ABB Integrated process and power automation
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Transcript of ABB Integrated process and power automation
3BSE062589
© ABB / PA / Control SystemsApril 12, 2023 | Slide 1
Electrical Integration with System 800xAIntegrated Process and Power Automation
3BSE062589
© ABB Group April 12, 2023 | Slide 2
Outline
What is Electrical Integration?
ABB’s solution: Integrated Process and Power Automation
Customer benefits
References
3BSE062589
© ABB Group April 12, 2023 | Slide 3
Outline
What is Electrical Integration?
ABB’s solution: Integrated Process and Power Automation
Customer benefits
References
3BSE062589 © ABB / PA / Control SystemsApril 12, 2023 | Slide 4
What is Electrical Integration?A hot topic – Larry O’Brien, ARC
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© ABB Group April 12, 2023 | Slide 5
What is Electrical Integration?
Electrical Integration is the integration of Process Automation and Power Automation into one system
Process Instrumentation Measurement and
control of pressure, temperature, flow…
Process Electrification Monitoring and control
of motors, pumps, fans…
Substation Automation Protection, monitoring
and control of generators, transformers, switchgear…
Power Management Advanced control of
power distribution
Process Automation Power Automation
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© ABB Group April 12, 2023 | Slide 6
What is Electrical Integration?Users of Electrical Integration
Power Generation
Power ConsumptionPower transmission and distribution
Power Plants Generate Power
Process Plants Consume Power
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© ABB Group April 12, 2023 | Slide 7
What is Electrical Integration?Objectives of Electrical Integration
Power Generation
Power transmission and distribution
Power Consumption
Power Plants value optimized utilization of
generating capacity
Reduce auxiliary system’s energy
consumption
Oil & Gas want to maximize production
P&P / M&M want to manage electricity
usage
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Electrical Integration Traditional approach
Many protocols, lack of global standard
Separate system for power automation
Organizational barriers among process and power department
Device specific solutions for integration into DCS
A lot of hardwiring needed
Lack of information from electrical devices
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© ABB Group April 12, 2023 | Slide 9
Outline
What is Electrical Integration?
ABB’s solution: Integrated Process and Power Automation
Full Plant Integration with System 800xA
Electrical Integration Based on Open Standards
Complete Portfolio from ABB
Customer benefits
References
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© ABB Group April 12, 2023 | Slide 10
Electrical IntegrationTraditional approach
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© ABB Group April 12, 2023 | Slide 11
Integrated Process and Power AutomationElectrical Integration with System 800xA
Electrical Integration Based on Open Standards
Full Plant Integration with System 800xA
Complete Portfolio from ABB
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© ABB Group April 12, 2023 | Slide 12
Integrated Process and Power automation Full Plant Integration with System 800xA
Common information
management
Centralized
Historia
n and Data
Archiving
Common asset manageme
nt
Common system architecture
Common operations
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© ABB Group April 12, 2023 | Slide 13
Integrated Process and Power AutomationElectrical Integration Based on Open Standards
System 800xA fully supports open standards for both Process and Power Automation
Power Automation
IEC 61850
Process Electrification
Profibus / Profinet
Modbus / Modbus TCP
DeviceNet
Process Instrumentation
Foundation Fieldbus
Hart / WirelessHART
Profibus
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© ABB Group April 12, 2023 | Slide 14
Integrated Process and Power Automation Electrical Integration Based on Open Standards
IEC 61850
IEC 61850 is a global standard for the design of substation automation systems
Benefits
Provides interoperability between Protection & Control IEDs (Intelligent Electronic Devices)
Open and flexible standard for future extensions
Future proof by choice of Ethernet based communication for cost effective, fast and reliable data transmission
Endorsed by IEC and ANSI
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© ABB Group April 12, 2023 | Slide 15
Integrated Process and Power AutomationComplete Portfolio from ABB
Main ElectricalContractor
Main AutomationContractor
Integrated Process and Power Automation
ControlSystems
LVPowerDistri-bution
Intelli-gentSwitch-gears
Drives MotorsSafetySystems
Telecom Systems
Intelli-gentFieldInstru-ments
Analyzers
Expertise andConsulting services
Consulting Services
HV/MVPowerDistri-bution
Bridging two worlds together with Electrical Integration
3BSE062589 © ABB / PA / Control SystemsApril 12, 2023 | Slide 16© ABB Group April 12, 2023 | Slide 16
Integrated Process and Power AutomationComplete Portfolio from ABB
DCS ABB is market leader in DCS with System 800xA, a
complete DCS intended for all types of industrial automation
Substation Automation integration ABB is market leader in products for substation and
distribution automation including native IEC 61850 Protection and Control IEDs
Process Electrification integration ABB is market leader in products for process
electrification including low voltage switchgear, variable speed drives and motor controllers
Project Execution and Services ABB has experienced project execution capabilities within
power and automation for all industries, as well as a wide range of product services for operations and maintenance
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© ABB Group April 12, 2023 | Slide 17
Outline
What is Electrical Integration?
ABB’s solution: Integrated Process and Power Automation
Customer benefits
Benefits of Integration
Reduced Investment Costs
Improved Operator Effectiveness
Reduced Maintenance Costs
Increased Plant Availability
Reduced Energy Cost
References
3BSE062589 © ABB / PA / Control SystemsApril 12, 2023 | Slide 18
Benefits of Integration Enable the power engineer
The Past - Expensive substation to DCS interlock schemes
Hard-wired signals Complex software gateways Extra logic required when using
ModBus Modbus is slow! 5 sec feedback!
The Present - Cost effective substation to DCS interlock schemes
Less hard-wired signals; Ethernet backbone instead
IEC 61850 broadcast messages eliminate extra logic needed when using ModBus
Relay A
Relay B
Direct Trip Command
Shell Gumusut Non-ABB DCS ABB PMS 20 sec delay via OPC Now hard-wired
3BSE062589 © ABB / PA / Control SystemsApril 12, 2023 | Slide 19
Benefits of Integration Enable the power engineer (cont’d)
Better HMI than a typical SCADA Online parameterization of IED logic Modify protection schemes from
remote operations center Enhanced Auto Transfer Systems
control Online parameterization of Auto
Transfer logic Immediate visibility on any bus
transfer or event Alarming on events Email & text message notification
Relay A
Relay B
Direct Trip Command
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© ABB Group April 12, 2023 | Slide 20
Customer BenefitsReduced Investment Cost
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Customer BenefitsReduced Investment Cost
Reduced system footprint with one integrated system Reduced wiring with Ethernet based solutions Shortened project execution and commissioning time by using
standardized control logic, libraries and testing Reduced project risk by choosing ABB with complete portfolio,
expertise and experience in both power and automation
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Customer BenefitsImproved Operator Effectiveness
Power groupProcess group
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Customer BenefitsImproved Operator Effectiveness
Process Operator Power Operator
Same operator interface for process and power group enables collaboration
Consistent operating philosophy reduces risk of errors
Common access point for both process and power data provides faster error analysis
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Adoption
High
High
Med
Medium
Low
LowValue
Turbines
Compressors
Fans Blowers
Mechanical Equipment
Electrical Equipment
Control Valves
Centrifugal Pumps
Field Devices
Customer BenefitsReduced Maintenance Costs
Extending Asset
Management into electrical
equipment
*Survey completed by ARC Advisory Group
Typical Asset Management
areas*
3BSE062589 © ABB / PA / Control SystemsApril 12, 2023 | Slide 25
Customer Benefits – Reduced Maintenance CostsSingle strategy for asset management
Not just for smart instruments Single view for all critical process and electric plant assets
Visibility Common user environment for operations & maintenance Troubleshoot problems more quickly Relevant actionable data to prevent plant upsets and predict
equipment failure CMMS Integration
Streamline maintenance activities up to 25% by reducing paperwork and administration effort
Maintain only one interface to CMMS Maintenance planning more efficient
Single source for maintenance analysis Spend less time planning and more time doing
Process based Asset Monitors
Instrumentation
Rotating equipment
Vibration
DCS controller health
IT assets
Heat exchangers
Control loops
Electrical equipment Asset Monitors
Transformers
LV circuit breakers
UMC 22 motor starters
MNS iS LV switchgear
Motors
Drives
Protective relays (IEDs)
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Customer BenefitsReduced Maintenance Costs
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Customer BenefitsReduced Maintenance Costs
Process Instrumentation
Substation Equipment
Process Electrification Equipment
Common user environment for operations and maintenance
Relevant actionable provided to the right person including operators, engineers, and maintenance personnel at the right time
Troubleshoot problems more quickly
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Customer BenefitsReduced Maintenance Costs
Reveal previously hidden critical plant equipment status
Electrical device health information is lost with legacy system integration methods
With IEC 61850 and open fieldbus standards, the hidden critical plant electrical equipment health is now revealed
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Customer BenefitsReduced Maintenance Costs
Maintain only one interface to CMMS
Maintenance planning more efficient
Single source for maintenance analysis
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© ABB Group April 12, 2023 | Slide 30
Customer BenefitsIncreased Plant Availability
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© ABB Group April 12, 2023 | Slide 31
Customer BenefitsIncreased Plant Availability
System 800xA is widely used as integrated or standalone Power Management System
Power Management Systems are used for industrial plants with:
In-plant generation Critical Loads Insufficient reliability of grid supply
Typical Power Management functionality: Fast load shedding
Ensure at any time the availability of electrical power to all critical loads in the plant
Switching off non-essential loads in case of a shortage of power in the plant
Typical response time: < 100 ms
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Customer BenefitsIncreased Plant Availability
2.2 1.8 1.8 2.13.3
2.50.11.57.25.7
MW MWMW MW
MW
MW
MW
Hz
kV
Generator trip
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© ABB Group April 12, 2023 | Slide 33 © ABB Group April 12, 2023 | Slide 33
Customer BenefitsIncreased Plant Availability
0.0 1.8 1.8 2.13.3
2.50.11.54.83.9
MW MWMW MW
MW
MW
MW
Hz
kV
Fast load shedding Avoidance of black-outs with System 800xA
based Power Management Systems
Faster load shedding than hardwired with IEC 61850 high speed protocol
Quality monitored load shedding signals
Reconfiguration without rewiring
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Customer Benefits Reducing Energy Costs
Improving visibility into power consumption Understand and easily access power usage information Explore energy saving opportunities Enhance existing energy usage reduction program Track and trend power consumption
An increase in power consumption can indicate equipment malfunction and wear
Integrate equipment and systems to make energy efficient decisions
Centralized control of power consumption Plant personnel will have complete visibility and
control of a situation regardless of where a problem originated (i.e. an electrical glitch, process control problem, or a failing IT asset)
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Customer Benefits Motivation for Reducing Energy Usage
Issues
7 – 15% of energy does not leave the fence
Increase in operating costs Plant net and gross heat rates gradually deteriorate
CO2 emission costs
Cap and trade in US and Canada
$15 to 30/ton of CO2?- emissions are no longer going to be free
Defacto moratorium on new coal plant construction?
Need to increase output of existing plants
Need to extend lifetime of existing plants
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© ABB Group April 12, 2023 | Slide 36
Integrated Process and Power AutomationElectrical Integration with System 800xA
Electrical Integration Based on Open Standards
Full Plant Integration with System 800xA
Reduced Investment Costs
Improved Operator Effectiveness
Reduced Maintenance Costs
Increased Plant Availability
Reduced Energy Costs
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© ABB Group April 12, 2023 | Slide 37
Outline
What is Electrical Integration?
ABB’s solution: Integrated Process and Power Automation
Customer benefits
References
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© ABB Group April 12, 2023 | Slide 38
Integrated Process and Power AutomationReferences
Global Installations across all Industries
Oil, Gas, Petrochemical
Power Generation
Metals and Mining
Chemical
Pulp and Paper
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Integrated Process and Power AutomationREPAR Refinery, Petrobras, Brazil
Customer’s need: Refinery process control and power management Single plant interface, integrated operations and maintenance
ABB solution: Full Plant Integration with System 800xA
Integrated Process Automation and Power Management System
Electrical Integration Based on Open Standards IEC 61850 integration of ABB and Schweitzer Protection & Control
IEDs
Complete Portfolio from ABB DCS, PMS, IEDs
Customer’s benefits: 30% less engineering hours due to reuse of engineering data 15% savings in installation time with standardization of
solution 20% savings in training costs with improved visibility of one
system
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© ABB Group April 12, 2023 | Slide 40
Integrated Process and Power AutomationFlasjo Hydro Power Plant, E.ON, Sweden
Customer’s need: Hydro power plant process control and substation automation High availability unmanned station with remote operations
ABB solution: Full Plant Integration with System 800xA
Integrated Process Automation and Substation Automation System
Electrical Integration Based on Open Standards IEC 61850 integration of ABB Protection & Control IEDs
Complete Portfolio from ABB DCS, SAS, LV Switchgear, IEDs
Remote Diagnostic Services Remote troubleshooting and fewer trips to site
Customer’s benefits: Cost effective solution, short installation time Standardized concept for coming hydro power renewals Reduced maintenance costs with remote access to plant data
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© ABB Group April 12, 2023 | Slide 41 © ABB Group April 12, 2023 | Slide 41