit project into a
mation and electrical systems; it also single contract. In addition to equip- ABB at the cutting edge
provides indispensable functionality ment delivery, ABB has provided a ABB can draw on more than 50 years
and reliability in a plant where a sys- wide range of engineering services, of experience with automation and
tem shutdown could cost millions of including a long list of electric net- electrical systems to optimize their
dollars. Although full communication work studies. These are required to integration. Uniting the electrical and
and data exchange with the process ensure safe operation and maximum automation systems is becoming a
plant’s automation system is provided, efficiency of the plant. necessary feature of large process
the ECSS is not depending on it to plants. Operating such plants without
operate. On the contrary, the ECSS Since the Snøhvit plant is physically an automated system is almost un-
can operate in isolation to ensure safe connected to the northern Norwegian thinkable, not only for safety reasons,
but also for reasons of cost savings
and increased efficiency. Customers
like Statoil rely on experienced com-
panies like ABB to ensure safe and
reliable plant operations.
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 article “Not on my watch” on pp 30–34 of this
issue of ABB Review Special Report.

ABB Review
Powerful
renovation
Rejuvenating the Scholven coal-fired power station
to meet new market requirements
Harald Bruns, Stefan Lauxtermann
Many of Germany’s 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 ABB’s
System 800xA.

ABB Review
Powerful renovation
E .ON Energie is a multinational

corporation, serving 15 million
customers across Europe with gas and
A further requirement was, that the
unit had to be able to follow demands
from dispatch control center, ie, to be
the main turbine. The integrated tur-
bine, the unit and the process control
platform creates numerous synergies
electricity. It relies on state-of-the-art able to accommodate frequent, highly and advantages for users.
control systems to ensure customer dynamic load swings and triangles.
satisfaction on a local level and to E.ON also specified a need for partial The control system for the plant’s soot
maximize efficiency across the group. load or island system operation; ie, blowers and burner had already been
When the process control system at load rejection to auxiliary systems implemented using PLCs (program
the company’s Scholven power plant demand (house load) or island net- logic controllers). Both systems were
needed updating, E.ON approached work operation. Partial load operation integrated via Profibus (process field
ABB with a clearly-specified list of at 33 percent (400 t/h of live steam) bus). The design of the interface en-
requirements. These included: of the full rating of the unit was speci- sured that the systems could be moni-
fully automatic operation of the fied (recirculation). tored and operated in accordance with
power station processes during E.ON’s specified project standard.
normal load operation, start-ups, Scope of the replacement program for
load ramps, shutdowns, standstills, the process control system Model-based unit control
and during upsets In addition to installing the new pro- ABB’s Modan automation concept was
an ability to operate and monitor cess control system, ABB redesigned used to meet the challenging specifi-
the entire system from one control the entire control room. The existing cations regarding primary and second-
console using individual displays actuators and sensors had to be up- ary control capability. This concept
and large screens graded and, in some cases, replaced. coordinates the two main control vari-
straightforward process monitoring All upgrades accommodate E.ON’s ables of the power plant; fuel set
to be carried out by a single process need for the entire power production point and turbine control valves, on
operator process to operate automatically dur- the basis of dynamic parallel models.
fast and accurate fault analysis to ing start-ups and shut-downs. Most of It consistently applies a combination
minimize the risk of outages and to the existing field cabling remained in- of model-based feed forward control
reduce downtime, should outages tact, although some new wiring was and dynamic set point control. This is
occur required to accommodate the newly done for the turbine control as well as
time- and fuel-optimized startup installed actuators and sensors. for the set points of the main steam
with full consideration of material valve pressure and fuel control. The
constraints – changeover time from The plant’s new turbine control sys- Modan unit control is patented and
oil to coal firing to be as short as tem is based on the ABB’s System uses the turbine control valve and the
possible 800xA with AC 870P controller. This fuel set point value for the steam gen-
was used to implement a Turbotrol® erator as control variables. The basic
Although originally designed to oper- turbine control application package outline shown in 1 is greatly simpli-
ate as a base load unit, the changed for the regulation and protection of fied and applies to „turbine follow op-
market conditions now require the
Scholven power plant to serve as an
1 Outline of model-based unit control
intermediate load unit. The operating
modes that must be supported when
remote dispatcher
generating power are “turbine follow setpoint fuel
setpoint 90
mode”, in which the turbine controls Unit SW
≈≈ ≈
pLS PEI (DVG)

the live steam pressure, and “boiler turbine valve Κ∗Δf: grid-frequency %
position controller deviation
follow mode”, in which the boiler 80 PSG (boiler output load)
controls the live steam pressure. Both dyn. 30 s 10 min
dyn. dyn. dyn.
modes must support the coordinated pressure feed-forward MW Model
feed-forward time
control
unit control for pure and modified Model control boiler
turbine
sliding live steam pressure typical for
- +
one-through boilers. The unit must +
pressure <) RH
satisfy the UCTE grid code require- controller -
turbine load
ments for both primary and secondary
controller G
frequency control. Primary frequency PEI
control is achieved by throttling the P
-
- +
main steam valve. Secondary frequen-
fuel
cy control is accomplished while controller
maintaining primary control capabili-
ty. This means that the load changes
resulting from increased demand may
be ramped up by means of feed-for-
4 3 2 1
ward control using the fuel flow Coordinated boiler folowing operation mode
only.

ABB Review
Powerful renovation
eration“. The Modan concept Files in PDF format for

2 The new control room at Scholven
also allows other operating scanned-in, non-process-
modes such as „boiler follow able documents such as
operation”. manuals
Supplier web sites
Control room design Microsoft Excel documents
The unit control console 2 (tabular calculations,
was installed in a new twin adapted protocols, etc.)
control room that serves Microsoft Word documents
units B and C of the plant. (operating and calibration
The newly-designed room in- instructions, data sheets,
corporates clearly defined etc.)
work areas for the operators,
shift superintendent, electri- This ends painstaking search-
cians (auxiliary systems) and es for data that are distribut-
the electrical equipment iso- ed across various locations,
lation management. computers and applications.
Users navigate intuitively
The control system change- through the entire plant and
over for unit B and the move into the has a broad range of new functions, are therefore able to maintain a con-
new control room are scheduled to while maintaining a uniform user instant overview.
occur during the annual maintenance terface. The scope of the functions
shutdown in 2007. goes far beyond conventional operat- Users can configure the process dis-
ing and monitoring systems, encom- plays to suit their own particular re-
The display screens are only the exter- passing both information management sponsibilities, setting their own prefer-
nal indication of a significant increase and engineering. ences, allowing them to choose ap-
in the degree of automation at the propriate work methods. The fast,
plant. As a result of the enhancements, The underlying data access, storage flexible, secure access to relevant in-
the operators’ job description has and management system is based on formation and data makes it possible
changed from manually controlling the ABB’s patented aspect-object technol- for operators to carry out their moni-
process to one monitoring and correct- ogy. The „objects“ represent process toring and operating activities effi-
ing a now fully automatic controlled elements of varying complexities, ciently and accurately.
process. It was therefore all the more such as drives and measurements,
important to design the control room coal mills, feed pumps, turbines or Alarm management for fast reaction to
environment to be stimulating so that boiler systems. The „aspects“ are char- faults
employees would be better able to acteristic data associated with these A range of new features has been in-
concentrate. The individual objectives components that are required for sys- tegrated into System 800xA. One ex-
that were achieved are as follows: tem operation and maintenance. ample is a distinct plant overview in
Carefully designed control room the header line 3 . A summary alarm
architecture with clear separation of Using this system, aspect data is line appears underneath it. It shows
areas for units B and C. stored only once and can be called the most recent unacknowledged
Central positioning of the screens upon from various objects. Examples alarm that has the highest priority. In
for auxiliary services at the shift of aspects include: System 800xA, users can jump directly
supervisor’s workstation. Function diagrams from the header line to the associated
An area that that allows shared use Operation and diagnostic displays plant diagram. Another key feature is
of the equipment isolation counter Maintenance management functions that the header line indicates how
for the two units. AutoCAD drawings (eg, connection many messages there are per plant
Direct and indirect work area illumi- drawings, P&I-diagrams) sector and which has the highest pri-
nation; the ceiling is used as a re- Monitoring camera images ority.
flector to provide an evenly lit work
area. 3 Plant overview header line, a new integrated feature of System 800xA
Ceiling, equipped with micro-porous
acoustic panels, evenly distributes
air and minimizes noise.
Low-level lighting to improve visibil-
ity of larger screens.
a b c d e f
A novel concept for operation a Plant overview d Online help

and monitoring b Plant event and alarm list e Alarm line
In choosing System 800xA, E.ON se- c Navigation strategy f Date and time
lected a process control system that

ABB Review
Powerful renovation
The entire alarm list can be cesses such as the following

4 Zoom function showing all data within a chosen time interval.
selected from the unit area also run on this computer
or from a dedicated selec- Calculation of current per-
tion point at the top of the formance indicators of all
screen. It is possible to store major plant components
individual notes for each a b and the total plant.
alarm for the alarm list as Simulation of load depen-
well. The individual alarm dent reference data of all
list elements can be shown major plant components.
or hidden and be listed in Calculation of the quality
any order. The alarm list can factors of all major plant
also be sorted by the indi- components and the total
vidual elements. This can be plant process data valida-
very useful, for example, to tion.
c
sort according to time d
stamp, plant equipment tag Calculations resulting in
or priority. The alarm list trends and process graphics
can be exported directly to can be viewed on various cli-
a Zoom window c X-Y plot
Excel for further analysis ent computers located in the
b Ruler function d Time off-set
using “copy and paste”. main control room and in the
administrative building. Client
Analyzing the process using computers can be used to cre-
trend curves duced fuel consumption by increasing ate and modify the simulation or data
Processes can be reliably analyzed the efficiency of energy conversion in validation model. A network license
with the help of trend-chart displays. the power plant. for the engineering software is for this
A wide range of functions, some quite purpose installed.
innovative, are available in System An alternative to cost-intensive con-
800xA to generate such trend charts. struction of new power plants is to im- E.ON KGW1 plant management decid-
Both real-time data and historical data prove the quality of energy conversion ed to implement a pilot project for the
are presented seamlessly in these in existing power plants. Even if the Scholven power plant’s 676 MW unit
charts. The time interval can be select- efficiency of the process cannot be F. After successful implementation and
ed by the user. Real-time trend char- ramped up arbitrarily by changing the acceptance in October 2005, an order
acteristics can be compared to curves way a plant operates, an attempt can followed for the implementation of
generated yesterday, last week or last be made to come as close as possible process quality monitoring for units C
month using the „time offset“ func- to the operational optimum. and E.
tion. A zoom function is also avail-
able, which can be used to call up all The implementation of process quality Outlook
data within a particular time interval management systems at the different After Unit C had been successfully
to the exact minute 4 . New functions power plants within E.ON is designed restarted on schedule, E.ON gave ABB
for the chart displays include a magni- to allow plant personnel to monitor the order to upgrade Unit E process
fying glass and the ability to create and optimize plant operation in order control system to System 800xA. The
horizontal lines or define horizontal to achieve sustained improvements of changeover took place during the
and vertical areas. the process quality. 2006 maintenance outage. E.ON also
plans to upgrade the process control
Process quality monitoring E.ON’s decision to implement process system for Unit B during the 2007
As a result of the liberalization of quality monitoring in most of their maintenance outage. These steps will
the energy market and changing plants was also driven by the require- make optimum use of potential syner-
environmental restrictions there is a ment to have comparable operational gies.
need for detailed knowledge of the key parameters of their main produc-
current and the historical quality of tion units.
the process management in power
plants. The process quality management sys-
tem at the Scholven power plant’s Harald Bruns
As a consequence plant operators face Unit F consists of one server PC and Power systems, ABB AG
a multitude of challenges. On the one several clients. The PIMS database for Mannheim, Germany
hand, the liberalization of the energy storage of analog and binary process harald.bruns@de.abb.com
market creates an ever-increasing cost values, calculation results and validat-
pressure. On the other hand, environ- ed values is installed on the server Stefan Lauxtermann
mental restrictions aim to reduce the PC. The process values are collected Power systems, ABB AG
output of carbon dioxide. Both chal- from different control systems sources Minden, Germany
lenges can be dealt with through re- (Siemens Teleperm, ABB 800xA). Pro- stefan.lauxtermann@de.abb.com

ABB Review
Serving the needs of the Asian market and beyond
Barry Williams, Dan Mantey
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 doing this, ABB saw that it was

positioning itself to better serve the
needs of the Asian market, especially
cal excellence, knowledge of the busi-
ness, experience, specialist skills,
project management capabilities and
Project managers – ABB accredited
Project managers course.
Engineers and designers – external
China. This included covering the inter-personal skills, which are all and internal technical courses tailor-
long term service needs of its custom- required to meet the challenges and made to meet their job require-
ers. By designing and building sys- the demands related to working with ments.
tems in China, ABB could both reduce both Chinese and international clients. Sales, engineering and service per-
the costs of fabrication and avoid sonnel – ABB product and third par-
large shipping costs from North Amer- ABB was fortunate to secure the ser- ty analyzer courses.
ica and Europe. To ensure success it vices of knowledgeable Chinese per- Workshop personnel – electrical,
was necessary for ABB to recruit and sonnel with experience of analytical mechanical and welding courses.
properly train local personnel with the systems from the oil, gas and petro- All staff – safety training.
necessary engineering skills and the chemical fields. The very capable local
motivation to ensure the on-time de- staff was supplemented by several key ABB’s Shanghai SIU is now a totally
livery of high quality analytical sam- expatriates from Europe with a broad integrated operation and has a staff of
pling systems. range of experience in supplying large 61, which is engaged in the following
scale analyzer systems globally. disciplines: external/internal sales,
The Shanghai SIU started operation in project management, engineering, de-
January 2003 with only four full-time sign, procurement, business support,
staff. Initial projects were subcontract-
Poorly designed analyzer quality assurance, manufacturing, in-
ed to a local third party vendor for systems have a significant spection, testing, commissioning,
manufacturing. In the meantime a additional financial impact training, service and support. The
plan was formulated to develop a to- 2000m² Shanghai SIU facility was cus-
tally integrated SIU, which would em- over the life cycle of the tom designed and purpose built to
ploy all ABB personnel. All key func- plant due to plant shut- meet our manufacturing floor space
tions would be located in the same requirement complete with test, weld-
facility in order to assure tight control
downs, design changes, ing, stores and material quarantine
of project management, quality and increased maintenance, areas.
customer communications. The plan and increased call out
was fully realized in April 2004 when The Shanghai SIU initially served the
the operation moved to the Waigaoq- charges and spare parts rapidly expanding market in China,
iao Free Trade Zone in Shanghai. holdings. especially in the chemicals sector.
Now, after building upon a strong
It was also recognized that the Shang- reputation for providing quality ana-
hai SIU would need to increase its ABB’s goal was to deliver projects lyzer systems, the Shanghai SIU ex-
personnel considerably in order to with the same quality, methodology ports systems to other countries in the
ensure that projects could be execut- and efficiency as from the SIUs in Asia Pacific region, as well as servic-
ed and delivered in a timely and effi- Europe and America. Despite the high ing the European and Middle Eastern
cient manner. The initial focus was to experience levels of the local Chinese markets.
find project managers, analyzer spe- staff a considerable amount of skills
cialists and system design engineers. training was required and implement- Since its start in 2003 and until the
ABB sets high expectations for techni- ed via the following courses: end of 2006, the Shanghai SIU has

ABB Review
since most suppliers do not manufac-

Factbox Major project applications awarded to ABB Shanghai SUI
ture analytical systems in the country.
Application System delivered Year of order The number of service engineers will
LDPE 2 Houses 2003 continue to increase both in China
OXO & AA/AE 5 Houses + Field Systems 2003 and abroad as customers demand fast-
LDPE pH/Conductivity/Hydro Leak 2003
er response times from this highly
trained cadre of personnel.
LOP 7 Houses + Field Systems 2003
MA/PA/FA 7 Houses + Field Systems 2003
This full value-chain approach pro-
Olefins 4 Houses + Field Systems 2004
vides the clients with a single commu-
Thermoxidizer 1 House 2004
nication channel, and the same ABB
Methanol 1 House 2004
multi-discipline project team is in-
Isocyanates 7 Houses + Field Systems 2004 volved in the project throughout its
Naptha FTIR Analyser/Sample 2005 life cycle. This results in reduced
Acetic Acid 1 House + Field Systems 2005 costs, long term reliability, ease of
CEMS 3 Houses 2006 maintenance and most importantly,
OXO & AA/AE 2 Houses 2006 lower total cost of ownership due to
Acetic Acid 1 House 2006 partnering with a single solutions pro-
Silicone 9 Houses 2006 vider.
Refinery 8 Houses + Field Systems 2006
The number of service
engineers will continue to
successfully delivered over 47 analyz- base. Sales personnel are encouraged increase as customers
er houses. These deliveries include to bring prospective customers to the
about 185 ABB analyzers Factbox . Over facility to see the quality of the ABB demand faster response
33 percent of the delivered analyzers products first hand. times.
are manufactured by ABB, while the
remaining share is sourced from vari- The Shanghai SIU has been awarded
ous third party suppliers. There are and works to the following quality as- The majority of clients now realize
several customers in China, who use surance standards: that poorly designed analyzer systems
third party analyzers, but still require ISO 9001: 2000 have a significant additional financial
ABB to design, construct and deliver ISO 14001: 2004. impact over the life cycle of the plant
the sampling system due to the quali- due to plant shutdowns, design
ty of its work. changes, increased maintenance, and
Since its start in 2003 increased call out charges and spare
ABB considers its people its greatest and until the end of 2006, parts holdings.
asset and the staff in Shanghai is not the Shanghai SIU has
viewed any differently. It has been in- ABB Shanghai SIU’s fully integrated
strumental in ensuring a continually successfully delivered operation with a multi-national and
expanding operation resulting in both over 47 analyzer houses. multi-discipline staff has the experi-
an increased market share and client ence and track record to handle major
These deliveries include global analyzer system projects. ABB
about 185 ABB analyzers. is able to take advantage of the cost
structure of the operation, which al-
The Shanghai SIU assumes total re- lows the SIU to deliver quality analyz-
sponsibility for the project from pur- er systems at extremely competitive
chase order to client handover; ongo- prices in this very price oriented mar-
ing service support is also available ket place.
via ABB’s strong service network,
which is present in China as well as in
almost any other end-user destination
country. Services range from spare Barry Williams
parts support and demand service to ABB Engineering (Shanghai) Ltd.
full resident maintenance service con- Shanghai, China
tracts. ABB in China currently has a barry.williams@cn.abb.com
dozen service engineers dedicated to
analytical systems. This enables ABB Daniel P. Mantey
to provide its customers with excel- ABB Global Analytical Business
lent local after sales support. Within Raleigh, NC, USA
China this is a real ABB advantage, dan.mantey@us.abb.com

ABB Review
Risk management
Process Analytical
Technology
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
Process Analytical Technology
Risk management
P rocess Analytical Technology (PAT)

is a system for designing, analyz-
ing, and controlling manufacturing
Better process understanding
The physical and chemical processes
involved in the manufacture of phar-
and early fault detection delivers a
more flexible agile asset with much
improved OEE.
processes based on an understanding maceuticals are complex and not well
of the scientific and engineering prin- understood. However, during both the ABB’s PAT Center of Excellence (CoE)
cipals involved, and identification of development and manufacturing stag- Following the need to offer an inte-
the variables which affect product es, PAT-enabled processes provide grated approach to PAT, ABB created
quality. The PAT initiative is based on access to information rich data – in re- a CoE in 2004. Its mandate is to devel-
the FDA (The US Food and Drug Ad- al-time – which can be “mined” to find op ABB products and services which
ministration) belief that: “quality can- the critical quality parameters through will enable customers to reap the ben-
not be tested into products; it should multivariate analysis. Once these are efits of PAT. The PAT CoE builds on
be built-in or should be by design.” determined, it is then easier to estab- ABB Analytical’s experience of provid-
lish accurate control schemes for the ing Pharmaceutical PAT Fourier Trans-
The primary goal of PAT is to provide relevant process parameters so that a form Infrared1) (FTIR) and Fourier
processes which consistently generate more robust process can be estab- Transform Near Infrared (FT-NIR)
products of a predetermined quality. lished in a shorter timeframe and analyzers to the market for the past
Effective PAT implementation is found- right-first time production is ensured. ten years, as well as ABB’s position as
ed on detailed, science-based under- a leader in Automation and Control, in
standing of the chemical and mechani- Repeatable batch trajectory particular with its 800xA platform.
cal properties of all elements of the Quality control requires a highly de-
proposed drug product. In order to tailed level of process understanding. The PAT CoE leverages ABB’s global
design a process that provides a con- ABB offers a combination of advanced resources, which include experienced
sistent product, the chemical, physical, and regulatory control based on ro- research and development personnel,
and biopharmaceutical characteristics bust process models that deliver veri- application specialists, chemometri-
of the drug and other components of fiable results. The PAT solutions detect cians, process engineers, IT engineers,
the drug product must be determined. and manage critical control points in senior validation consultants and
the process so that deviations from a advanced process control specialists.
The role of on-line advanced measure- required profile are correctly managed Its mandate covers the entire range of
ment systems is pivotal to realizing the and fed back into the high perfor- PAT applications:
benefits of PAT. However, the transfor- mance control zone. Initial integration with Manufactur-
mation of process performance to pro- ing Excellence programs
vide greater efficiency and cost effec- Reduction in overall cycle time Multivariate analysis
tiveness, in addition to assured quality, Processing to a quality-based end- Basic and advanced analyzers
requires much more than the applica- point is a key part of the PAT quality Data gathering
tion of measurement technologies. assurance regime. This eliminates Data storage
wasted cycle time associated with pro- Data mining
Realizing such gains also requires an cessing using a fixed time-based end- System integration
integrated measurement, control, point including subsequent reprocess- Connectivity with manufacturing and
workflow management and informa- ing time – and provides a streamlined business systems
tion environment which meets the workflow through the facility. Advanced Process Control (APC)
needs of research and development,
manufacturing and quality processes Reduction in Quality Assurance (QA) Analytical and measurement
within the business. costs technologies – the platform for PAT
Reduction in Out of Specification At the heart of any PAT system is a
Using PAT, ABB offers a unique indus- (OOS) events and consequent investi- series of measurements made on real
trial solution so that its customers in the gation leads to significant cost sav- processes under realistic manufactur-
Life Sciences industry can enhance their ings. PAT enabled unit operations ing conditions. Data from convention-
processes to deliver the benefits of PAT, reduce the reliance on laboratory test- al process measurement systems (eg,
from process investigation right through ing and associated lead times, thus temperature, pressure and flow) give
to achieving operational excellence. reducing the overhead costs associat- some insight into manufacturing pro-
ed with product quality. cesses so as to achieve a basic level of
The benefits of PAT process understanding. However, man-
In a nutshell, the benefits of PAT can Improvement in Overall Equipment ufacturing processes are usually too
be summed up in the following sen- Effectiveness (OEE) complex for simple approaches to be
tences: PAT improves asset uptime and OEE is the industry accepted tool to effective in achieving process under-
availability for pharmaceutical unit measure and monitor production standing and control. An in depth
operations by up to 40 percent. Costs performance. It can be applied at the degree of understanding and tight con-
are reduced by up to 30 percent while machine, manufacturing cell or plant
fundamental product quality is main- process level. Making cycle times Footnote
tained. How this is achieved is out- repeatable and reducing in-batch 1)
See also “Waves to data”, ABB Review 3/2006
lined in the following paragraphs. down-time through improved control pp 73–74.

ABB Review
Risk management
trol can only be achieved by employ- Typical drug substance solutions The IndustrialIT for Process Analytical
ing the correct technologies to measure include: Technology suite
relevant process parame-ters. These Reaction monitoring To address these drawbacks, ABB is
technologies are often based on chemi- Fermentation monitoring currently developing an IndustrialIT
cal composition and/or physical form Crystallization monitoring PAT suite that features an integrated
measurements, ie analytical techniques. Dryer monitoring IT platform using proven analytical
Solvent Recovery monitoring and automa-tion core components.
ABB has top class analytical technolo- This platform is based on the award
gies, from FT-IR/NIR spectroscopy Typical drug product applications are: winning 800xA Industrial IT Automa-
right through to mass spectrometry Raw material identification tion technology2). The concept 1 is
and Gas chromatographs. Fully inte- Blend monitoring based around a flexible, modular,
grated into ABB’s Industrial IT (IIT) Spray coating monitoring scaleable and open architecture 2
concepts, the systems have unparal- Fluid bad dryer monitoring which uses OPC – a standard commu-
leled connectivity capability and pro- Solid dosage form content uniformity nication protocol – to exchange data
vide a robust measurement platform Moisture in lyophilized solids between modules.
for all PAT applications. Connected to
the IIT information backbone, the Even though the available analytical FTSW800 – Analyzer control process
process data developed can be used technology fulfills a wide variety of software for data acquisition
in everything from advanced control measurement needs, there is still a This flexible, open architecture process
to process troubleshooting. very wide Information Technology analyzer software 3 is designed for
gap which is preventing the industry implementing analytical methods and
FT-IR/NIR analytical solutions from efficiently gathering and using control sequences. It offers a single
FT-NIR is, by far, the most widely used this data in real-time for process un- platform for the local control of multi-
and proven analytical technology for derstanding and control. To be more ple analyzers from spectroscopy (IR,
PAT applications. ABB has ten years of specific, most of the advanced PAT UV-VIS, Raman etc) to other advanced
experience in supplying off-line, at-line analyzers currently available do not analyzer types (particle size, acoustics,
and on-line FT-IR/NIR PAT solutions to share a common user interface and HPLG, mass spectroscopy etc). In addi-
the pharmaceutical industry and is a data format, and do not offer the con- tion, it provides unified engineering and
preferred supplier of most of the lead- nectivity required to efficiently ex-
ing companies. Turn-key analytical so- change this data with plant and busi- Footnote
lutions are provided for research and ness systems. Furthermore, the data is 2)
http://www.abb.com/productguide Information on
development for scale-up, drug sub- highly scattered and is not available in ABB’s 800xA IndustrialIT Automation technology is
stance, and drug product manufacturing. real-time in a central location. found under the “Control Systems” section.
1 IndustrialIT for PAT concept
3rd party SCADA & Batch Engine

PAT Data PAT Method Data
Operator
Management Central Visualization &
Interface
(with Audit Trail) Configuration Export 3rd party Visualization
Vector and scalar data
Multivariate
On-Line PAT Asset FTSW 800 3rd Party Historian (IP21... )
Data Analysis
Plant data (LIMS, Predictor Optimization Configuration Advanced
(ABB or 3rd party)
Scalar data
access and
EBR, MES, PLC, Process Control

Real-time
export
DCS, etc...) (ABB or 3rd party)

PAT Data Manager PAT Clients
Control Network Vector and scalar data
Vector and scalar
Vector and scalar
Vector and scalar
Vector and scalar
Vector and scalar

Scalar data
Scalar data
data, results,
data, results,
data, results,
data, results,
data, results,
flags, etc
flags, etc
flags, etc
flags, etc
flags, etc
AC800M AC800M
controller or 3rd controller or 3rd
Party PLC FTSW 800 FTSW 800 FTSW 800 Party PLC FTSW100 FTSW100
ph ph temperature
Crystallise
Raman FBRM
Spectrometer Particle Size
LOCAL Milling
Blender
Reactor
CENTRAL NIR Drying Monitor Monitor

ABB Review
Risk management
operator interfaces as well as tools for process control system (PCS) and the Data mining, visualization, multivariate
multivariate analysis and predictions. business systems. analysis, and batch Management
The IndustrialIT for PAT suite includes
Data storage: PAT data manager ABB’s PAT data manager is unique in a wide range of modules to provide
The management of PAT data is highly that it stores all the data in a single an operator workplace, central meth-
complex not only because the flow of distributed database and can handle od configuration, multivariate analysis
information is enormous, but because huge flows of both scalar and vector batch configuration and management
it also includes a mix of data formats data coming from the analyzers, the as well as asset management for ana-
(spectral, vector and scalar data) that PCS and SCADA systems: It handles lytical and process equipment. The
makes it difficult for standard histori- the batch structure data, the vector system also has the ability to connect
ans to handle. Furthermore, the cen- and scalar data, alarms and events as to third party commercial multivariate
tralization of PAT data is not sufficient well as a complete audit trail. It can analysis tools for off-line and real-time
as it needs to be combined with the also exchange data with other third predictions.
batch information coming from the party historians
Control
IT
Controlling processes in a flexible and
2 Industrial for PAT network architecture
repeatable manner requires process
understanding to be realized within
PAT Data regulatory and advanced control envi-
Visualization Clients
Manager
& Chemometric tools ronments, while at the same time tak-
(Consolidation)
ing advantage of a range of process
models. This is facilitated by dynamic
Optional Plant Network/Intranet/Internet solutions – predict, control and infer-
Other SCADA Batch ential measurement platforms which
Server Historian Manager Visualization integrate with operator interface, and
PAT Data Clients Router/
Manager & Chemometric Firewall regulatory control and process data
tools management components.
Control Network
The way forward
PAT provides an opportunity to move
FTSW800 FTSW800 from the current “testing to document
SCADA OPC quality” paradigm to a “continuous
Server
quality assurance” paradigm that can
3rd Party ABB improve a company’s ability to ensure
Analyzer 1 to 6 Analyzer that quality has been “built-in” or is
FTSW800/
Analyzers “by design”. Not only that, but it gives
PAT IT System companies a greater insight and
understanding of their processes; it
provides the potential for significant
reduction in production (and develop-
3 Local trending with FTSW800 software
ment) cycle times; and it minimizes
the risk of poor process quality.
PAT will revolutionize the way phar-

maceuticals are made and will forever
change the face of the industry. This
is why ABB’s investment in PAT is the
single biggest development initiative
in Life Sciences, and it also presents
the company with an exceptional
opportunity to become the market
leader in Life Sciences.
Thomas Buijs
ABB Automation Technology
Process Automation
Quebec, Canada
thomas.l.buijs@ca.abb.com

ABB Review
Risk management
Flexibility guaranteed
Streamlining applications and process changes
with ABB’s Extended Automation System 800xA libraries
John Croft
Today’s processing industries are demands for access to additional, rel- ing the device and equipment libraries
experiencing increased demands to evant and up to date information. within the System 800xA. ABB has
reduce schedules and costs, while introduced the world’s first truly ge-
maintaining more stringent quality ABB’s Extended Automation System neric, reusable software library for
and safety standards. The trend 800xA responds to these demands. It batch applications in the pharmaceu-
towards consolidation of the process integrates the process control with all tical and fine chemical sectors.
control, shutdown, facility, electrical extended automation applications
control and maintenance manage- and smart devices in a single opera-
ment systems into a single unified tions, engineering and information
platform continues, with increasing management environment. By extend-

ABB Review
Risk management
T he ability of ABB’s Extended Auto-

mation System 800xA1) to gather
information from multiple plant sourc-
structures, and device objects results
in significant time savings in specifi-
cation, engineering, testing and vali-
These extensions were possible be-
cause of the Aspect-ObjectTM design of
ABB’s Extended Automation System
es and transform it into relevant infor- dation, all of which ultimately reduces 800xA. They break new ground by
mation for a diverse set of users such the time to market for new products. distributing the control intelligence
as maintenance technicians, process Similarly it allows process engineers through a control hierarchy, thus en-
engineers, production managers, or to make changes to existing recipe abling truly generic, pre-tested and re-
plant operators enables plants to operations and Phases without the usable library objects to be provided
perform smarter and better with sub- need for programming expertise. for Units, Equipment Modules and
stantial cost savings. Phases 1 . It is the only system that
Extending the equipment library provides truly generic Phases that can
The advantages of using the System The extensions to the equipment li- be used out of the box. It removes a
800xA device and equipment libraries brary build upon the already proven level of complexity, meaning that
on a project result from using stan- libraries in order to deliver similar highly qualified programmers are no
dardized configurable objects with benefits for batch applications. They longer needed. A process engineer
preserved integrity and inheritance, provide a comprehensive library of can carry out much of the application
while ensuring and maintaining the generic Phases, Unit and Equipment engineering at the recipe level. This
necessary flexibility. Module templates, together with a way the system maximizes reuse at
toolkit of components designed to op- the phase level, allowing customer
Now ABB has taken things to a new timize the specification and building engineers to focus more on what they
level. To extend the device and equip- of batch applications utilizing ISA actually make rather than on the intri-
ment libraries, the company has de- S883) style Equipment Modules and cacies of programming.
veloped a library2) of objects and tem- customized Process Units. Generic
plates which effectively provide pre- Phases enable new products to be in-
engineered components to engineer troduced by developing new recipes
ABB has introduced the
a batch application with the minimum only, all in compliance with cGMP world’s first truly generic,
of configuration. Furthermore, these (current Good Manufacturing Practic- reusable software library
components can be used over and es) and FDA (Food and Drug Admin-
over again without any need for proj- istration) validation requirements, thus for batch applications in
ect specific controller programming. minimizing the scope and complexity the pharmaceutical and
The ability to employ truly generic of testing. Because it has been de-
Phases, Unit and Equipment Module signed to be integrated with standard
fine chemical sectors.
device library control objects, the
Footnotes equipment library shares common ter- With other available systems, each
1)
For more indepth information, please refer to
minology, engineering principles, se- batch application needs significant
www.abb.com/product/us/9AAC115756.
curity and naming conventions. This configuration and controller program-
aspx?country=US (November 2006)
2)
A library is a collection of foundation objects (com-
ensures the information displayed to ming every time for every project,
ponent solutions) from which unique instances can operators is consistent while engineer- particularly for Equipment Modules
be created. Each instance is effectively a clone of ing and testing time is greatly re- and Phases. This incurs additional
the foundation object. duced. time and cost as these components
1 The library extensions distribute the control intelligence through a 2 Devices are encapsulated in Equipment Modules, which combine one
control hierarchy or more control devices together into a common function
Philosphy of Approach Medium A

Recipe Inert gas
Fl
Product Medium B Pressure
Recipe Control
F
Fl E E
F P PC
Generic Library Modules E
Unit
Charging M
Procedures Vacuum
PC Equipment Library
Outlet Air
TC E
T
Reactor, fermenter, L LI
Operations Phases Unit separator, etc. E
Heat
Equipment Vapor services,

Modules inlet manifold, agitator, etc. Temperature
Control Cool
Mix
PC Device
Control Valves, pumps, loops, etc.
Library
Modules Transfer/
Storage

ABB Review
Risk management
3 Units are configured to represent the physical plant units and

comprise multiple equipment modules, associated process
measurements and applicable process phases
will invariably need to be re-validated. The use of an S88 structured frame- “aspects”, including controller code,
In addition, the new libraries, allow work and a pre-tested and proven faceplate and graphic display element
manual control at all levels via face- component library makes specifica- which support device management
plates, and they provide the granulari- tion, implementation and configura- over the entire life cycle. Devices
ty, transparency and diagnostics to tion of control systems less complex have configurable general options,
enable efficient commissioning and and less time consuming. The library including alarm and state colors, user-
maintenance. components are also used in a hierar- definable functions and text with
chical manner. native language support. Devices are
The component objects provided by encapsulated in Equipment Modules,
the libraries include Control Modules, The libraries making the reuse of complex packag-
Equipment Modules, Units and Phas- The device library provides a large es of device control simple, accurate
es. These objects are used to build up portfolio of tested process control and repeatable. Equipment Modules
single devices, from Equipment Mod- devices such as motors and on/off combine one or more control devices
ules and Units, to operations and reci- valves. Each device is represented in together into a common function 2 ,
pes that ultimately control the plant. the library by an object enriched with which in turn can be used across sev-
eral units to provide a high degree of
reuse, as well as ensuring operating
Factbox The ABB System 800xA extended libraries when applied to batch processes deliver:
consistency through the plant, and
reducing engineering and testing
Capital Productivity: Leveraging System ments to be made as plant requirements
effort. Units are configured to repre-
800xA’s object-oriented technology, the develop over time logically and consistently.
libraries provide the ultimate balance be- In addition remote support and service is
tween flexibility and standardization. This simplified which minimizes the risk to plant 4 The library of generic Phases requires no
minimizes project specific library develop- production. configuration. Parameters define the actions
ment and the project specific software, to be taken by a Phase to achieve a
thereby minimizing the cost of developing a Operational Profitability: The use of the process action
batch automation solution while maximizing libraries provides efficient commissioning
the plant operability. and maintenance due to the transparency,
granularity and diagnostics. Operator re- Adjust PV
Global Responsibility: The library objects sponse time to process and batch events is
Adjust Alarm
are developed under stringent Quality Assur- reduced; they can immediately see the root
ance standards, tested and encapsulated to cause affecting a phase, an Equipment Timer
ensure functional integrity. This can greatly Module or a Unit and can fully trust that the
reduce project testing and compliance docu- trip and interlock displays are correct and up
mentation, especially for validated projects. to date with the configuration, because they
are automatically built. Transfer
Risk Management: The fact that ABB
maintains the libraries minimizes risk by Quality
Moitor
ensuring the future migration and upgrade
path. It enables modifications and enhance-

ABB Review
Risk management
sent the physical plant units 3 . They from the Phase faceplate under manu- tained by ABB to ensure future migra-
comprise multiple Equipment Mod- al control. tion and upgrade paths.
ules, associated process measurements
and applicable process phases. The Operation procedures represent the System 800xA in Korea
Units include the state model for han- process steps necessary to control the Engineers can select which foundation
dling process upsets and control de- manufacture of a batch of products. objects to use from the libraries to
vice physical errors, and they provide They drive the plant via one or more satisfy the requirements of an auto-
a feature for monitoring quality criti- process Phases by supplying suitable mation solution, and this makes the
cal process values. parameters. In addition, operation libraries applicable for most applica-
procedures generally handle the coor- tion sectors. Korea’s Yeochun NCC
A library of generic Phases 4 is in- dination of multiple phase initiations Co. Ltd (YNCC)4) demonstrated this by
cluded; these require no configuration and non time-critical activities, such selecting, in a strongly competitive
(logic is unchanged for each instance as operator questions, monitoring environment, the 800xA integrated
of use) no testing and no validation. for phase start conditions, data process control and safety system to
The set of generic Phases was select- recording. upgrade the petrochemical company’s
ed to maximize reuse. Parameters number two ethylene plant in order
define the actions to be taken by a The ABB library objects are developed to improve the facility’s performance.
Phase to achieve a process action. All under stringent Quality Assurance and YNCC selected ABB and System 800xA
of the generic Phases are available to Safety Assurance standards, and are due to features such as integrated
operations under batch recipe control tested and encapsulated to ensure control, safety and the advanced
and can be supervised by an operator functional integrity. They are main- process/interlock visibility provided
by the ABB Device Library and the
distributed control system’s Aspect
Factbox What do these libraries mean to:
Object technology.
The Financial Director? ating staff flexibly – I do not need to select According to the company, “Using
“We can implement a full automation solution based upon system operating experience.” ABB’s expertise and the device library,
for our batch plant, with all its inherent bene- the engineering will be simplified and
fits, for significantly less cost than previously. The Process Engineer? made consistent across the solution,
The solution benefits both CAPEX (capital “I can readily understand how the control is and commissioning costs will be re-
expenditure) at the engineering and installa- structured and therefore I can sort out most duced. Device library objects not only
tion phase and OPEX (operating expenditure) problems without the need to call in a control ensure the best practice in device en-
throughout the entire life cycle of the system engineer or automation specialist – I feel gineering and control, but also auto-
and plant.” more in control. I can easily modify existing matically generate displays for opera-
recipes to improve productivity, quality or tors of any interlocks that may be
The Business Manager? yield and can introduce new product recipes present that could delay production.
“We have a plant automation solution that myself.” As a proven and fully supported ABB
gives us the flexibility to introduce new prod- library, YNCC is assured that future
ucts, improve productivity and make delivery The Automation Specialist? upgrades and enhancements to the
promises with the minimum of risk. It enables “I can authorize a batch automation solution system software will be implemented
manufacturing to be adjusted at short notice that is secure and flexible with the minimum without issue and retesting. This opti-
thereby allowing new products to be intro- of risk. Because it adheres to S88, I need to mises YNCC’s capital productivity not
duced much faster. Similarly we can scale up provide the minimum of training to new only for the initial installation, but
production utilizing proven solutions based staff.” also over the life cycle of the plant.”
upon these objects and the flexibility of the
800xA batch management package.” The Control Engineer?
“I can focus on the processing requirements
The Plant Manager? rather than the system when engineering a
“I have confidence that I can maximize my batch solution. I can engineer a batch solu-
plant throughput, consistency and quality tion with the confidence that the operations
because my automation is based upon a staff will be able to maintain it throughout its John Croft
proven solution route that is easily under- lifecycle – I will not get called out so often to Batch Automation Consultant
stood by my operations staff. We can sort sort out problems, such as which interlock is ABB UK Process Industries
out plant upsets quickly and efficiently our- holding up production. I can focus on inves- john.croft@gb.abb.com
selves. My operators like the control and su- tigating control techniques and improving
pervision it gives them – they can feel in productivity.”
Footnotes
charge of the plant and can confidently 3)
ISA S88 batch production standards define good
optimize production. By having a consistent
design and operation practices to improve control
approach to the control I can utilize my oper- of batch manufacturing plants.
4)
Yeochun NCC Co. (YNCC), Ltd is Korea’s leading
petrochemical company.

ABB Review
Risk management
Serving local and global markets from China
Jane-Zhen Yu, Sidney-Yueshan Chen
With the goal of minimizing project local ABB units. Local ABB units are
risk and increasing engineering reuse distributed in different countries
and quality, ABB Process Automation around the world and represent the
has established an organizational interface to the ABB customer during
model called “Center of Excellence”, project execution, as well as for daily
or CoE. Each ABB industry unit has contact. The CoE represents ABB’s
established one or more CoEs to industry know-how, while the local
serve the unique needs of a particular ABB unit is the contact to the cus-
market or industry. The role of the tomers. Finally, the CoE provides
CoE is to develop products and strategic sales support to major
applications for a particular market project pursuits around the world,
and to then make them available for ensuring that ABB is offering the most
global use by local ABB units. The optimum solution to meet a custom-
CoE is also responsible for technical er’s budget and functional require-
development and technical leadership ments.
in project execution, together with

ABB Review
Risk management
H istorically, ABB CoEs were based

primarily in Western Europe and
North America. Traditionally, this is
Pangang Group Ø 340 tube mill line
– world largest seamless steel tube
production line
execution and management as well as
technology development and localiza-
tion. The CoE’s early successes have
where ABB’s core competencies resid- Ningbo Baoxin stainless steel line – allowed the local team to build up
ed for many industries. However, in world largest stainless steel process- extensive field experience in technol-
view of the huge capital investments in ing lines ogy, application and project manage-
Asia, coupled with the wide supply of Taiyuan Iron & Steel – world largest ment.
highly educated engineers throughout cold annealing and pickling pro-
the region, it was time for ABB to com- cessing line “Our team is formed by a group of
mit to an Asian based CoE. The boom- Baosteel processing line – the world young professional, well-educated and
ing steel industry in China gave ABB third fastest steel production line very hard working people. They are
its chance. Within ABB’s Metals busi- located where the business is in the
ness, it was decided to establish a CoE A mixture of local and expatriate experts world and where abundant skilled
for Processing Line and Tube Mills form a winning team engineers are available at world-class
(CoE PLT), in Beijing, China. Since its The success of the CoE PLT was de- cost structure,” said Christer. “They
establishment in 2002, the CoE PLT has pendent on ABB’s ability to delivery are always ready to learn new things
become one of the most successful the high quality of engineered solu- and will bring our metals business to
units in ABB Process Automation. Ben- tions which were expected of the cus- the next level.”
efiting from the local dynamic and tomers, but to use local Chinese engi-
booming steel industry and its own neers and project managers for imple- References in the domestic market
technical and engineering competence, mentation. The decision was taken to
CoE PLT has undergone a rapid devel- relocate key ABB Metals engineers to Pangang Group Ø 340 tube mill line –
opment, and has strived to extend its Beijing, where they could develop lo- world largest seamless steel tube
footprint in and outside China. cal competence while using the expe- production line
riences built over many years with ABB’s CoE PLT China team helped
Why China for processing line and tube projects in Europe and the Americas. Pangang Group Chengdu Iron & Steel
rolling mill CoE? The project operation team continues Co., Ltd. (CSST) build a tube pro-
“It has been proven as a very wise to be the key to success. duction line for the largest scale in
decision,” said Christer Skogum, head 2005 1 .
of CoE PLT and Process Automation
division North Asia. “In our global
Each ABB industry unit The seamless steel tube production
management team, we have a clear has established one or line was a key project in metal indus-
and common understanding – many more centers of excel- tries. This was recognized as high
of the future demands exist in the technology project by the National
‘new’ world, and our local team is lence to serve the unique Reform and Development Commission
ready to take on the business in both needs of a particular during the period of macro control
the new markets as well as the old tra- on metals and some other over-heated
ditional markets”
market or industry. industries. The line has set a few
records in the metal industry:
“Our first-ever center of excellence Narendra Gupta, an ABB veteran in The Ø 340 tube mill line adopted the
in Asia has achieved a remarkable the metal field, who has been in most advanced technology including
achievement,” proudly added Fu Jian- China since 1999, leads the operation the latest process control system
peng, head of the local business unit team. The team focuses on project and medium voltage drive system.
for metals in China, “we have in-
creased business 500 percent since its
establishment.”
Today 50 percent of the world’s 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.
The rapidly growing market gives CoE
PLT a fabulous opportunity to develop
its business and people. The new
projects in China are among the
world’s leading lines in terms of ca-
pacity and technology. Some exam-
ples where CoE PLT has delivered
process automation solutions are:

ABB Review
Risk management
The diameter of 340 mm is Baosteel processing line –

1 Pangang Group’s Ø 340 tube mill line is China’s largest seamless steel
the largest scale seamless the world third fastest steel
tube production line
steel tube in China. production line
The shortest cold and hot CoE PLT helped Baosteel 3
commissioning period (less to build a steel processing
than three months). line with a speed of 1,040
The sole line in the industry meters per minute, making it
which has a one-time hot the fastest production line in
trial success. China, and the third fastest
in the world.
ABB’s scope of delivery in-
cludes MV and LV drives, This is the first carbon steel
basic automation, level II pro- production line at Baosteel
cess control and LV motors. Shanghai headquarters.
2 ABB helped the Chinese steelmaker Baoxin more than double
its production capacity and create the world’s largest hot and cold
The Ø 340 line is another ABB has successfully execut-
annealing and pickling lines
successful reference of ABB ed many projects for Baosteel
CoE PLT China team, after the group, one of the major iron
completion of two similar and steel makers in China.
projects in Tianjin City and
Hunan Province. CoE China – serving industry
needs outside China
Ningbo Baoxin stainless steel The success of the CoE PLT
line – world largest stainless in China rapid, but not sur-
steel processing line prising. However, the real
ABB technology supported key to a successful CoE is
the development of the the ability to support proj-
world’s largest stainless steel ects globally, not just within
processing line in Ningbo the Chinese market. CoE PLT
Baoxin Stainless Steel Co., is supporting many orders
Ltd. 2 , and helped Baoxin outside of China, in coun-
more than double its produc- tries as diverse as Nether-
tion capacity. lands and Mexico. These
Under the terms of contract, ABB is projects include AC/DC motors and
CoE PLT provided equipment and sys- providing the customer with a basic drives, automation systems, control
tems to help develop the largest hot automation system, a computer pro- desks, movement control centers
and cold annealing and pickling line cess system, and AC drives and motors (MCCs), electrical and mechanical
in the world, as well as state-of-the-art for the line. Production capacity is erection, full system engineering and
rolling mills. ABB will supply special- expected to reach 500,000 tons annu- commissioning.
ized technologies for rolling, flatness ally. The delivery is slated for comple-
control and metal conditioning, as tion in one year. The key to success
well as process control products, ABB has CoEs in metals, chemicals,
drives and motors. oil and gas, pulp and paper, marine
Today 50 percent of the and other industries. ABB is con-
This work will support Baoxin’s drive world’s steel production is vinced this is the right approach to
to boost its current annual output of in Asia, and 85 percent of ensure consistent project execution,
300,000 tons of finished products to regardless of industry, scope or geo-
700,000 tons. ABB has already de- the incremental growth is graphic location. The success of the
signed, engineered and commissioned in China. The country CoE PLT in Beijing shows that such
a complete annealing and pickling centers can be located close to the
line for another part of the Ningbo
reached 349 million tons market demand without sacrificing
facility, as well as providing other in 2005 and forecast an quality or efficiency.
specialized equipment and technolo- additional 10 percent
gies.
growth in the year after.
Taiyuan Iron & Steel – world largest cold Jane-Zhen Yu
annealing and pickling processing line Taiyuan Iron & Steel (Group) Co., Ltd. Sidney-Yueshan Chen
CoE PLT won an order from Taiyuan (TISCO), founded in 1934, is a giant ABB China Ltd.
Iron & Steel Group, to supply the iron and steel complex whose main Shanghai, China
world largest cold annealing and pick- product is steel plate. It is China’s larg- jane-zhen.yu@cn.abb.com
ling processing line in 2004. est stainless steel production enterprise. sidney-yueshan.chen@cn.abb.com

ABB Review
Risk management
quality, a powerful controller is need-

ed to handle all required functions
Rolling mill from low level binary control up to

advanced and sophisticated control
solutions. The high end AC 800PEC
controller from the 800xA Automation
platform is outstandingly well suited
simulator to meet these requirements [1].
The complexity of the process and the

corresponding requirements with re-
spect to the control system are rising
A new platform for testing, analysis and with the number of stands being in-
optimization of cold rolling mills. volved. Tandem Cold Rolling Mills
Axel Brickwedde, Frank Feldmann, Nicolas Soler (TCM) with up to four or five stands
in a row can be considered as a most
demanding example of what has to be
The cold rolling of flat metal products especially in tandem or multi-stand handled by the control system 1 .
mills is a highly complex process where the product quality is influenced by Some of the main aspects explaining
various aspects. With the help of a hardware-in-the-loop simulator, the com- the complexity are:
plete rolling process can be simulated and tested in real-time. This allows highly non-linear process, eg with
respect to roll-gap
pre-commissioning and pre-optimizations before the actual commissioning
interstand coupling and interaction
work is done on the plant site. This reduces project schedule and safety risks via strip
and guarantees a much faster plant start-up. loop interactions from interstand-
tension and thickness control loops
rolling speed dependant transport-
delay between stands
I n hot and cold rolling mills, the de-

mands on mill profitability, produc-
tivity and product quality are on the
draulic equipment, auxiliary supplies
and control strategy. The many associ-
ated variables have to be tightly con-
on-line tracking for head, tail and
strip weak points
synchronization required for all
rise. Thickness and flatness tolerances trolled to meet product quality targets. stand interactions
are decreasing while surface quality The entire control process enters into variety of different disturbances, eg
must further improve. At the same extreme parameter ranges, especially eccentricities, coil-bump, input-
time, mill flexibility has to match the when one considers controlling up to thickness and hardness disturbance,
growing variety of products, while 40 tons of moving parts to a precision Coulomb friction, etc
high mill productivity (throughput and of 1 µm with rolling speeds of up to various operational modes, eg
yield) is a key issue to remaining 100 km/h. threading, acceleration /
competitive in the global economy. deceleration, tail-out, low / high
Strip quality and mill throughput are To be able to control such a large and speed
influenced by various factors such as complex plant and meet the high de- large range of thickness reduction
mechanical design, electrical and hy- mands on process speed and product from 6 mm down to 0.2 mm

ABB Review
Risk management
Exploiting the full production poten- ings from the actual rolling operation, a ulation, was transferred and compiled
tial requires an overall and well-inte- non-linear dynamic simulation model for real-time mode (using MATLAB
grated approach to cold rolling mill of the process was developed, validat- Real Time Workshop® [3]) and down-
automation, optimization, control, ed and extended with respect to con- loaded onto the ABB Process Control-
adaptation and supervision. trol functionalities 3 . This allows the ler AC 800PEC. Connecting this plant
simulation of rolling a complete coil in- model to the AC 800PEC process con-
This approach has to cover: cluding threading, acceleration, decel- trollers that handle the complete auto-
mechanical and hydraulic systems eration, tail-out, changeover between mation and application software for
drive trains different operational control modes for the actual plant allows full rolling op-
material flow thickness and tension control, tracking eration as a Hardware-in-the-Loop
visualization and control system of head and tail and dynamic program (HIL) simulation in real-time 2 , 4 .
modeling and simulation change, eg for continuous rolling.
pass scheduling and set-up The result is a highly dynamic plant-
technological control This simulation setup can be used to and process-simulator that acts in real-
supervision and diagnosis solutions test and develop new control concepts time and allows ghost rolling for:
in order to improve thickness quality Testing in the lab without having
To efficiently design, test, analyze and and to meet the increasing demands the actual plant available.
optimize such a complex system, simu- with respect to off-gauge length. For Testing, pre-commissioning and pre-
lations based on a process model are this purpose the complete process optimization of controller-applica-
necessary. This is the best and only way model is realized as an off-line simulation software.
to fully understand the complete system tion programmed in MATLAB®/Simu- Testing of interface and interaction,
with its various interactions without link® [3], thus allowing flexible testing, eg between the application software
having the actual plant available. optimizations and evaluations with far of the different controllers.
more degrees of freedom than on the Data evaluation and analysis based
Therefore a non-linear dynamic pro- actual plant. on process signals that would not
cess model of a multi-stand cold roll- be available on plant site as mea-
ing mill was developed to meet the The performance of different control sured signals.
technological demands of such a com- strategies, mechanical configurations, Testing without risk of strip-breaks,
plex system with respect to required sensor equipment and drives can be instabilities or causing damages to
product quality, disturbance rejection, compared in simulation studies. From the actual plant.
plant stability and reliability, safe op- these, the most suitable setup can be Testing without the need for various
eration and fast commissioning. This selected and effective process im- test-coils.
is especially important in case of a re- provements identified. Dynamic simu- Training for operational personnel
vamp in order to keep the downtime lation can also be used to analyze to get familiar with the new automa-
to set up the new automation system customer specific problems such as tion system as well as man-machine
as short as possible and to guarantee oscillations, which can have a nega- interaction.
a fast start-up to full operation. tive impact on product quality. Reducing on-site commissioning and
plant start-up time.
Off-line simulation On-line hardware-in-the-loop simulator
Based on process and plant data as The non-linear process model 3 , Modular and Scalable
well as measurements and data record- which was developed for off-line sim- The non-linear dynamic process mod-
1 Four stand rolling mill configuration 2 Ghost rolling using tandem cold rolling mills
(TCM) process model as real-time simulator
Simulation
TCM Process

ABB Review
Risk management
el for off-line and on-line simulation Stand module coil-bump generation for uncoiler
consists of different modules for coil- dynamic stand model including non- and coiler
er/uncoiler, strip, stand, actuators, linear roll-gap coulomb friction in mill-stands
sensors, filters, control, etc. 3 . This al- multi-mass mill drive-line configura-
lows the modular and flexible design tion Control / sensor
of different multi-stand cold rolling speed control including feed-for- sensors for thickness, tension,
mill configurations. The plant de- ward compensation speed, roll-force measurement
scribed here is a four-stand cold roll- modeling of position- and torque- speed dependant transport-delay for
ing mill with an uncoiler at the entry loop thickness-measurement
and a coiler at the exit side. thickness control, inter-tension
Strip module control, disturbance rejection loops,
In order to be able to perform useful dynamic model with variable strip decoupling loops, etc.
and dependable evaluations, the pro- thickness and stiffness bump-less changeover between
cess modeling has to be detailed speed-dependable transport-delay different control concepts
enough to cover all dominant static, generation for inter-stand distance
dynamic and non-linear effects. Some internal modeling for tracking of For the process modeling as hard-
examples of the features that are head, tail and weld-seams ware-in-the-loop simulation in real-
being covered are: time all dynamic components are dis-
Disturbance module cretized and the complete multi-stand
Coiler / uncoiler input thickness disturbance based process model is executed on one
variable radius as a function of the on measurements from real plant AC 800PEC controller with a task
rolling process disturbances from hardness and sampling time of 1000 times per sec-
multi-mass drive-line configuration weld-seams ond.
integrated indirect tension control eccentricity generation for top and
speed control including feed- bottom backup rolls including har- The communication between the AC
forward compensation monics 800PEC with the process model and
modeling of torque-loop the AC 800PEC Controllers for the
automation and application software
is performed via high-speed optical
3 Modular process model for a four-stand tandem cold rolling mill
links, providing fast and flexible inter-
facing and communication. Data-re-
cording for analysis and evaluation
can also be performed via optical link
connection to an ibaPDA (PC-based
process data collection and analysis
system) [4].
Ghost rolling with HIL-process simulator

Referring to 2 , the TCM Process Mod-
el on the AC 800PEC is acting as a re-
placement for the actual plant. There-
fore the application controllers are
Coil
Pay off reel
Strip
Stand 1
Strip
Stand 2
Strip
Stand 3
Strip
Stand 4
Strip
Tension reel
operating against the process model

instead of the real plant.
Different setups and observations can

be performed with respect to the HIL-
Process Model in on-line mode.
4 Interface between TCM process model and application controllers
Modes of operation can be selected
for the HIL-Simulator, such as:
Pilot & Coiler Mill Drives Tech. Stand 1 & 2 Tech. Stand 3 & 4
selection of different test-coils
selection / activation of different
disturbances
operation without strip
operation with endless coil
Current process signals and trends

during rolling can be visualized.
These include speed, thickness, ten-
TCM Process Model sion, roll-force, forward slip, position
and torque.

ABB Review
Risk management
5 Ghost rolling with HIL-TCM simulator for full coil 6 Process signals from coil rolling on real plant
For a more detailed analysis and Ghost rolling results with control software, without needing
evaluation the process signals can TCM HIL-simulator in real time the actual plant and without risking
be transferred via optical link to an 5 presents the results from perform- damages to the actual plant.
ibaPDA [4] 4 , 5 . This inside view ing ghost rolling with the TCM HIL- The HIL-simulator significantly
allows a much better and straight- Simulator in real-time. The rolling of a reduces plant start-up time.
forward performance and problem full coil is shown for a four-stand cold The HIL- simulator can be applied
evaluation than on the actual plant. rolling mill with uncoiler and coiler. for demonstration in real-time.
Various process signals are often not The process performance is very simi- The HIL- simulator can be used for
available on the plant. There are lar to the one on the real plant as cor- operator training, without interfer-
usually no thickness- and speed- responding process signal recordings ence with the real plant or risk of
measurements between every stand, show 6 . causing any damages.
and the actual thickness in the gap The HIL-simulator can be imple-
cannot be measured at all (since the The testing based on ghost rolling mented in the 800xA automation
sensor has to be placed after or be- with the TCM HIL-simulator proved to platform on a single high perfor-
fore the stand). All these process be extremely efficient with respect to mance AC 800PEC controller, while
signals are easily available while per- pre-commissioning and pre-optimiza- operating at a sampling rate of 1000
forming HIL-process simulation and tion for the plant-related application times per second and communicat-
can be used for fast analysis and opti- and control software. The benefit re- ing with the application controllers
mization. sults especially from the fact, that the via high speed optical links.
testing and optimization can be done The modular design for process-
without the risk of damaging the real modeling as well as control guaran-
plant and without the need for any tees flexible and easy adaptation to
Factbox Various features can be pre-tested
specific test coils. Also pre-commis- different rolling mill configurations
using HIL TCM Simulator
sioning can already be started long and provides realistic process mod-
before the actual plant is available for eling even in real-time.
model setup, adaptation and reference any kind of testing.
generator
dynamic program change and head- / Summary / conclusion Axel Brickwedde
tail-tracking The off-line simulation of the pro- Frank Feldmann
interstand tension- and thickness cess allows flexible and straight for- Nicolas Soler
control including pre-optimization ward optimization and development ABB Automation GmbH
disturbance compensation and of new control concepts for cold Mannheim, Germany
decoupling control loops rolling mills in order to meet future axel.brickwedde@de.abb.com
bumpless changeover between different high demands on process perfor- frank.feldmann@de.abb.com
control modes mance, quality and reliability.
full coil rolling including threading, dv/dt, The off-line simulator can be used References
constant speed and tail-out for performance evaluations and [1] Armin Eichmann, Andreas Vollmer, Roll and
Control, ABB Review 2/2006, pp 26–29
interface setup for communication plant optimizations already in the
[2] Andreas Kroll, Andreas Vollmer, Industrial IT for
between different AC 800PEC design phase.
Cold Rolling Mills, ABB Review 4/2004, pp 44–49
Controllers The HIL-simulator in real-time pro- [3] The Mathworks, User Manual, In particular Matlab,
interface setup to Operator Interface vides flexible and efficient pre-com- Simulink, Real Time Workshop
and data-recording system (eg, ibaPDA) missioning and pre-optimization of [4] ibaPDA, PC-based Process Data Collection and
the plant related application and Analysis System, www.iba-AG.com

ABB Review
Risk management
The challenge of
device integration
Making sure “plug-and-play” equals “plug-and-work”
Ahmad Khan, Stefan Bollmeyer, Friedrich Harbach
The last decade has seen a sustained process automation architecture remote locations such as the pro-
increase in the acceptability of field- paradigm, intelligent field devices and cess-automation level. Currently,
bus solutions for process automation control systems form a single system, PROFIBUS, HART and Foundation
needs. While the underlying reasons fused by a high-speed digital Field- Fieldbus are the most commonly used
for this trend include rapid advance- bus. Now, in addition to the process fieldbus standards. ABB’s Device In-
ments in the fields of digital commu- value, status, diagnostics and any tegration Center tests hundreds of
nication and microprocessor technol- other information embedded in a devices every year to ensure maxi-
ogies, the end result is that the tradi- device, with its enhanced – and ever mum intercompatibility of its control
tional boundaries between centralized growing – ”intelligence“, can be trans- systems with devices from a whole
control systems and devices in the ferred to the control system, making range of vendors.
field have disappeared. In the new the device visible and usable from

ABB Review
Risk management
F ieldbus integration can provide

many benefits to users, yet, de-
spite compatibility standards, there
(FDIC), to ensure that devices and
ABB Systems would work together.
The goal of FDIC is to provide tested
www.abb.com, provides a list of all
devices that have undergone integra-
tion testing.
are risks that a system will not work solutions for all the commonly used
correctly with a given device. A key field devices on the market, when The integration team in Bangalore
goal of open vendor independent used in conjunction with ABB automa- performs basic connectivity as well as
fieldbus technologies is to integrate tion systems. advanced integration tests for field
devices from multiple manufacturers devices. The lab is well equipped
into automation systems. Theoretical- The DIC is made up of two main cen- with dedicated and standardized test
ly, the implementation of fieldbus ters: Minden in Germany, and Banga- benches to carry out integration tests
standards allows “plug-and-play” con- lore in India. The activities at these with the latest released versions of
nectivity between a device and its locations are assigned according to ABB’s control systems including
automation system. However, several individual areas of expertise and tech- 800xA, Melody/AC870P and Freelance
factors make it difficult to achieve this nical strengths. 800F.
ideal situation. These include:
Different interpretation of standards The integration lab has been modeled
among different designers and im-
The goal of FDIC is to on the concept of the software pro-
plementers, by both the device ven- provide tested solutions duction line. The key features include:
dors and automation system manu- for all the commonly used Standardized software development
facturers. and test processes, updated with the
Changes and updates in the stan- field devices on the latest release of standards and spec-
dards. market, when used in ifications
Differences in the speed with which Inspection of hardware and software
adaptations to standards are imple-
conjunction with ABB to filter out those devices that have
mented by the automation systems automation systems. a high chance of failing detailed
supplier and the device vendors. integration tests
Frequently the typical lifecycles of The Fieldbus product management Standardized and strict quality
devices and automation systems dif- team in Minden focuses on identifying checks for all phases of develop-
fer, resulting in multiple versions of and defining the devices that need to ment, test and release
devices and automation systems be- be tested for integration, based on Close cooperation with the Fieldbus
ing on the market at any one time. regular interactions with sales and R&D team in Minden
Attempts to exploit infrequently marketing staff, and customers. The
used standards to provide product targeted devices are prioritized and The Field Device Tool (FDT)/Device
differentiators. assigned for integration according to Type Managers (DTM) technology is
factors such as physical availability of fully integrated with ABB’s control
ABB’s Field Device Integration Center hardware/software and overall market systems.The DTM is either generic,
In 2004, ABB decided to establish a demand for the particular device type. working for a family of devices, or
Field Device Integration Center The FDIC web page, accessible via specific to a single device. The de-
vice-specific DTM is cognizant of all
instrument rules, including configura-
1 ABB’s Extended 800xA automation system integrates the three major fieldbus protocols
tion, diagnosis and maintenance. It
in a single structure
has a simple intuitive user interface
that allows project engineers to access
Each device type object includes all device functionalities. A key task
aspects for for FDIC is to subject DTM’s to exten-
Real Object
Product Documentation sive testing to reduce the risk of los-
ing functionality while using DTM’s in
Configuration ABB’s control system. The report for
each device tested and released by
Commissioning FDIC carries information about the
Operation
functioning of DTM in the target ABB
control system.
Maintenance Management
Parameterization The Integration Cycle

The integration test cycle is typically
Asset Monitoring
12 weeks long and results in a portfo-
Diagnosis lio of integrated devices that is contin-
uously expanding. The integration
Object Type, delivered with the tests are performed on devices that
Device Type Library
are available on the open market.
A typical integration cycle includes

ABB Review
Risk management
2 Device integration components in a single structure
basic connectivity tests, to verify any failures observed during integra- integrated devices tested would prob-
cyclic data transfer between the de- tion tests. Feedback from the FDIC ably be in the region of 1000 per year
vice and the automation system, and often results in improvements in and the number of devices in the inte-
detailed tests with DTMs to verify the device software and, in some cases, grated portfolio would exceed 2000.
device features including parameters, firmware.
configuration, diagnostics etc. De-
tailed tests are also carried out to Commitment to device lifecycle support
All deviations detected
ensure device asset monitor function- Since it began in 2004, the FDIC has during testing are record-
ality, which include the assessment of played a key role in making fieldbus ed in a formal defect
the performance of other higher-level solutions easy to implement and effi-
applications such as calibration man- cient to maintain over the device life tracking system and
agement, computerized maintenance cycle. analyzed in consultation
management, device interoperability,
bus master and other key features The primary benefits to the end cus-
with Fieldbus R&D.
(applicable to Foundation Fieldbus). tomer include:
Verified inter-operability The FDIC is a single point of contact
All deviations detected during testing Re-use of proven solutions for all fieldbus integration needs, cov-
are recorded in a formal defect track- Reduced engineering and ering the whole suite of ABB’s control
ing system and analyzed in consulta- commissioning effort systems for process automation. It
tion with Fieldbus R&D. Depending Support, via ABB’s standard support performs an essential service, main-
on the severity of the observed devia- organization, including access to taining ABB’s reputation for reliability
tion, device software is either released integration experts. and intercompatibility of its control
for general use via the ABB Solutions Possibility of continuous improve- systems.
Bank, or rejected. If the device soft- ment as FDIC takes care of releasing
ware has been rejected for release, updated versions of devices
the cause of rejection is informed to Reduced risk and improved safety of
device vendor so that necessary im- the manufacturing plant Ahmad Khan
provements can be done for a re-test ABB Corporate Research
and release at a later date. Since the end of 2005, the FDIC has Bangalore, India
worked on a standard throughput of ahmad.khan@in.abb.com
Cooperation with device vendors 120 devices per quarter. The total
Cooperation with device vendors is number of integrated devices ap- Friedrich Harbach
crucial to the overall success of device proved each year is approximately ABB Corporate Research
integration. The FDIC receives infor- 425, from more than 50 device ven- Ladenburg, Germany
mation from device vendors in ad- dors. However, if the FDIC was to friedrich.harbach@de.abb.com
vance of new releases, including the evaluate its throughput by the mea-
key inputs required for Device Specif- sures used by some of its competitors Stefan Bollmeyer
ic Asset Monitors. It shares results (who count sub-variants of devices, ABB Automation GmBH
regarding the integration performance eg different operating voltage ranges, Minden, Germany
of devices with vendors and discusses separately), then the total number of stefan.bollmeyer@de.abb.com

ABB Review
Risk management
The system
type test
A global organization ensuring that 800xA performs as advertised
Bill Anderson
In 1999, ABB announced its vision for

the next generation automation plat-
form, called IndustrialIT. 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-
trialIT required a new process control
platform, ABB’s 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 ABB’s 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.

ABB Review
Risk management
A BB’s award winning IndustrialIT

System 800xA has been extremely
successful since its release in 2003.
system in an environment as close to
customers’ working conditions as can
be achieved.
and use-case scenarios. Each center
focuses on different test cases for
each use case in combination with
This success has been due to many different specialized equipment and
factors. Two of the most important are Each STT location specializes in some applications.
the breadth and scope of its function- aspect of 800xA testing. Minden deals
ality, and its ability to support the heavily with the fieldbus and I/O (in- In Västerås, there are 15 test profes-
evolving development of all ABB’s put/output) subsystems, as well as the sionals who perform a variety of tasks
earlier systems. To fulfill the needs of interface to the Melody Open Control to make sure the system works as in-
many different industries, business Systems (OCS). Wickliffe specializes in tended. Västerås also regulates prod-
landscapes, and expectations, ABB extended applications such as Produc- uct quality for the entire global test
employs a global support network for tion Management, Information Manag- organization, ensuring that the test
the research and development of the er, and Asset Optimization in addition process is stringent and effective,
system. This structure allows the to the Harmony, MOD and DCI OCS maintaining global customer satisfac-
800xA system to benefit from truly system interfaces. The Västerås center tion of new releases of the 800xA
global development, capitalizing on is responsible for ensuring that the system, product rollups and service
the skills, talents and market intelli- core 800xA system (PPA and AC800M), packs. The center organizes personal
gence from a global pool of talent. engineering, core history reporting, computers and AC800M controllers
licensing, calculations, etc. operate into test networks to support the vari-
Since its introduction, several revi- properly for all users. The center is ous system versions and system con-
sions have been made to improve also responsible for the 800xA inter- figurations.
the performance of 800xA. The latest face to the AC400 OCS, PLC Connect,
release, System version 5.0 (SV5.0) and Safeguard Connect. Test development process
was released late in 2006. With each While development teams are busy
release, companies like ABB must designing and implementing function-
ensure that the new version has been
The objective of the STT ality, the STT organization is develop-
comprehensively tested and is ready organization is to test the ing new tests or enhancing existing
for customer use. The problem is how 800xA system in an envi- tests. Test development includes both
to test a system devised by more than the written procedure, as well as any
20 different product development ronment as close to cus- test configurations and applications
teams to ensure that it meets ABB tomers´ working condi- required to execute the test plan. Ap-
quality standards in all industries plications used to execute the tests
served by ABB, in all locations around
tions as can be achieved come from several sources. Some
the globe. The solution is ABB’s were designed by the Västerås test
System Type Test (STT) organization. Test planning staff to execute specific functions,
Before each new product or revision such as controlled alarm bursts, heavy
The role of System Type Test (STT) of an existing product is released, system load, and other stress condi-
STT is a global organization with loca- ABB devises a global system test plan tions. Other applications came from
tions in Västerås (Sweden), Minden that ensures all system level and some end customers and are used to oper-
(Germany), and Wickliffe, Ohio product level requirements are tested. ate the system in user-typical scenari-
(USA), with additional support for The system level test is designed as a os. STT creates test cases within the
Microsoft security patch testing from whole and is broken down into com- following use cases:
Bangalore (India). The objective of ponents for testing at each test center. System-wide installation and config-
the organization is to test the 800xA All centers use the same test strategy uration

ABB Review
Risk management
System- and application upgrades 800xA system. This starts with a small best results are often produced when
Application engineering for various system and is integrated, step by step, engineers from end-user companies
system functions into a full, working system. The sys- are integrated into a test team and able
Run-time characteristics and usabili- tem configurations grow progressively to interact freely with ABB test engi-
ty of the system under normal oper- over time, as do applications and neers. This blend of backgrounds,
ation and transient conditions. basic load, until the system size and expectations and experience in a test
Recurrent and complete system capacity is ready for formal testing. team provides the balance needed to
maintenance produce a good result.
Performance characterization of the System Type Test
system under normal runtime and The formal STT is run once the appro-
transient conditions. priate quality level is achieved. This
The System Type Test
System and network security in con- test is executed on more than 12 dif- process is designed to
junction with use case for extended ferent system configurations, distribut- take the system through a
systems. ed across the three centers to create a
Use case for special functions variety of user scenarios. STT has a series of stages that grow
wide scope to identify all errors that in scope and complexity
impact customers.
The best results are often to ensure improvements
produced when engineers Release Acceptance Test in system quality at each
from end-user companies When the STT is completed, a Release step.
Acceptance Test is conducted on the
are integrated into a test final version of the software to ensure
team and able to interact that it is ready for release for manu- The story of STT in Västerås is one of
facturing and distribution to end cus- continuous improvement. Many im-
freely with ABB test engi- tomers. provements to the process and innova-
neers. tions have been made over time and
Keys to success more are planned for the future. Auto-
Test execution process One key to Västerås’ success is collab- mated testing, AutoTestIT, is a growing
The STT process is designed to take oration with many internal ABB organi- component of the current tests being
the system through a series of stages zations and end-users. Each test net- performed in all test centers. This in-
that grow in scope and complexity to work is lead by an experienced profes- novative tool was developed specifi-
ensure improvements in system quali- sional tester. The test team is normally cally for 800xA testing in Västerås and
ty at each step. composed of a blend of ABB engineers has been invaluable as a tool to in-
from various specializations such as crease test speeds, reducing cost and
System Integration Test technical support, operations, and field helping developers debug issues that
At pre-planned stages in the product service. This type of cooperative col- are normally hard to reproduce with
development process, the product is laboration benefits all of the organiza- manual steps. Projects are underway
subjected to a System Integration Test tions in the chain that are expected to in collaboration with the ABB Corpo-
to ensure that the individual compo- provide a full range support to end- rate Research Center on a new genera-
nents can be installed and run as an users as soon as a release is made. The tion of process and tool improve-
ments. The next generation of tools
will automate many of the manual
steps that testers use to design and
conduct tests and to report results.
Finally, another benefit of the STT is

not at all related to fixing “bugs”.
Since STT employs both ABB project
engineers and customers, system us-
ability improvements are routinely
identified and incorporated into new
releases. Ultimately, the role of the
STT is to ensure the successful release
of 800xA, providing customer satisfac-
tion, straight out of the box.
Bill Anderson
ABB Inc., Automation Technologry Products
Warminster, PA, USA
bill.anderson@us.abb.com

ABB Review
Safety management
in process industries
The ABB approach
Robert Martinez, Per Christian Juel, Per Fjelldalen
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.
A BB has been supplying safety

systems to process industries for
25 years and is the most experienced
supplier of programmable safety
systems. The first safety system was
developed and supplied to Mobil Inc.
for the Statfjord B oil and gas produc-
tion platform in 1979. Since then, ABB
has been supplying industrial safety
systems to most industry segments
and major operating companies
around the world.
The oil industry has been at the fore-

front of safety management for many
years. National legislation for safety in
exploration and development of the
oil fields in the North Sea was forcing
a shift in safety awareness and sup-
porting technology long before new
international standards were intro-
duced. ABB played an important role
in the development of the technology
that today forms the basis for modern
integrated automation and safety sys-
tems.
This has provided ABB with the expe-

rience necessary to support its process
industry customers in facing the tech-
nical and organizational challenges
and costs related to strict safety man-

ABB Review
agement regulations. Another impor- The consulting role of safety experts come productive immediately 1 . The
tant argument in favor of ABB is the was not forgotten. The proposed safe- user can perform a gap analysis on
System 800xA control system1), provid- ty tool chain was conceived to be por- the requirements and then automati-
ing a broad collection of “out of the table with a minimum of dependen- cally generate checklists and specifica-
box” services enabling the tightly cies and with an open design simpli- tion documents. The tool is also load-
integrated management required by fying the import of data from a variety ed with ABB’s expert interpretation of
IEC-615112): auditing, authentication, of sources. These features are essen- IEC-61511 and their applicability to
access management, document man- tial for ABB’s safety consulting engi- the company’s own systems. This fea-
agement, asset monitoring and CMMS neers at customer sites and in custom- ture allows ABB engineers to respond
(maintenance) integration. These and er training. quickly and uniformly to customer
other software services provide func- safety requirement specifications.
tionality which help enforce and In 2004 pre-product prototypes were
prove compliance during the opera- completed for both safety project Safety system design and programming
tional phases of the safety lifecycle. management, and cause and effect After the Safety Instrumented Function
matrix programming. These proto- (SIF)2) has been configured, the reli-
ABB’s Corporate Research in Norway types are discussed in the following ability of all its components is input
performed a gap analysis of the sections. to a Safety Integrity Level (SIL) calcu-
System 800xA platform versus the lation to check that it meets the target
IEC-61511 management requirements Supporting safety project management risk reduction. This calculation is not
to determine where support of the The ABB Process Automation business trivial, especially when the effects of
standard could be strengthened. The area has implemented formal and redundancy and common-cause fail-
study revealed an opportunity to offer TÜV-approved safety management ures are considered. Fortunately, a
complete lifecycle coverage by pro- within its safety product development group of safety engineers at ABB
viding support for this functionality in organization. This approval was a nec- Engineering Services in England had
the following planning and engineer- essary pre-requisite for the successful earlier developed a stand-alone SIL
ing phases: development of the new AC 800M HI calculator called TRAC (Trip Require-
Safety project management. safety controller. The knowledge-path ment and Availability Calculator) 2 .
Hazard and risk assessment. needed to gain approval provided The ABB team in Norway compiled a
Safety function design for integrity valuable input to the prototyping of a roadmap for integrating the calculator
and reliability. tool which can be rolled out to proj- with System 800xA and the other tools
Cause and effect matrix safety ect teams and customers, the “Compli- in the safety suite.
programming. ance Manager”.
The SIL calculations are very useful for
ABB Corporate Research, together Compliance Manager helps the user validating the SIF design, but they can
with the Safety section of ABB Process build safety teams, describe member also provide valuable data such as
Automation, identified the benefits of competences and assign responsibili- time intervals after which the customer
a System 800xA “Safety Workplace” ties using a responsibility-accountabil- must perform proof-testing on the SIF
package, combining the existing and ity (RACI) chart. The built-in compli- components. Other useful figures from
proposed functionality to provide a ance editor allows input of any re- this phase are the availability and total
seamless solution to both engineering quirement set. The IEC-61511 standard downtime, mean time between failures
and operational users. is pre-loaded so that the user can be- (MTBF), and the mean time to restora-
1 Compliance Manger screenshot. 2 ABB TRAC (Trip Requirement and Availability Calculator)
SIL Calculator screenshot.

ABB Review
3 System 800xA Safety Builder editor screen shot. 4 System 800xA Safety Builder viewer screen shot.
tion (MTTR). There is a strong demand standard for programming ESD/PSD derlying document. The design ap-
from project teams and sales engineers safety systems or any system with proach enables the underlying CEM
for integrated tools which can calcu- interlock logic. In its simplest form, a document to be shared with contractors
late and aggregate this data to all lev- CEM is a matrix containing named who are not System 800xA equipped.
els of a control structure. tags. The matrix symbols indicate that They specify the design in the matrix
a “trip” of a column’s effect occurs and then send the document back for
At this stage of the lifecycle, all SIF when the corresponding “cause” row System 800xA code and display genera-
hardware has been configured, but is triggered 3 . tion 5 . This facilitates flexible and dis-
the safety application software has tributed development practices.
still to be implemented. The most To support CEM programming for
challenging task in this phase is faced IEC 61131 control platforms, ABB Translation errors are eliminated by
by programmers of large ESD/PSD developed the “System 800xA Safety automatically generating the control
(emergency/process shutdown) sys- Builder” toolkit. The Editor tool helps logic and operator display from the
tems. These SIS systems span all pro- users specify complex emergency and same safety design matrix. This reduc-
cess areas and access a huge number process shutdown logic visually and es initial engineering effort by a factor
of process variables or “tags”. Shut- intuitively with a matrix grid. High- of ten and makes modifications easier
downs are typically structured in a quality SIL-certified code for the new to implement, test and trace.
cascading hierarchy of many levels AC 800M HI controller is automatically
with the higher “emergency” levels generated from this matrix.
tripping lower “process” levels. Robert Martinez
The “Viewer tool” can then be in- Per Christian Juel
Due to these special requirements, voked to generate a fully-integrated ABB Corporate R&D
cause and effect matrix (CEM) pro- System 800xA operator display and Billingstad, Norway
gramming has emerged as the de-facto navigation element 4 . The navigation robert.martinez@no.abb.com
element shows the aggregate alarm, per.c.juel@no.abb.com
or inhibit status of the entire safety
5 Flexible “cause and effect” programming.
system divided into process areas Per Fjelldalen
“sheets”. With one click, the operator ABB Process Automation
CEM Document can drill-down to the sheet in alarm Oslo, Norway
and see at a glance which devices and per.fjelldalen@no.abb.com
which levels have been tripped. One-
Customer/contractor designs and verifies click navigation to all the system’s
devices is provided. Footnotes
Engineering team 1)
Taft, Mark W., “IndustrialIT System 800xA, Extend-
The System 800xA Safety Builder tools ing the reach of automation to achieve continuous
build on the success of the Safety productivity improvements”, ABB Review 1/2004
System 800xA
pp 32–37.
Builder product for Safeguard, adding 2)
See also Martinez, Robert, Juel, Per Christian,
many new features and more flexibility.
Fjelldalen, Per, “Safety management in process in-
System 800xA Safety Builder introduces dustries, Part 1 – Standards”, ABB Review 3/2005,
the powerful concept of “single-source pp 47–50 and Martinez, Robert, Fengler, Frank,
engineering”: drawing, programming “Safe instruments” on pp 96–99 of this edition of
and display all based on the same un- ABB Review Special Report.

ABB Review
Integrated End users of older automation sys-
but separate
Advances in integrated and safety control
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
Roger W. Prew 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
today’s 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.

ABB Review
W hat are the advantages

of integrating a Safety
Instrumented System (SIS)
1 With ABB's System 800xA HI there an increase in data access
between the safety system, and the DCS application and process
strophic incidents that oc-
curred at Flixborough2) (UK),
Serveso3) (Italy), Bhopal4)
management tools
and a Basic Process Control (India) and on board the
System (BPCS)? For one thing, Piper Alpha5) North Sea pro-
the lifetime cost of ownership duction platform. Now pro-
of the system is significantly cess safety expertise has ex-
impacted, as are project de- tended into the general skill
sign, engineering and modifi- set of engineers and opera-
cation costs. At the system tors, and many industry-
definition phase, the flexibili- wide guidelines for process
ty of being able to transfer in- safety have been developed.
puts and outputs (I/O), and The current industry generic
functions between the SIS and standard for electronic and
the BPCS, without materially programmable systems,
altering the system architec- IEC615086), is the result of
ture, improves the efficiency concerted efforts by industry
of the design process and re- and regulators over the past
sults in a more cost effective 30 years. The global objec-
solution. During system inte- tive of such a standard is to
gration, this same flexibility ensure that proper risk re-
ensures that the split between duction strategies are adopt-
BPCS and safety matches the ed by all industries with
actual requirement and has hazardous processes so that
not been forced into an archi- the incidents mentioned
tecture that was ordered many above can be prevented.
months earlier. This generic standard and
tions – only possible if the two appli- the process industry specific standard,
cations are executed in a single com- IEC 615117), are essentially advisory.
ABB´s 800xA HI common controller node – means that However, they are now considered
bined safety and control expensive field equipment and wiring “good practice” by regulators in the
architecture has proved can be shared between them thus op- UK and other industrial countries and
timizing the physical architecture 1 . also as a means of determining if a
that true integration is reasonable practical level of electrical,
possible and functional Moreover, full integration means that electronic and programmable elec-
all data associated with the Safety In- tronic safety (E/E/PES) has been
separation of control and strumented Function (SIF)1), such as achieved. The standards are used to
safety is ensured. the Safety Integrity Level (SIL) calcula- benchmark installations and are, to all
tion, system and field device diagnos- intent and purposes, considered man-
Cost savings arising from common tics, trip frequencies, trip responses, datory.
configuration tools, communications valve condition and so on, are avail-
networks, spare parts, maintenance, able to the BPCS Asset Management IEC 61511 defines methods of assess-
training, service, and upgrades are system. In addition, the high level ing risks associated with a particular
obvious, but the biggest advantage is data collection and analysis tools of a hazardous process and it determines
an increase in data access between BPCS can be exploited in a common the risk reduction the safety system(s)
the safety system, and the Distributed and consistent way by the SIS 2 . must achieve. The standard is pre-
Control System (DCS) application and scriptive in that risks must be assessed
process management tools. “Real Regulations and standards and reduced to “as low as is reason-
time” connection of parameters be- Process safety has gained corporate ably practicable”. It does not however
tween safety and DCS control applica- importance especially since the cata- prescribe what technologies and
Footnotes
1)
A Safety Instrumented System (SIS) contains many safety loops or Safety Instrumented Functions (SIFs), each with its own Safety Integrity Level (SIL).
2)
http://www.hse.gov.uk/comah/sragtech/caseflixboroug74.htm (January 2007)
3)
http://www.chm.bris.ac.uk/motm/245t/245th/seveso.htm (January 2007)
4)
http://www.bhopal.org/whathappened.html (January 2007)
5)
http://www.answers.com/topic/piper-alpha (January 2007)
6)
IEC 61508 is the international standard for electrical, electronic and programmable electronic safety (E/E/PES) related systems. It sets out the requirements for ensuring
that systems are designed, implemented, operated and maintained to provide the required safety integrity level (SIL).
7)
The IEC 61511 standard refines the functional safety requirements laid down by IEC 61508 specifically for the process industry sector. It provides guidance in the proper
application of a Safety Instrumented System (SIS).

ABB Review
architectures should be used to The 1oo2 dual, 2oo3 triple and 2oo4 same controller or keep the functions
achieve the reduction. quad systems available on the market separate but within the same integrat-
today come from a design era that ed network. Known as the 800xA High
used redundancy and fault tolerance Integrity (HI), it is definitely not a
The 800xA HI safety as a means of reducing the probability “modified DCS” or a DCS with added
system shares a common of a dangerous failure occurring. To- safety functionality. Instead it is a sys-
processing unit and other day dangerous failure modes can be tem designed from the outset to meet
completely designed out and 100 per- the requirements of the safety market
components with the cent diagnostic cover can be provided and the current safety standards.
DCS, and brings a to protect integrity without resorting
to duplication. The requirements of
number of significant “fail safe” for “safety integrity” and
Safety related programs
enhancements to the “fault tolerance” for “availability” can are compiled using a limit-
overall BPCS package. now be considered independently and ed instruction set compiler
used when and where they are appli-
cable 3 . certified for 800xA HI
Current technologies safety programs.
Many of the stand-alone safety systems There is always much debate about
currently available on the market pre- the hardware reliability of electronic
date the new IEC standards and em- and programmable systems. However There are four key areas that must be
ploy a variety of technologies to modern surface mount, high integra- addressed for a safety-related system
achieve the high integrity control re- tion electronics is considered extraor- to meet the aforementioned standards.
quired for safety applications. “High dinarily reliable. In an SIS, the logic Many incorrectly believe that as long
integrity” normally suggests a combi- solver hardware is the most reliable as the calculated Probability of Failure
nation of “fail safe” and “fault toler- element in the entire safety loop! on Demand (PFD) is within the right
ance” operation. Fail safe ensures that More evidence can be found in some band, the system complies. A system
if a fault occurs the system will react modern simplex systems where the complies only when the following
in a pre-determined and safe way Mean Time Between Failure (MTBF) four considerations are met.
whereas fault tolerance minimises the figures are better than the last genera- Reliability (PFD) is of course impor-
likelihood of a failure that would pre- tion dual or triple systems. In fact the tant and the figures for all subsys-
vent the system from performing its triple and quad systems suffer from tems that make up the safety func-
functions. These two terms often get the law of diminishing returns on reli- tion must form part of the certified
confused! A fault tolerant system may ability in that the inherent failure rate data set so that the overall loop SIL
not be fail safe. Just because it may be rises in proportion to the increase in can be assessed.
redundant or triple modular redundant components and complexity. The Safe Failure Fraction (SFF),
doesn’t automatically make it suitable which is a measure of the ability of
for safety applications. Also a fail-safe A new generation of system the system to detect and avoid
safety system does not require redun- The new generation 800xA Extended dangerous failure modes, is also
dancy to achieve its SIL. Redundancy Automation System from ABB is flexi- part of the certified data set.
is built in solely to improve system re- ble enough to either combine the con- Any constraints or integrity advan-
liability and availability. trol and safety functions within the tage resulting from the complete
2 Risk graph for a related safety function to protect against a hazardous event

ABB Review
system architecture must be as- components with the DCS, and brings modular nature of the new system
sessed and the implications on the a number of significant enhancements meets the standard requirements for
SIL rating documented. to the overall BPCS package including: functional separation and common
Finally, the systematic integrity of Higher BPCS reliability through: mode failures. Memory partitioning,
the system including the develop- – Diagnostics – extensive diagnostic separate execution contexts, firewalls
ment processes utilized, the lifecy- cover is a prerequisite for integrity and stack management techniques
cle safety management of the sys- – Determinism – the safety model that come from the defence and high
tem, and the methods used to brings with it a deterministic exe- integrity data processing worlds en-
develop and prove high integrity cution model sure that safety and non-safety pro-
software must also comply with the – Integrity – this brings greater reli- grams running in the same processing
letter of the standard. ability and accuracy of measured environment are actually separate and
values and control action non-interfering. The integrity of the
Faster communication between safety function is assured by limiting
A fault tolerant system BPCS and SIS functions allows a general communication with the Man
may not be fail safe. Just higher degree of process control Machine Interface (MMI) to read-only,
because it may be redun- optimization with respect to the ac- and instituting a “safe write” function
tual safety boundaries (or safety dis- for over-rides that can only be en-
dant or triple modular tances). abled by manual intervention at the
redundant doesn’t auto- controller. Peer to peer communica-
Integrated but separate tions between safety and non safety
matically make it suitable The debate about the separation of functions is strictly controlled to en-
for safety applications. the safety function from the BPCS will sure integrity of the safety function.
no doubt continue. However the Additional Cyclic Redundancy Check-
The development of the 800xA HI IEC 61508 and IEC 61511 standards do ing (CRC) and relevance checking
safety system addressed the above actually recognise that safety and non- means the peer to peer network can
issues. The design teams operated safety functions can reside in the be considered a grey channel.
under audited functional safety man- same system if “it can be shown that
agement processes and the design the implementation of the safety and
concept and detail was approved at non safety functions is sufficiently in-
The 800xA HI is a system
every stage by TÜV (The TÜV Product dependent (ie, that the failure of a designed from the outset
Service is considered to be the fore- non safety related function does not to meet the requirements
most independent certification author- cause a dangerous failure of the safety
ity in the business) 4 . A certification related functions)” (IEC 61508-2 of the safety market and
specialist in the team, helped by third clause 7.4.2.3). The standards also re- the current safety stan-
party consultants, steered the detail quire that the possibility of common
design continuously confirming com- mode dependent failures is reduced to
dards.
pliance with the requirements and the an acceptable level. (IEC 61511 Part 1
standards. clause 9.5.1/2). Detailed analysis was carried out
against the “Layers of Protection Anal-
The 800xA HI safety system shares a ABB’s new generation System 800xA ysis (LOPA)8)” method of risk reduc-
common processing unit and other is faithful to these requirements. The tion. This analysis confirmed that the
3 System 800xA HI safety system architecture 4 ABB’s 800xA HI safety system is certified to the IEC 61508
and IEC 61511 safety standards, and approved by TÜV
Duplex SIL 2 High Avail-

Simplex SIL 2 S880 I/O ability Safety System
Safety System

ABB Review
down control together with the

5 Functional Separation
unique processor/safety module archi-
tecture eliminates common mode
faults. Not only this but audited Fail-
ure Mode and Effects Analysis (FMEA)
BPCS Application BPCS and failure rates place the product
within the top 6 percent of the SIL3
band. Audited PFD figures are pub-
Protection
lished and based on a proof test inter-
SIL Layer 1 val of eight years.
Safety Application
Transmitters
800xA HI Safety
Audited FMEA and failure
Protection
Layer 2
rates place ABB’s 800xA
HI SIS within the top six
percent of the SIL3 band.
LOPA credits 1000 for the Protection Layer Real and intermediate Safety Variables
2 implemented in SIL2 application and 10 are internally transmitted to the BPCS In the oil and gas markets safety logic
for protection Layer 1 implemented in non application for control and display solver systems are expected to (a) run
SIL2 application. Field transmitters may be optimised without interruption for at least fifteen
Real time BPCS control functions years and (b) endure all sorts of up-
NB. This data is provided as an example. achieved using Safety Transmitter data grades, modification and change dur-
Actual LOPA credits achieved will be ing that time. System 800xA HI offers
dependent on the detailed architecture and a redundant architecture that can be
function. independently implemented at the I/O
level, the processor level and at the
operator workplace level to add fault
tolerance – and hence high availability
LOPA credits for protection functions, piled safety program. The block exe- – to an already high integrity system
implemented in the DCS application cution of the application during run wherever it is required. This redun-
and operating in either a combined time is verified for order, timing and dant system can also upgrade the
control and safety node or a separate discrepancy. Internal communications system application safely on line.
800xA node, are equivalent to those between processing elements and I/O
implemented in systems with totally are duplicated and double checked The debate about grass roots princi-
different control and safety systems 5 . using proven techniques to ensure ples is set to continue but history has
The additional integrity gained from that all erroneous or unexpected mes- shown that progress is being made by
running BPCS applications in the sages are ignored. The use of diverse challenging the accepted view, ad-
800xA HI controller outweighs the and dissimilar hardware in the I/O dressing the problem from a different
additional risks from possible com- and processors, and a TÜV certified direction whilst complying with the
mon mode failures. Real Time Operating System (RTOS) standards.
in the safety module ensure that the
System 800xA HI meets the integrity
To the oil and gas mar- requirements of IEC61511 on all
kets, System 800xA HI counts.
offers a redundant archi-
Highest possible reliability and
tecture that can be inde- availability Roger W. Prew
pendently implemented at The 800xA HI design is inherently fail- ABB UK
safe with near 100 percent diagnostic roger.w.prew@gb.abb.com
the I/O level and at the coverage even as a simplex applica-
operator level to add fault tion (ABB claims 99.9 percent SFF and Footnotes
tolerance. there are actually no known danger- 8)
LOPA is a simplified risk assessment method for
ous undetected failure modes in the evaluating the risk of hazard scenarios and compar-
system). This is achieved by virtue of ing it with risk tolerance criteria to decide if existing
Safety related programs are compiled an initial hardware design intended to safeguards are adequate, and whether additional
safeguards are needed. http://www.primatech.com/
using a limited instruction set compil- fully meet the requirements of SIL3
info/faq_layers_of_protection_analysis_(lopa).pdf
er certified for 800xA HI safety pro- (Four SIL levels are possible, with (January 2007)
grams. During the compiling process, SIL4 being the most dependable and 9)
For a more comprehensive explanation of SIL, see
additional compiler test suites and SIL1 being the least)9). Hardware di- “Safe instruments” on pp 96–99 of this edition of
CRC ensure the integrity of the com- versity in the I/O, local CRC and shut- ABB Review Special Report.

ABB Review

Global responsibility for quality and safety
Markku Haikola
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.

ABB Review
F or many years ABB has been a

pioneer in the development of
paper machine (PM) drive systems.
most up-to-date supercalenders for
printing papers and many others. Even
though the idea of efficient repetitive
neering units are authorized at differ-
ent levels to execute projects to the
highest global application standards.
The high quality system solutions work is not easy to achieve, ABB im- These levels are determined by the
delivered by the company have been plements on time and to the highest expected repeatability of the project as
achieved by the consistency and quality, an average of two PM drive well as the experience of project engi-
repeatability of the work. In other systems per week! So how does the neers – each project lead engineer is
words, decades of experience and company do this? To begin with, it is usually certified according to personal
thousands of projects combined with to the customer‘s and supplier’s advan- experience. The authorized units are
finely-tuned organizational and per- tage to standardize and stabilize the then committed to train and develop
sonnel skills have enabled the devel- work as much as is reasonably possi- dedicated PM drive experts to effi-
opment of technological solutions that ble for quick and smooth start-ups. ciently manage the detailed features of
not only meet process requirements in ABB has been able to do this because the standards.
all paper making production situations of its PM Drives Network. The PM
but which can also be implemented Drives Network encompasses a unique Standards for large, small and complex
quickly and efficiently. business model and a set of solution systems
standards that are the result of years PM drive systems primarily take care of
of experience and expertise in paper power transmission from the electrical
If the know-how contained machine drive solutions. Global appli- motors. For a delicate process such as
in the global application cation standards constitute the bulk of paper making, engineers must have
the network and when the know-how detailed knowledge of the sensitive
standards is applied effec- contained in these standards is applied control of megawatt class motors as
tively, on-site engineers are effectively, professional local lead en- well as an excellent understanding of
able to ensure a high level gineers and lead commissioning engi- the process characteristics. The motors
neers on-site are able to ensure a high are regulated by inverters which are
of engineering reuse of up level of engineering reuse of them up themselves highly sophisticated devic-
to 80 percent! to 80 percent! Standard features include es with many functions and features.
proven electrical design for safety and Providing a standard inverter solution
various safety related functions in the for a single unit is not that difficult, but
ABB drive systems can be found in system software. Engineering reuse is a standard for a coordinated inverter
many machines including pulp dryers, not the only factor. The quality of system solution (where tens or even
production machines for different paper ABB’s PM drives operation is backed hundreds of inverters are involved) is a
types (with on- or off-line coating), the up by clearly defined domains of ex- demanding task. In spite of the com-
fastest LWC winding machines and the pertise. For example, local ABB engi- plexity, however, high performance in-
All levels of the global Paper Machine (PM) drive programs are easily Standards include tens of preconfigured drive settings,
monitored and accessed through standard interactive windows in the transferred automatically from a standard system
programming tool configuration chart

ABB Review
verter solutions are included in ABB’s large new greenfield project, system of getting expert help quickly and ef-
global application standards. safety will not be compromised by non- fectively. Whether the expert is on site
standard engineering. Requirements and or remotely connected, a global solu-
Large new systems with the latest standards regarding safety may vary tion is easier to troubleshoot because
machine solutions, the most advanced around the globe but the overall aim engineers can quickly navigate the fa-
system controls, and general complex amounts to the same thing. In this area, miliar system for any necessary changes.
integration schemes are typical to only the US, Europe and many emerging
a few of the largest ABB drives proj- countries refer to the international IEC
ects yearly. In such cases the efficient safety standards. Having the know-how
With ABB’s PM Drive
reuse level can only be centrally to implement these and other local Network, customers are
maintained. However, ABB’s PM standards in a project from scratch re- offered high quality global
Drives Network, with defined stan- quires extensive investment. However,
dards and certification ensures that all safety functionality is included in ABB’s solutions with local system
projects, no matter the size or com- PM Drive Network as a standard global service know-how,
plexity, are supported by experienced application solution, and is distributed
personnel at a local level. Operating to local specialists. This working model
thus giving them a real
in this way, ABB will always strive to is the safety assurance in ABB drive competitive advantage.
maintain the highest quality possible. deliveries. Additionally, the company‘s
global center of excellence for PM Many process and machinery suppliers
For small machines and drive systems, drives supplies complete – in terms of also operate on a global level. Suppli-
ABB has recently launched the PMC800 safety and functionality – fine-tuned ers naturally benefit from a proven
basic drive. This system is based on system software packages for demand- solution just as much as the end user.
the same functionality contained in the ing machines, or machine parts, such as Nowadays, working processes are
PMC800xA solution for high perfor- center winders, calenders, or for special standardized and the expectations for
mance machines, but is configured to machine concepts. a smooth and prompt start-up are
be used with a wider variety of avail- high. To avoid any unforeseen and
able products. However more stringent A global operation costly delays, process suppliers will
standards are required if global solu- Most paper companies operate global- benefit enormously by being involved
tions, using a broader selection of ly, and on a global scale customers with the system suppliers in the devel-
components and functions, are to be gain access to the same solutions and opment of standards and working pro-
managed efficiently. Then, with just a consistent services. These paper com- cesses for projects. These must then
little less customization, clients will get panies, like many global companies, be made available to each and every
all the necessary functionality to fulfil depend to a large extent on the avail- project irrespective of whether they
their operational demands . ability of knowledgeable and experi- are managed locally or globally.
enced local support. However there
Safe solutions will always be times when wider ser- In the global paper making business,
The size of a project is irrelevant when vice resources are required to solve it is very important to meet the same
it comes to safety. Irrespective of particular problems. Remote connec- requirements in all parts of the world.
whether it is a small scale revamp a tivity is one of the most common ways Quick start up times are crucial for all
customers and this can be achieved if
uniform standards and processes exist,
Over 250 Paper Machine (PM) drives specialists serve paper makers in ABB’s PM drives network
ensuring repeatable and therefore
prompt work. It is also important for
customers to be able to exchange ex-
periences between mills and commu-
nication becomes easier if global stan-
dard solutions exist. Not only this but
maintenance methods and special skills
for the different mills or machines can
also be unified.
With ABB‘s PM Drive Network, custom-

ers in any part of the world are offered
high quality global solutions with local
system service know-how. In today‘s
business world, this gives ABB‘s cus-
tomers a real competitive advantage.
Markku Haikola
ABB Finland
markku.haikola@fi.abb.com

ABB Review
Safe
instruments
Safe instruments for a safer process
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-
Robert Martinez, Frank Fengler
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 or process industry system builders

and operators, a hazard is the
result of a misbehaving process. The
these would have on the plant sur-
roundings. When this “risk level” is
known, the process safety engineer can
The IEC 61511 standard provides pro-
cess engineers strict guidance for this
task, but also puts responsibility on
safety instrumented function (SIF) choose SIF instruments with a matching management, process operators and
must act to bring the process to a safe Safety Integrity Level (SIL). The SIL lev- people in other project lifecycle phas-
state. As the name implies, a SIF con- el of the entire chain of instruments is es to ensure that the process is ade-
sists of a chain of instruments to de- always that of the lowest SIL compo- quately protected. This lifecycle ap-
tect this hazardous condition, manipu- nent ie, “the weakest link in the chain”. proach is so successful that it has be-
late the input data in a pro- come the preferred model
grammable device (the CPU) 1 Schematic SIF loop structure
for other draft international
and then send a command to standards for machinery, nu-
the output instruments. These clear and even for security.
Input interfaces Output interfaces
output devices are also known
(for example, A-D Communications (for example, A-D
as “actuators” because they converters) converters) The classification of safety
act to bring the process under instruments by SIL level is
safe control or to shut it down itself an enormous achieve-
completely. A schematic of a ment for industry. Born in
Programmable
SIF loop is shown in 1 . the aftermath of the tragic
electronics (PE)
chemical plant accident at
The main challenge for process Seveso, Italy in 1976, this in-
safety engineers is to identify ternational standard allows
Input devices Output devices/final elements
all the possible hazards related (for example, sensors) (for example, actuators)
engineers to focus on the
to that process and then to process hazards, confident
quantify the impact each of that their safety instruments

ABB Review
Safe instruments
will perform at the required level. to the end-customer to maintain it in SIL2 application, for example, as
This separation of functions is more the field. The PFD calculation is: shown in 3 .
than just a practical convenience; it
carries legal obligations for both the PFD = λ • τ / 2 The third approach involves duplicat-
system builder or operator and the where: ing critical elements to achieve greater
safety instrument supplier. λ : number of dangerous, undetected Hardware Fault Tolerance (HFT). In
failures per hour ABB’s SIL pressure transmitter, for ex-
To make this regime work in practice, τ : testing interval in hours ample, a differential inductive sensor
safety instrument suppliers today must provides two independent signals pro-
follow the rules in the ”sister” IEC A lower λ can be achieved in one of portional to input pressure and a dual
standard #61508 “Functional safety of three ways: architecture processes these signals
electrical/electronic/programmable Re-design of critical parts independently.
electronic safety-related systems” and Increased detection capability
achieve the desired SIL certification Increased hardware redundancy In 3 , the columns numbered 0,1,2
for their products. refer to the number of simultaneous
The FMEA document provides valu- hardware faults which the device can
“Sister” standards for safety able input to the first approach: re-de- tolerate. Increasing redundancy clearly
ABB is in the interesting position of sign for greater integrity. For ABB’s has a beneficial effect on SIL but at
being both an instrument supplier (eg, 2600T pressure transmitter 2 , some of the cost of some duplicated hardware.
safety pressure transmitters) and a the key points were; CPU and clock
system builder (eg, safety and auto- integrity, power supply monitoring, The standard has a loophole which
mation for oil and gas projects). Thor- analog output stage integrity and soft- allows suppliers to claim a higher HFT
ough knowledge of the application of ware sequences. Analysis also re- if the device is “proven-in-use”. Prov-
the IEC safety standards is crucial in vealed that λ could be reduced by en–in-use imposes a significant bur-
maintaining the company’s position as using an all-welded design in a critical den on the supplier who often does
a safety leader. area of the device. not have access to high-quality, long-
term historical data showing device
The IEC standards for these two dif- The second approach to reducing λ failures. Without such data, it is rec-
ferent levels of supply are surprisingly means adding extra circuitry and soft- ommended that safety transmitters, for
similar and can be mutually under- ware enabling the device to detect a example, have a HFT value of 1.
stood by a simple change of terms: greater number of dangerous internal
For safety instrument engineers the failures and alarm the system accord- It is particularly important that software
hazard comes from within the com- ingly. This approach increases the failures be included in this SFF analysis.
ponent itself in the form of device Safe Failure Fraction (SFF) of the de- As software in instrumentation gets
failure. vice, but at the cost of extra hardware more and more complex, field failures
The process engineer performs a and code development. The SFF rating due to systemic software errors are in-
hazard analysis whereas the instru- of a device affects the allowable archi- creasing. Therefore, any assessment of a
ment engineer performs an FMEA tecture if IEC 61511 or ISA-S84 is be- device must include the potential soft-
(Failure Mode and Effect Analysis). ing used as the design standard. An ware failures and/or have reliable soft-
For safety instrument engineers it is SFF rating of 90 percent or greater is ware diagnostics built-in to the device.
the impact of a dangerous event on needed to use a single transmitter in a
the safe output of the device which Understanding MTBF
must be assessed. Mean Time Between Failures (MTBF)
2 PFD failure rates
is defined as the inverse of the Safe
Engineers in both disciplines must Failure Rate. The λ data is normally
SIL PFD
quantify the likelihood of their respec- presented in terms of “FITs”, failures-
1 0.1 < PFD <= 0.01
tive dangerous events. The instrument in time. Typical FIT data is expressed
2 0,01 < PFD <= 0.001
engineers calculations result in a PFD in 10-9, or the number of failures per
3 0.001 < PFD <= 0.0001
(Probability of Failure on Demand). 4 0.0001 < PFD <= 0.00001
one billion hours usage.
The PFD value can be directly mapped
to a SIL level according to 2 . For ex- MTBF = 1/λ (for 1oo1 architecture1))
ample, a SIL2 device must fail less
than once out of every 100 demands. There is often a trade-off between SFF
3 Safe failure fraction ratings versus SIL
and MTBF. For instance, one transmit-
Understanding failure rates ter on the market has a SFF of 96.7
SFF 0 1 2
The simple PFD value is a powerful percent and an λ rating of 963, while
< 60% – SIL1 SIL2
number; not only does it determine another has specifications of 70 per-
60–90% SIL1 SIL2 SIL3
the market for the device by virtue of cent and 490. The first achieves the 90
90–99% SIL2 SIL3 SIL4
its SIL certification, but it also deter- > 99% SIL3 SIL4 SIL4
mines the complexity and hence price Footnote
of the instrument as well as the cost 1)
1oo1 is explained later on in the article.

ABB Review
Safe instruments
percent SFF criteria for single device partial-stroke only, allowing produc- proach to calculating the required SIL
usage in SIL 2 applications but has an tion to continue uninterrupted. Field- using either Risk Graph or LOPA
MTBF that is half of the second device. bus diagnostics carry stroke test data (Layer of Protection Analysis). TRAC is
What the user needs to understand is to the logic solver where potentially pre-loaded with both field reliability
that safety transmitters are designed to dangerous failures can be detected. In data and the manufacturer’s reliability
have a very high reliability in terms of this way, they decrease the device’s λ data, including data for many of ABB’s
their main function but may be less and allow operators to wait longer be- safety instruments. All calculations
reliable from a pure MTBF perspective. tween mandatory full shut-downs for discussed so far in this article are
A good rule of thumb for a safety valve testing. The research center is used within TRAC, permitting the user
transmitter, therefore, is to specify a also investigating the use of new safe- to focus on the design task.
minimum of a 100-year MTBF value. ty variants of Profibus and Fieldbus
Foundation to complete the picture Finding the optimum configuration
Proof testing to maintain integrity in for robust safety asset management. One of the main benefits of TRAC is
operation allowing project engineers to investi-
The second term in the PFD calcula- Safety Instrument Portfolio gate various redundancy schemes.
tion, τ, represents the hours between ABB supplies a range of safety pressure Some standards prescribe the use of
mandatory proof-testing of the device transmitters that use a variety of sens- redundancy as the cure for system reli-
when in operation. This is a luxury for ing methods. ABB also offers a range ability, but do not explain the quanti-
device suppliers since frequent testing of temperature sensors, positioners and tative analysis this redundancy is
has a beneficial effect on SIL. Opera- a flowmeter all classified to SIL2. The based upon. Risk analysis is based on
tors, however, must bear the burden AC800M-HI High Integrity SIL2 Safety probability theory and can be derived
of proof-testing every such device as Controller and its associated safety I/O
often as several times a year – a part round off the company’s safety portfo-
4 ABB’s 800xA HI safety system is certified
of the lifetime operating cost that will lio. These SIL classifications are award-
to the IEC 61508 and IEC 61511
not go unnoticed at purchasing time. ed after assessment by accredited third-
safety standards
party companies 4 , an effort which re-
As a general rule, actuators such as so- quires ABB to provide thorough docu-
lenoid-operated valves represent at mentary proof of compliance.
least 50 percent of the dangerous unde-
tected failures of the entire SIF loop. The 2600T-Series pressure transmitter
The sensor accounts for approximately 5 has models certified to SIL2. 37
30 to 40 percent and the remainder is have recently been sold to Statoil in

attributed to the CPU and I/O boards, Norway. Other customers of ABB SIL
collectively known as the “logic solver”. instrumentation include Tractebel Gas
Engineering GmbH (TGE), who have
The research and development effort particular expertise in the areas of
invested to achieve the lower failure storage, conditioning and shipping of
rates in ABB SIL instrumentation is liquefied gases (LNG and LPG) and
worth the effort. The typically high petrochemical gases.
failure rates of actuators is an opportu-
nity for sensor and logic-solver suppli- A tool for optimizing safety design
ers such as ABB to reduce their prod- The complexity of trade-offs involved
5 ABB’s 2600T pressure transmitter is
uct’s PFD values so that the SIL of the in safety instrument design is multi-
certified to SIL2
entire safety loop can be preserved. plied when an entire SIF is configured.
Lower PFD values translate into lower These can be investigated and visual-
costs and simplified engineering for ized in the ABB TRAC tool’s Trip Re-
end customers because they will not quirement and Availability Calculator.
need to boost SIL by specifying redun- This was developed by John Hunt and
dant transmitters or by choosing more Ian Bradby of ABB Engineering Servic-
expensive actuator valves. es in the U.K. TRAC is a PC-based
software tool used to assist safety,
Automation vendors have only recent- project and maintenance engineers in
ly started to exploit fieldbus-based determining the optimum design con-
diagnostic capabilities to offer on-line figuration and periodic test intervals 6 Simplified PFD formulae for redundancy
proof-testing. Such a technique elimi- for safety instrumented functions.
nates field visits and will maybe one TRAC is used by ABB engineering Architecture PFD
day even be fully automated. The consultants and has also been licensed 1001 λ⋅τ/2
ABB Corporate Research Center in for use by end-customers worldwide. 1002 λ2⋅τ2/3
Norway has investigated this tech- 2002 λ⋅τ/2
nique for the proof-testing of actua- The TRAC tool provides the engineer 2003 λ2⋅τ2
tors such as valves by executing a with a systematic and consistent ap-

ABB Review
ABB Review Special Report
from several methods. All methods the device in question – the safe failure Automation Systems
rely on certain key elements in order rate, and dangerous undetected failure March 2007
to provide objective analysis – failure rate. The analysis typically will assume
Editorial Council
rates, failure modes, diagnostic cover- the same MTTR (mean time to repair)
age and common cause data. The most and TI (test interval) values. The equa- Veli-Matti Reinikkala
Process Automation Division Head
common architectures used in the pro- tions used are shown in 6 .
Member of the Executive Committee
cess industries are the following: ABB Ltd.
1oo1 One-out-of-One The good news is that the data re-
Scott Spencer
When using a single device, the quired for the calculations shown Group Vice President
safety is affected by the dangerous above is now published by most major Head of Process Automation Marketing
failures, the reliability by the safe vendors and has been included in the Nils Leffler
failures. TRAC software package. This allows Chief Editor
1oo2 One-out-of-Two the user to perform what-if analysis, as nils.leffler@ch.abb.com
With 1oo2 voting, if either transmit- shown in 7 , to assist selection of vari-
Publisher’s office
ter fails, then the process is tripped. ous vendors and/or architectures. ABB Schweiz AG
This increases safety (versus 1oo1) Corporate Research
at the expense of reliability. Finding the optimum proof test interval ABB Review / REV
2oo2 Two-out-of-Two The tool represents one approach to CH-5405 Baden-Dättwil
Switzerland
With 2oo2 voting, both sensors calculating SIF proof-test intervals. By
need to fail in order to trip the sys- focusing on the relevance of the system Partial reprints or reproductions are per-
tem. This increases reliability at the and consequence of failure on demand, mitted subject to full acknowledgement.
expense of safety. the tool provides a range of test inter- Complete reprints require the publisher’s
written consent.
2oo3 Two-out-of-Three vals. In many cases, this is likely to
This architecture is very common in permit an extension to existing inter- Publisher and copyright ©2007
the process industries since you vals. Where an integrity level is not de- ABB Ltd. Zurich / Switzerland
have very good safety and reliability, fined, test intervals may be justifiably
Printers
but at the expense of added cost. extended to align with the convenience Vorarlberger Verlagsanstalt GmbH
of a plant shutdown or other inspection AT-6850 Dornbirn / Austria
A set of simplified equations has been criteria such as electrical integrity – or
developed to provide a quick risk anal- simply just repair on breakdown. TRAC Layout
DAVILLA Werbeagentur GmbH
ysis based on a few key parameters of provides multiple solutions for testing
AT-6900 Bregenz / Austria
inputs and outputs within the bounds
of the required maximum and mini- Disclaimer
7 TRAC tool for safety function configuration
mum allowable probability of failure on The information contained herein reflects
the views of the authors and is for infor-
demand. For each span of test intervals,
mational purposes only. Readers should
the cost of testing is calculated from not act upon the information contained
known annual testing costs. Results are herein without seeking professional advice.
displayed graphically and a compre- We make publications available with the
hensive report is issued in a fully trace- understanding that the authors are not
rendering technical or other professional
able format 8 . advice or opinions on specific facts or
matters and assume no liability whatsoever
in connection with their use. The com-
Robert Martinez panies of the ABB Group do not make
any warranty or guarantee, or promise,
ABB Corporate Research
expressed or implied, concerning the con-
Billingtsad, Norway tent or accuracy of the views expressed
robert.martinez@no.abb.com herein.
ISSN: 1013-3119
Frank Fengler
ABB Automation Products GmbH www.abb.com/abbreview
8 TRAC tool for proof-test interval optimiza-
Minden, Germany
tion
frank.fengler@de.abb.com
References
[1] IEC 61508 “Functional safety of programmable
electronic safety-related systems”
[2] IEC 61511 “Functional safety – Safety instrument-
ed systems for the process industry sector”
[3] ISA Automation West 2004, “Selection of Safety
Transmitters in SIS applications, Michael Cush-
ing”, ABB Pressure Products
[4] Safety Solutions and Safe Networks Highlight
Hannover Fair, ARC Insights, 28.04.2005

ABB Review
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Automation Systems Global responsibility

ABB Special Report

Operational profitability Capital productivity

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ABB Process Automation –

Risk is a major characteristic of any process automation

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N owadays, end users are finding

1 Core business values 2 Empowering the knowledge worker

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Infrastructure Equipment Process Control Energy Control

Maintenance Operations Production Engineering

ABB OCS Batch Management Infomation Management

Variable Speed Drives Production Intelligence

Motor Control Center

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Every year, heavy industries spend

A s ships were to seafarers in the

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2 Asset Master maintenance workplace

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“Emerging technologies” is a term probably heard most

Yet for companies like ABB with a huge client installed

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W ith an installed base of more

Field engineer Call center

Internet, modem, direct line, etc

Propulsion Asset Web-based On-line Remote Remote

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Winning the battle

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P lant engineers fight a continuous

Factbox Typical recent results

Average inspection interval Consequence

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It was concluded that the nine days. The necessary en-

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R eal plant systems comprise a wide

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a drive shaft system 3 . It continuously

ABB MV Drives focuses

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C ontrol loops are an intrinsic part

variable (PV), controller output (CO)

cal data for each category. troller settings; external problems;

viations from targets are more difficult

12 % 10 % automatically detected – with help, for

CLCM typically focuses on basic con-

where highly advanced control loops

Commissioning control (eg, a model-predictive con-

Maintenance ensures this requirement.

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