abb integrated process and power automation

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© ABB / PA / Control SystemsApril 12, 2023 | Slide 1

Electrical Integration with System 800xAIntegrated Process and Power Automation

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© ABB Group April 12, 2023 | Slide 2

Outline

What is Electrical Integration?

ABB’s solution: Integrated Process and Power Automation

Customer benefits

References

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Outline



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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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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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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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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Outline



Full Plant Integration with System 800xA

Electrical Integration Based on Open Standards

Complete Portfolio from ABB

Customer benefits

References

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Electrical IntegrationTraditional approach

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Integrated Process and Power AutomationElectrical Integration with System 800xA



Complete Portfolio from ABB

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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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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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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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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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Outline



Customer benefits

Benefits of Integration

Reduced Investment Costs

Improved Operator Effectiveness

Reduced Maintenance Costs

Increased Plant Availability

Reduced Energy Cost

References


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


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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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*


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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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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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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Maintain only one interface to CMMS

Maintenance planning more efficient

Single source for maintenance analysis

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Customer BenefitsIncreased Plant Availability

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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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© ABB Group April 12, 2023 | Slide 32 © ABB Group April 12, 2023 | Slide 32


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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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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Integrated Process and Power AutomationElectrical Integration with System 800xA



Reduced Investment Costs

Improved Operator Effectiveness

Reduced Maintenance Costs

Increased Plant Availability

Reduced Energy Costs

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Outline



Customer benefits

References

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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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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 integrated process and power automation

Technology

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