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Editor's Notes

• #3: First, we answer the question “What is Electrical Integration?” Second we show the ABB solution of Electrical Integration: “Integrated Process and Power Automation” Then we take a look on what benefits of the ABB approach Last, we will see some references installed
• #4: So, what is meant by Electrical Integration?
• #5: Why are we here today talking about EI ? It is a hot topic!!! ARC‘s Larry O‘Brien is heavily promoting ABB as the leader in Electrical Integration ABB‘s CEO, Joe Hogan, is 110% behind EI. He views EI as the biggest differentiator we have among our DCS competitors He has established cross functional teams to promote EI and breakdown barriers within ABB. I particpated in the 2009 OTC in Houston, TX. Our customers and competitors were very impressed with our EI architecture. Emerson practically video taped our demonstration system and tried to take our EI brochures (but I slammed my hand on the brochure stack to stop him). Siemens was less sneaky than Emerson. They ended up sending three more of their colleagues to visit our booth and check out our EI demo system. SEL was also very impressed. Over a two day period, they sent in at least 6 people to learn about our EI capabilities. We view SEL as a competitor in Power Products but we also know they dominate the market in the Americas for protective relays. As a result, we are working together with them to add one of their IEDs to our demo system to show interoperability. Many customers ask me if we can integrate SEL relays into 800xA so we must show them we can. GE has given us a Multlin relay for our demo system. We intend to show it in the same way as the SEL relay.
• #6: Electrical Integration is the Integration of Process Automation and Power Automation into one System Process Automation and Power Automation is usually done in two separate systems for a given industrial site. Process Automation is done by the plant DCS, and can be divided into process instrumentation for control and measuring of the process parameters, and process electrification for monitoring and control of process actuators and rotating machinery. This is the core of traditional DCS Power Automation however is a new area for traditional automation people. It is the monitoring and control of the power distribution of a plant, usually done by its own system. It can be substation automation for protection, monitoring and control of the substation equipment, or more advanced power distribution control with power management
• #7: So, who are the users of Electrical Integration? Electrical Integration, the integration of process and power automation, are of interest where you have both process automation and power automation systems. This is within power generation plants, where the power is produced, and within process plants, where the power is consumed.
• #8: Different industries have different objectives. Power plants want to optimize their generating capacity. Reduce auxiliary system’s energy consumption Oil & Gas need to maximize production by keeping the process running especially at refineries and offshore platforms so Load Shedding during power interruptions is very important. The motivation for integrating process and power automation is a bit different however. For power plants, an optimization of the generating capacity is of main interest. They want to optimize the power output For process plants, the motivation could be a bit different. For Oil & Gas, the most important thing is to keep the process running at all times and produce as much as possible. For more competitively challenged industries, such as Pulp & Paper, Metals and Minerals, they need to keep an eye on the cost side as well, and treat electricity as a raw material. For all industries however, they want to optimize the power input.
• #9: Electrical Integration is not new. ABB has been doing it for over 20 years. The traditional methods of Electrical Integration limitations. CLICK: On the substation side, there are too many standards and no one standard has become dominant. CLICK: Two separate systems for process and power automation. Integration of the systems requires custom solutions. Which equates to hard-wiring. Plus critical electrical asset health information is lost. CLICK: Lastly, organizational barriers exist among departments and suppliers. This illustrates a normal situation within a process or power plant today Two separate systems, one for process automation, one for power automation. Within Process Automation, we have process instrumentation and process electrification as described. Power Automation could be substation automation or power management. Usually the two systems are separate and there has been barriers to integrate them for the information they need to share. This is illustrated by a wall in between. The problems of the traditional approach of Electrical Integration have been CLICK Within Power Automation, a large number of different standards and protocols have been used, creating large engineering and installation costs CLICK As said, usually a separate SCADA has been used for power automation, creating the need for two systems CLICK The integration of the two systems has been quite tedious, with device specific solutions of integrating the electrical devices from the power automation side. A lot of hardwiring or serial buses with low bandwidth and lack of information from the devices , leading to device or project specific solutions CLICK Furthermore, it is often the case that organizational barriers among process and power department is a barrier for efficient operations of the plant. Not only is there a technical barrier between the systems, it could also be an organizational barrier between departments
• #10: So what is ABBs solution to Electrical Integration that solves the traditional problems? We call it “Integrated Process and Power Automation”, which has three main highlights Full Plant Integration with System 800xA Electrical Integration Based on Open Standards Complete Portfolio from ABB Let’s see what that means
• #11: The ABB solution is to overcome the traditional barriers of traditional Electrical Integration solutions and offer…
• #12: And now with System 800xA, we have Integrated Process and Power Automation. Full plant integration with System 800xA. Electrical Integration based on open standards like IEC 61850, Profinet, and Profibus. And we offer a complete portfolio from ABB. Integrated Process and Power Automation, which is Electrical Integration with ABB’s System 800xA This means CLICK Full Plant Integration with System 800xA, i.e. using one system for both process automation and power automation CLICK Electrical Integration based on Open Standards, utilizing open fieldbus solutions and IEC 61850 to integrated all areas CLICK Complete Portfolio from ABB, meaning ABB has the products, expertise and experience to deliver fully integrated systems
• #13: We have Full Plant Integration with System 800xA. It provides a common architecture for both electrical and process controls. It provides a common engineering tool set, common operations, common information management and common asset management. Full Plant Integration with System 800xA One integrated system for both process and power automation means CLICK Common system architecture, same HW and SW components for the only system CLICK Common engineering for all application areas of the plant CLICK Common operations, meaning an integrated operational CLICK Common operations for both process and power operators CLICK Common information management and access to all plant data from one common database CLICK Common asset management strategy for both process and power assets
• #14: Electrical Integration Based on Open Standards System 800xA is the only control system that supports such a variety of open standards and fieldbus solutions for both process and power automation For power automation we support the only global standard for substation automation, IEC 61850, more to come on next slide For process automation we support a variety of fieldbus solutions: Profibus, Profinet, ModBus, TCP, DeviceNet e.g. for process electrification and FF, Hart, Wireless Hart and Profibus for Instrumentation Common Ethernet backbone for all field devices including process and power automation
• #15: Electrical Integration Based on Open Standards So what is IEC 61850? It is the only global standard for substation automation systems, released in 2004 to meet the needs from power automation industry to replace all the different protocols used, to lower the engineering and installation costs It has been defined by the standardization committees together with the big suppliers in the field, including ABB, Siemens and Areva The benefits of the IEC 61850 standard include Interoperability between Protection & Control IEDs from different brands and vendors Open and flexible standard for the users application A future proof standard by choice of Ethernet based main stream communication
• #16: ABB offers a complete portfolio for both process and power automation. We have expertise in both areas and now we are bridging the two worlds together with Integrated Process and Power Automation. Complete Portfolio from ABB ABB, being a power and automation company can offer the complete portfolio to cover both process and power needs. Everything from substation equipment, process electrification equipment, control system, instrumentation, safety systems etc to the services, project execution capabilities and expertise needed to cover all customer needs through the lifecycle of the plant. We can act as both MEC and MAC to cover all needs
• #18: What are the benefits of Integrated process and Power Automation from ABB? Reduced investment costs, Improve the Operator effectiveness Reduce the Maintenance Costs Increase the Plant Availability Let’s see how
• #19: In the past, the electrical operator could not interlock the DCS operator without a complex software gateway or hard-wiring signals between the substation system and the DCS Modbus has a master/slave communication scheme while IEC61850’s GOOSE messages are multicast. As a result, special logic is required when using Modbus to allow the power engineer to interlock the DCS operator. Modbus is very slow. It takes 5 seconds for the operator to see feedback from the relay after initiating a state change. Electrical operator can prevent the DCS operator from starting/stopping a LV motor. This is not possible with the old architecture because ModBus has a master/slave relationship which requires additional logic in the RTU. The extra logic will make the RTU more complex and therefore more increase lifecycle costs. With traditional EI there needs to be a decision whether control shall be done from DCS or the power distribution system. MISC Visualization for both Power and Process operators Power Engineer can interlock the DCS operator Fast control over the electrical equipment by the DCS operator Interlock the DCS from starting/stopping motors from the substation Stagger starting of inductive loads by monitoring local feeders via System 800xA during plant startup Differential Line Protection: Sum of line up, feeders going out or there is a fault versus waiting for an overcurrent to build up and trip. This is called high speed bus differential protection. Busbar Protection with GOOSE messaging is 30% faster than conventional hardwired interlocking-based busbar protection schemes
• #20: In the past, the electrical operator could not interlock the DCS operator without a complex software gateway or hard-wiring signals between the substation system and the DCS Modbus has a master/slave communication scheme while IEC61850’s GOOSE messages are multicast. As a result, special logic is required when using Modbus to allow the power engineer to interlock the DCS operator. Modbus is very slow. It takes 5 seconds for the operator to see feedback from the relay after initiating a state change. Electrical operator can prevent the DCS operator from starting/stopping a LV motor. This is not possible with the old architecture because ModBus has a master/slave relationship which requires additional logic in the RTU. The extra logic will make the RTU more complex and therefore more increase lifecycle costs. With traditional EI there needs to be a decision whether control shall be done from DCS or the power distribution system. MISC Visualization for both Power and Process operators Power Engineer can interlock the DCS operator Fast control over the electrical equipment by the DCS operator Interlock the DCS from starting/stopping motors from the substation Stagger starting of inductive loads by monitoring local feeders via System 800xA during plant startup Differential Line Protection: Sum of line up, feeders going out or there is a fault versus waiting for an overcurrent to build up and trip. This is called high speed bus differential protection. Busbar Protection with GOOSE messaging is 30% faster than conventional hardwired interlocking-based busbar protection schemes
• #21: By using one system instead of two, and using standardized Ethernet base solutions you will reduce your investment cost CLICK When eliminating one system, you eliminate duplicate equipment such as servers, workplaces, switches, etc CLICK By using Ethernet based Open Standards, you eliminate the need for protocol converters, tedious engineering of these and a lot of hardwiring, which reduced the installation and commissioning costs
• #22: So the benefits in investments phase by Integrated Process and Power Automation are Reduced system footprint by eliminating a second system and combining e.g. workplaces and servers Reduced wiring by using Ethernet based solutions of IEC 61850 instead of hardwiring Shortened project execution and commissioning time by using standardized solutions during project execution, e.g. protection logic in the IEDs, substation design, control logic in the controllers, libraries, faceplates to interface all devices from process and power Reduced project risk by choosing ABB with experience and expertise to cover all process and power automation needs
• #23: Improved Operator Effectiveness By integrating both systems, this also means integrating the operations Traditionally Process and Power has been two separate worlds technical wise and cultural wise This means a lock of collaboration between operator disciplines, and difficulties to share relevant information which makes operations inefficient
• #24: With one integrated system you get all accessible plant data from both process and power into one consistent user interface This can be adapted to each specific operators needs CLICK The process operator has access to all relevant process data for instrumentation and process equipment CLICK The power engineer has access to all relevant power information to control the power distribution CLICK And the information that needs to be shared among the groups, e.g. a Sequence of Event list, can easily be shared since all information resides within the same system. CLICK This enables collaboration between the department since it gives access to all relevant plant data for all disciplines It gives a consistent operational philosophy based on System 800xA Aspect Object Technology for all equipment It gives one common access point for all plant data for faster error analysis All of this improves the operator effectiveness for both process and power operators
• #25: Our next customer benefit is reduced maintenance costs. CLICK According to a survey done by the ARC Advisory group, asset management is typically deployed for turbines and smart instruments. These areas, however, have the lowest return on value from predictive asset management. CLICK With Electrical Integration, we are now able to extend asset management into electrical equipment. Electrical Equipment offers one of the largest opportunities for asset management solutions. NOTES: Plant asset management systems for turbine and compressors are primarily deployed for protection against catastrophic failures and not predictive maintenance. Predictive asset management solutions are typically deployed for all other assets.
• #26: Single strategy for asset management Reduces chance of a mishap with a single view of all critical plant equipment. Show AO print screens of Plant Asset Viewer, Reporter, Excel report, and common CMMS database.
• #27: An integrated system provides for a consistent asset management strategy regardless if we are concerned about the calibration of a CLICK A smart instrument CLICK A motor starter CLICK Or a predicting the remaining life of a MV circuit breaker.
• #28: CLICK: An integrated system provides for a consistent asset management strategy regardless if we are concerned about the calibration of a smart instrument or predicting the remaining life of a MV circuit breaker. CLICK: Common user environment for operations & maintenance CLICK: Relevant actionable provided to the right person including operators, engineers, and maintenance personnel Troubleshoot problems more quickly
• #29: With System 800xA, we have remote access to smart devices via DTMs and web links throughout the plant. CLICK Here is an example of a Valve Positioner’s DTM. It provides us with a state of the art valve diagnostics including valve signatures. CLICK This is a DTM for a UMC22 LV Motor Starter. It’s for user friendly diagnostics, configuration and parameterization. CLICK This is a web interface to a REF615 IED. Just like the DTMs, it is also for user friendly diagnostics, configuration and parameterization. CLICK With centralized remote access to smart devices, we reveal previously hidden critical plant equipment status. Often electrical device health information is lost with legacy system integration methods. Now, using open Fieldbus standards and IEC 61850, the hidden critical plant electrical equipment health is revealed.
• #30: CLICK An integrated system allows for a centralized interface point for the plant CMMS. CLICK As a result, there is only one CMMS interface to maintain. Maintenance planning is now more efficient with a single source for maintenance analysis. You will spend less time planning and more time doing All together, this will reduce the maintenance costs
• #31: The next customer benefit is Increased Plant Availability. CLICK: And we are going to do so with an integrated power management solution. To increase the plant availability, control and monitoring of the power distribution is critical. Control of the power supply is as vital as control of any process parameter. This can be done in a more advanced way the System 800xA based Power Management Systems
• #32: System 80xA has been widely used as integrated or standalone Power Management System A PMS avoids black-outs by optimizing the stability of the operation of the electrical generation- and distribution network of an industrial plant, by sharing the power between the generators (and public grid) in such a way that the plant can withstand bigger disturbances than without a PMS. It is usually used by plants with In plant generation Critical loads Insufficient reliability of grid supply If, in despite of that, a trip occurs, the PMS will secure the available electrical power to critical loads by switching off the less important loads. This is called load shedding.
• #33: Let’s do a very short click demo. CLICK: First, we have a generator trip. CLICK: Next, fast Load Shedding occurs. CLICK: The non-critical loads are shed based on a priority table. This is a single line diagram of an Oil & Gas application with in-house generators The power feeds motors on different voltage levels CLICK The use case here is that a generator trips, which reduces the available power for the plant. You cannot run all motors anymore, and must take appropriate action.
• #34: If using a Power Management Systems, a load shedding application kicks in and sheds the non critical loads CLICK This ensures that the critical loads of the system ken be kept in operation CLICK This is done by shedding the non critical loads with lowest priority CLICK So by using System 800xA, you can have a much more stable process with improved plant availability Furthermore, using Etnernet based IEC 61850 instead of hardwired load shedding solutions you can improve the trip reliability and trip response. This is done by monitoring the signal quality and using a high speed protocol defined in the IEC 61850 standard. As well reconfiguration of the trip logic can be done without rewiring.
• #35: Power management is more than Load Shedding. It is also about reducing energy costs. Visibility and Control - Leading industry analyst firm ARC research director Larry O’Brien has stated that increased operational efficiency is all about visibility and control. “In the HPI [hydrocarbon processing industry], many potential cost-saving opportunities related to power and energy consumption are ignored simply because people in refineries and petrochemical plants don’t have the appropriate visibility or control.” Larry O’Brien further states, “ARC believes that energy savings on the order of 10% can be achieved in many process plants by integrating power and automation.” With an integrated system, operators will now have visibility into power consumption which will enhance any existing energy usage reduction program. Operators can easily access power usage data and interpret the information. In addition, they will be able to track and trend power consumption which enables the exploration of energy savings opportunities. An increase in power consumption can indicate equipment malfunction and wear. Without visibility into power consumption, no one will know about the equipment malfunction resulting in unexpected downtime plus a preventable increase in energy consumption. Integrate equipment and systems to make energy efficient decisions. An integrated system will also provide centralized control. Plant operators can monitor the health of instrumentation, rotating equipment, IT assets, electrical equipment, and energy consumption to determine overall terminal station status. For example, operators will have immediate visibility of any power event such as bus transfer, load sheds, or trips, as well as process control events such as temperature transmitter failure or calibration required alert. The status of critical IT assets can be seen as well, alerting operators to potential system problems. For example, with ABB’s System 800xA, the information will be provided via alarm and events lists as well as email and text messaging notifications. It can also be sent to a Computerized Maintenance Management System (CMMS). Whether it is an electrical glitch, process control problem, or a failing IT asset, plant operators will have complete visibility and control of the situation. Improving visibility into power consumption Understand & easily access power use 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 Without visibility into power consumption, no one will know about the equipment malfunction resulting in unexpected downtime plus a preventable increase in energy consumption Integrate equipment and systems to make energy efficient decisions Centralized control of power consumption Whether it is an electrical glitch, process control problem, or a failing IT asset, plant operators will have complete visibility and control of the situation Immediate visibility of any power event such as bus transfer, load sheds, or trips The status of critical electrical equipment can be seen, alerting operators to potential system problems Information is provided via alarm and events lists as well as email and text messaging notifications Work orders can automatically be opened to a Computerized Maintenance Management System (CMMS) Automate plant revenue metering and billing with real-time power data from System 800xA
• #36: Another benefit of an integrated system is Reducing Energy Usage. Here are some motivators for Power Plants to reduce energy usage. An increase in operating costs due to natural degradation of the power plant and CO2 emission costs. What will happen if Cap and Trade takes effect? Perhaps $15 to $30/ton of CO2? Emissions are no longer going to be free. There seems to be a self induced moratorium on new coal plant construction. That means we have to Increase the output of existing plants. Extend the lifetime of existing plants.
• #37: So to summarize: Integrated Process and Power Automation, which is Electrical Integration with ABB’s System 800xA means CLICK Full Plant Integration with System 800xA, i.e. using one system for both process automation and power automation CLICK Electrical Integration based on Open Standards, utilizing open fieldbus solutions and IEC 61850 to integrated all areas CLICK Complete Portfolio from ABB, meaning ABB has the products, expertise and experience to deliver fuly integrated systems CLICK And can give huge benefits throughout investment, operations, maintenance extending to the full lifecycle of the plant
• #38: So lets take a look at a couple of examples
• #39: ABB has delivered systems for Integrated Process and Power Automation all over the world and in all power and process industries
• #40: In Brazil, Petrobras was seeking for a standardized way of integrating process automation and power management when investing heavily in upgrading and extending several refineries. At REPAR refinery, combined process control and power management was the key, with one single system interface to the whole plant ABB deliver integrated process and power automation, using IEC 61850 to integrated ABB and Schweitzer relays for power automation, and stood for the main part of the delivery The benefits were substantial Petrobras saw 30 % less engineering hours due to reuse of engineering data with standardized solutions, 15 % in savings during commissioning, and has even seen benefits already in operational phase, with reduced training needed for the operators with one common approach to the whole plant operations
• #41: In Sweden, E.ON control all their 60+ hydro power plants from a central control room. At Flåsjö hydro power station, 200 km from the Central Control room, they wanted to stanfardize the plant control solution when doing a revamp from the old installation. ABB was chosen as the only supplier that could deliver one integrated system using IEC 61850 integration to the IEDs The 800xA system serves as both process control and substation automation system for the hydro power plant, with remote access to the central control room and providing much richer plant data to the operators than with the old system Benefits included A very short installation time, due to using standardized solutions and being able to test a lot of funvitonalities before commisioning A standardized concept for coming hydro power plant renewals Reduced maintenance costs due to more troubleshooting remote with more plant data available