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in control

The customer newsletter ofABB Power Generation 2 I 11

in control

Staying competitive with serviceResponding to the customer's needs 6

Customer interview with EnipowerRemote monitoring of solar power plants 11

ABB launches remote operation and maintenance service for PV plantsService in Singapore 14

ABB provides EBoP service for the Changi Water Reclamation Plant

ABB tops market rankings 19ABB ranked world leader in DCS and EAM

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From the Editor

plant owner - Singapores national wateragency, Public Utilities Board - with serviceand maintenance of the plants extensive

electrical balance of plant equipment.In plant automation we illustrate howour life cycle management strategy fordistributed control systems providesplant owners with the ability to extendthe operating life of their automationsystems and enhance the sustainabilityof their investments through seamlessevolution, thus avoiding the high cost andrisk of the rip-and-replace approach tosystem modernization. Our commitmentto incremental stepwise evolution has been

the hallmark of our Symphony family ofdistributed control systems for more than30 years. The latest generation, SymphonyPlus, enhances its predecessors andis backwardly compatible with them inthe true spirit of our Evolution withoutobsolescence commitment.

This commitment to the long-terminterests of our customers is one of thecontributing factors to ABB being rankedthe global market leader in distributedcontrol systems and enterprise asset

management systems in 2010 by ARCAdvisory, the leading research and advisorycompany. We are proud to be able toexpand on this announcement on page 19.

Finally, we feature a revealing andstimulating discussion on the power andwater service market between two seniorABB representatives: Jari Kaija, head ofABBs global service business, and StefanHatt, head of global service for ABBspower generation and water business.

I trust you will find fresh and fascinating

insights into how ABB is working hard tohelp power generation and water customersachieve the most from their assets throughlife cycle management and service.

With kind regards,

Franz-Josef Mengede

Head of ABB Power Generation

Franz-Josef Mengede

Head of ABB Power Generation

in control 2 I 11Dear Reader,

in this issue of In Control we continueour Application focus series by highlight-

ing ABBs extensive portfolio of life cyclemanagement products and solutions forthe power generation and water industries.

ABB electrical, control and instrumen-tation products and systems are installedin thousands of power and water plantsall over the world. In hardware they rangefrom low voltage switches to large powertransformers, variable speed drive sys-tems and plant-wide distributed controlsystems. And on the software side theyinclude cutting-edge solutions for plant

optimization, information managementand remote diagnostics.

Innovation is a key component ofour service offering. In an interview withEnipower on page 6, Mr. Dimitri Gazzotti,head of Enipowers Engineering andMaintenance department, graciouslyexplains his experience of workingwith ABB in the field of service andmaintenance. He describes some ofthe solutions the two companies haverecently collaborated on. For instance,

ABB prov ided distribu ted control systemfunctionality that helped Enipowertransform its business in a very shorttime from cogeneration and base loadoperation to flexible market operation.

A second example of service innovationis our remote operation and maintenanceservice for photovoltaic (PV) power plants.From two dedicated control centers inItaly and Spain, ABB is offering customersworldwide an advanced remote monitoringservice that collects process data in real

time, handles alarm and failure detection,provides data reporting, and ensures thatthe plant is meeting its performance ratiotarget. The service is currently monitoringPV plants in southern Europe and is avaluable component in our turnkey offeringfor PV power plant owners.

A third instance of how we respond toour customers needs for life cycle serviceand innovation is provided by the ChangiWater Reclamation Plant in Singapore.Changi is the largest plant of its kind in the

world today and part of Singapores award-winning deep tunnel sewerage system,which in time will channel all Singaporesused water to the Changi reclamationplant for treatment. ABB is providing the

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ABB in control 2 | 11 03

Contents

16 Case studies

A selection of ABB service solutions worldwide

Projects

19 ABB tops DCS and EAM market rankings

ABB ranked globa l leader for the ninthconsecutive year

In brief

20 System evolution

ABBs life cycle commitment extends DCSoperating life

Technology and innovation

4 Life cycle management and service

An overview of ABBs service offering forpower and water plants

Application focus

6 Responding to the customer's needs

Interview with Enipower, Italy

Customer interview

8 Getting the most out of plant assets

Two senior ABB service representativesexplain how

14 Service in Singapore

Providing EBoP service for the Changi WaterReclamation Plant

12 Software service programs

Multilevel service programs for DCS software

11 Remote monitoring of PV power plants

ABB launches new O&M service for PV plants

Software service programs

12Service in Singapore

14

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04 ABB in control 2 | 11

Application focus

A

BB has been in the powergeneration industry for morethan 125 years and in the wa-ter business for more than

half a century.This, and the fact that we are a lead-

ing supplier of power and automationproducts and systems for utility and in-dustry customers, means that we knowthe processes, the technologies and theapplications.

Our philosophy is simple: We protectyour investment through the stepwiseevolution and upgrading of your electri-cal, control and instrumentation systemsto minimize the consumption of energy,

prolong asset operating life, and mini-mize the cost of ownership.

We do this by providing advancedand cost-effective services and solu-tions that preserve and increase thevalue of your facilities throughout theirentire life cycle.

Our solutions and know-how aredeeply rooted in all applications: com-bined cycle, coal, hydro, nuclear, waste-to-energy, district energy, diesel, biofuel,solar, water and wastewater, desalina-

tion and pumping stations.Our service spectrum covers the

complete scope of the plants powerand automation systems, from the dis-tributed control and plant optimizationsystems to the instrumentation andemission monitoring systems. On theelectrical side it covers the entire energypath, from electrical balance of plant tothe substation and grid connection.

We offer a full portfolio of life cyclemanagement services. It extends from

repairs and spare parts to completeplant upgrades and equipment retrofits.

And, it covers each phase of the plantlife cycle, from first concept to decom-missioning.

For all our products and systems, weoffer low-risk evolution strategies thatensure maximum return on investmentwhile enhancing equipment availability

and performance.

Energy efficiency and plant optimization

Energy efficiency and plant optimiza-tion are two of our specialties.

We perform energy efficiency assess-ments and use our unique process, prod-uct and application expertise to identifysavings that can reduce plant energy con-sumption by between 5 and 20 percent.

And we use that same expert ise tooptimize plant operations with a broad

range of solutions, from computer-basedmaintenance management systems(CMMS) to online optimization tools forturbines, boilers, membranes, thermaldesalination units and pumps, as well asonline lifetime assessment monitoring forturbines and boilers.

Our global service network is prob-ably the largest and most decentralizedin the power generation and water indus-tries. We have more than 1,300 dedicatedpower and water service specialists in 56

countries worldwide, ready to respondquickly and proactively to your needs.

Life cycle managementand serviceABB offers a comprehensive portfolio of life cycle management and serviceproducts for the power generation and water industries a por tfolio based onextensive process and application know-how and one of the largest installed basesin the world.

Our philosophy issimple: We protect yourinvestment throughthe stepwise evolutionand upgrading ofyour electrical, controland instrumentationsystems to minimize theconsumption of energy,prolong asset operatinglife, and minimize the costof ownership.

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ABB in contro l 2 | 11 05

Application focus

Raising the bar

Taking service to a higher level

ABB has recent ly strengthened itsservice offering for power and water

customers by enhancing its capability infive key areas:

Your own site- respons ible ABB

engineer

ABB assigns each service customertheir own site-responsible ABB engineer.

That person is your single point ofcontact with ABB for all service issues.

He is locally based and dedicated toprovide fast and expert response.

His job is to provide you with the serv-

ice solution and resources you require,manage ongoing service projects, andwork proactively with you to ensure thatthe plant is operating with the flexibilityand reliability required.

We help you identify the plants

needs

We offer: Programs to diagnose inefficiencies,implement improvements and ensurethat the improvements are sustained

over time; Energy efficiency studies to reduceplant energy consumption andcomply with ever-stricter emissionsregulations;

Product evolution strategies to im-prove equipment performance andsecure reliability;

Remote monitoring of electrical and

control equipment to monitor statusand diagnose faults.

A long-term commitment to our

customers

Partnership and a long-term commit-ment to our customers is the hallmark ofour service offering.

For instance, our long-term controlsystem policy of Evolution without ob-solescence ensures that each new gen-eration of our plant automation platform

enhances its predecessors and is back-wardly compatible with them.

The pol icy is now in its four th decadeand is unique in the power and waterworld. Its principles extend across ourentire service portfolio.

As a result of this long-te rm commit-ment, we are able to offer a variety of en-hanced service contracts with perform-ance-related elements to protect yourfinancial and intellectual investments.

New products, upgrades, retrofitsand extensions

ABB has a continuous stream of newproducts, upgrades, retrofits and exten-sions in the pipeline.

We can extend the capacity of exist-ing equipment. And we can upgrade orprovide evolution or replacement strate-gies for an aging installed base.

As a partner of ABB, you gain accessto the fruits of ABBs R&D program forpower and automation technologies, aprogram in which ABB invests around$1.3 billion annually.Third-party service

As the market and technology leaderin power and automation technologies,ABB has a unique understanding of themotors, drives, switchgear, transform-ers, generator circuit breakers, control

systems and instrumentation in a poweror water facility.

ABB covers the entire electrical, con-trol and instrumentation installed base,and is able to offer service of non-ABBsystems on a selective basis.

Evolution Upgrades &

Retrofit

Environmental

ServicesTraining

Diagnosis &

Consulting

Spare Parts Repair Maintenance

Troubleshooting

Support &

Remote Services

Service Contract & Asset Management

The ABB service chip A complete portfolio of services

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Customer interview

Responding to thecustomer's needs:

Interview with EnipowerIn Control interviewed Dimitri Gazzotti, head of Enipowers Engineering andMaintenance department, to learn about his company's service partnership with ABB.

Could we begin with you

briefly describing Enipow-

ers power generation assetsin Italy?

Enipower is one of the three largestelectrical energy suppliers in Italy, andthe largest producer of process steam.We own and operate eight thermoelec-tric power plants, which together pro-duce 5.4 GW of electricity. Nearly all thesites comprise high efficiency cogen-eration combined cycle units that werecommissioned between 2003 and 2005.We also provide steam and heated water

for two district heating networks in Milanand Mantova. About 20 percent of thepower we generate is for the refineriesand petrochemical plants of our parentcompany, Eni.

Can you briefly describe Enipowers

maintenance and engineering organi-

zation?

Our objective is to achieve excellencein power plant operation and mainte-nance. Our maintenance and engineer-

ing department is geographically dis-persed but highly integrated virtually. Theheadquarters team (20 engineers) fullysupports the local teams (5-10 peopledepending on plant size) in major over-haul planning and execution, as well aswith remote diagnostics and specialistassistance on critical equipment, majorupgrades and modification work. Thelocal teams are responsible for ordinarymaintenance, emergency work and day-to-day diagnostic and predictive mainte-

nance.We have developed strong in-

house knowledge and resources ininstrumentation and control, electricaland high-added-value mechanical

activities. We outsource only low value-added activities to local contractors

and highly specialized services toOEMs or equivalent high-skill serviceproviders.

What is the scope of your service rela-

tionship with ABB?

ABB is providing Enipower with a widerange of services, especially with regardto ABB's own products and systems.

For our distributed control systemsand electrical protection control sys-tems, ABB provides us with preventive

maintenance, anti-virus checkups, re-mote diagnostics, emergency interven-tion, spare part exchange, and life cyclemanagement. For our continuous emis-sions monitoring systems, theyve pro-vided new instruments and software thatenable us to comply with ever stricterItalian and European regulations.

On the electrical side, ABB providesplanned and unplanned maintenance forour high voltage circuit breakers, mediumvoltage generator circuit breakers, and

high and medium voltage transformers.ABB also provides us with mainte-

nance for our performance monitoringsystems, and they have helped us todevelop and install a control and pre-dispatching platform to coordinate pro-duction at five of our plants.

With regard to upgrades and retro-fits, ABB is currently providing us witha new turnkey 132 kV grid connectionfor our plant at Brindisi and a new 250MVA transformer for another plant.

And in the field of energy effic iencywe are currently examining with ABB thebenefits of equipping our pump appli-cations with high efficiency motors andvariable speed drives.

Dimitri Gazzotti

Head of Engineering and Maintenance, Enipower

I can honestly say thatin comparison with othermultinationals in thepower business I have

worked with, ABB isone of the closest to thecustomers needs.

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Customer interview

Plant reliability is a key requirement,

not just to ensure grid compliance

but to secure the supply of power toEni production facilities and refiner-

ies. In what ways does ABB help your

company maintain the required levels

of reliability?

Being responsible for the supply ofenergy to refineries and petrochemicalplants means that reliability is a mustfor Enipower. DCS redundancy, efficientremote diagnostics, accurate preven-tive and predictive maintenance, weaksignal analysis through plant data and

trends management these are key suc-cess factors in which ABB is a reliablepartner. Fast response to emergency sit-uations is also very important, and ABBhas always demonstrated its commit-ment to support us in any critical event,and not just with telephone support.

A major goal jointly achieved by ABBand Enipower is the perfect functioningof the load island operation of our large-size gas turbines during particularly se-vere national grid transients, thus ensur-

ing the regular and safe operation of therefineries.

The contract between Enipower and

ABB for the distributed contro l sys-

tems is based on a life cycle manage-

ment concept in which ABB under-

takes to continuously upgrade the

systems with new products and func-

tionalities. In what ways is this life cy-

cle commitment from ABB important

for your operations?

Four of our major power plants areequipped with ABB distributed con-trol systems. This life cycle commit-ment from ABB is very important forthe smooth operation of the plants. It

enables us to plan with ABB the partialand progressive upgrade of vital compo-

nents and software.Guaranteeing the availability of spare

parts and access to technical know-howis fundamental to our maintaining plantreliability, especially when the plantaging factor is increasing. Our guidingphilosophy is: We don't like surprises.Thats why we always try to anticipatepotential problems. Our aim is to planand predict even the unpredictable.

ABB has provided Enipower with DCS

functionality that supports your ener-gy trading operations and helps the

plants meet regulatory requirements

for reduced air pollutant emissions.

Can you describe the background to

your requirement, the solution and

the results it has achieved?

Enipower asked ABB to support thechallenge of transforming in a very shorttime its business from cogenerationand base load operation to flexible mar-ket operation. ABB provided solutions

through the evolution of the DCS andthe development of a platform to sup-port grid code compliance and tradingoperations.

The flexibility and user friendliness ofthe ABB DCS allowed Enipower to eas-ily adapt startup/ load variation/shutdownprocedures to volatile market requests.Basically, it enables Enipower to quicklyadapt load gradients, automatic se-quences, unbalance recovery systems,while maintaining full compliance with the

grid code, which is constantly evolving.More recently, Enipower asked ABB

to implement cost-effective solutions tomonitor air pollutant emissions duringtransients (startup and shutdown) and

comply with all the quality assurance re-quirements of the regulating authorities.

In what ways has ABB contributed

to improving the efficiency of your

plants?

ABB has prov ided us with a solutionthat monitors the critical plant equipmentin each generating unit. This includesthe gas and steam turbines, heat recov-ery steam generator and condenser. Thesolution calculates the key performanceindicators for each item of equipmentand their deviation from the reference

and optimal figures, taking into accountfactors that impact equipment perform-ance such as steam export for cogen-eration, fogging and anti-icing, aging,and so on. It also identifies the causesof the deviations and their remediation.

The solution has been a great suc-cess and has enabled us to recover andmaintain the highest efficiency levelspossible at our plants.

How would you assess ABB as a

provider of service and new servicetechnologies? Does ABB meet your

expectations?

I can honestly say that in comparisonwith other multinationals in the powerbusiness I have worked with, ABB is oneof the closest to the customers needs.This is something I appreciate about ABB.

Even though you are a big company,you still manage to focus on the customerand the customers needs. We are a smallorganization in a large company, and we

need strong relationships with serviceand technology providers like ABB.

Ferrara Erbognone power plant, Italy

Enipower is one of Italys largestpower generation companies anda valued partner of ABB.

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Application focus

Getting the most out ofplant assetsService is a mission-critical business. As a service provider you have to be closeto the customer in all senses of the term. You have to know the customersneeds and respond quickly and proactively to them at all times.

In Control spoke to Jari Kaija, headof ABBs global service business,and Stefan Hatt, head of globalservice for ABBs power generation

and water business, to find out how ABBservice solutions can make a difference

to the performance of plant assets.

ABB has made serv ice a strategic

priority and has identified power gen-

eration and water as two of its core

service businesses. Why is this and

why should this be of interest to cus-

tomers?

JK: ABB has a huge installed base inpower generation and water. We are oneof the largest OEMs in power and wa-ter, covering the entire electrical, con-

trol and instrumentation scope of sup-ply, including design and engineering,and installation and commissioning. Upuntil 10 years ago we were involved inturnkey power plant building and wereone of the largest in the industry. Today,we are a leading supplier of pumpingstations and solar power plants. Powerand water is in ABBs DNA. Our role isto nurture this installed base on behalfof our customers.

ABB is of ten perceived by powerand water customers as a DCS serv-

ice provider only. Is this perception

correct?

SH: Our commitment to our DCSinstalled base is indisputable. Around7,000 power and water units worldwidehave been equipped with ABB controlsystems over the past 30 years. DCSremains a priority, and we have demon-strated that with the global rollout thisyear of our new Symphony Plus total

plant automation system. SymphonyPlus is a dedicated control platform forthe power and water industries, whichevolves our huge installed base and isbackwardly compatible with it. It is the

perfect upgrade solution.But our service activities are by no

means limited to control systems. AsJari pointed out a moment ago, we haveone of the largest installed fleets of elec-trical equipment and instrumentation in

the industry transformers, switchgear,motors, drives, generator circuit break-ers, measuring instruments, and so on.

We provide standard and advancedservice products for all this equipment,and we specialize in using our knowl-edge of these technologies to maximizeplant efficiency and minimize energyconsumption.

Being close to the customer is a

phrase we hear all the time. What

does it mean for ABB?JK: It means many things, but prima-

rily it means that we want the customerto find it easy to deal with ABB. We area big company with many divisions,business units and product groups,and global and local organizations. Thecustomer can easily go astray. That iswhy we have long focused on creatingan efficient and direct channel betweeneach customer and ABB so that wecan learn and understand their needs,

respond quickly to them, and providethem with the best service possible.

SH: Trust and competence are keyrequirements for the customer. Theyhave to be able to trust their serviceprovider and the technical skills of itsservice engineers. If a plant asset isnot functioning optimally or standingstill, it costs the customer money. Ge-ographic proximity is also important,as the providers ability to respond im-mediately and have an engineer onsite

within a couple of hours can be critical.Knowing the history of the plant andits specifics is also a key element ofsuccessful service and life cycle man-agement. All of these points reflect the

Jari Kaija

Head of ABBs global service business

We provide standardand advanced serviceproducts for all ourpower and automationequipment, and wespecialize in using

our knowledge ofthese technologies tomaximize plant efficiencyand minimize energyconsumption.

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Application focus


value and importance of a close rela-

tionship between customer and serviceprovider.

Most suppliers want a long-term rela-

tionship with their customers. In what

ways would a long-term relationship

with ABB benefit the customer?

SH: This is as impor tant for the cus-tomer as it is for the service provider.In a long-term relationship both partiesdevelop things together as partners.They get to know one another, under-

stand one another, and trust one an-other. It also has a direct impact on thecustomers bottom line.

Let me give you an example. An ag-ing generator circuit breaker developeda fault and eventually broke down at apower plant in Asia recently. Unfortu-nately the customer didnt have a serviceagreement. We pulled out all the stopsto deliver as quickly as possible the re-quired spare parts, but it still took 14days before the plant returned to normal.

With a service agreement, we wouldhave performed frequent preemptivechecks and installed online monitoringto minimize the risk of the fault ever de-veloping in the first place and, we would

have had the spare parts readily avail-

able in case they were ever needed.

Traditional service is by nature reac-

tive (spare parts, repairs, training,

etc). Is ABB a proactive provider of

services?

JK: Service is not just either or,its both. Some customers may onlyrequire spare parts, others want adeeper relationship of collaborationand partnership with a proactive serv-ice provider. ABB meets both require-

ments. The value for the customer ofthe deeper, more proactive relation-ship can be measured financially.There is no question about the value,for instance, of continuous upgrades.Reduced costs, fewer outages, higheravailability this is well documented innumerous white papers.

ABB has several wide-ranging prod-uct programs that provide customerswith the framework for a relationship thatcovers the spare parts/repairs/training

aspect, and the deeper proactive aspect.For instance, for the life cycle man-

agement of process automation sys-tems we have our software upgradeprograms; for advanced support, in-

cluding for the electrical systems, we

have a very successful service pro-gram; and for performance-basedmaintenance in many industries, wehave ABB Full Service.

Being proactive means developing

new service products. What can we

expect from ABB in the coming year?

SH: The headline news for our cus-tomers in 2011 is the global rollout ofSymphony Plus first in the Americas,then in Europe, Asia, India and China.

Simultaneously with the rollout, we be-gan to release an extensive range of prod-ucts to enable connectivity of SymphonyPlus with our entire installed base.

Within the next few months well bereleasing a new generator control productand additional offerings for and around thegenerator itself. On the electrical side, wehave new online remote monitoring so-lutions for various components, and wecontinue to develop new concepts thatfacilitate the easy replacement and up-

grading of various products. And in ener-gy efficiency, were releasing a completeoffering that ranges from consultancyand energy audits to standard solutionsthat reduce plant energy consumption.

ABB has several wide-rangingproduct programs that providecustomers with the frameworkfor a relationship that coversthe spare parts/repairs/trainingaspect, and the deeper proactive

aspect.

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Application focus

How do you see the service seg-

ment developing over the next fewyears? What will power generation

and water customers require from

their service partner?

SH: There are several trends thatare already evident and which are likelyto intensify in the coming years. First,customers in many parts of the worldare facing the difficulty of replacing anaging workforce. They dont alwayshave the critical mass of a companylike ABB to retain or replace the knowl-

edge and expertise they lose when theirstaff retire. Second, following the boomin new power and water plants of the1980s and 1990s, there is now a needto modernize and upgrade these plantsto extend their operating life. Rarelydoes a company have sufficient engi-neering resources to perform these re-newals and upgrades itself. Third, thereare clear changes in consumer de-mands and grid requirements in manycountries. Power generators are now

subject to penalties for non-delivery,and consumers are demanding reliableand high-quality electricity. And fourth,customers themselves want to get themaximum performance from their as-

Does ABB have the capability and ex-

pertise to service non-ABB productsand systems?

JK: The short answer is yes, we canservice most of our competitors prod-ucts and systems. We certainly want toincrease our share of this market, but ina controlled and selective manner. Ourmain focus remains our own installedbase, but we are always prepared toservice third-party products and systemswhen a customer requests it and we havethe capability to do it.

ABBs competitors tend to have a cen-

tralized service organization, where-

as ABBs is decentralized. Is this a

strength or a weakness?

JK: ABB is a global company, butservice is a local business. For a poweror water plant, service is also mission-critical as a service-provider you haveto be close to the plant. Whereas manyof our competitors have chosen to cen-tralize their service operations to a hand-

ful of hubs, ABB has chosen a different and in our opinion better and morecustomer friendly route. We combine thestrengths of being a global company witha truly unrivaled global service network.

sets and a good return on their invest-

ment. ABB is ideally resourced to helpon all four counts.

How important is the human aspect in

ABBs service business?

SH: This is a vital element of ABBsservice business, and we demonstrate itby assigning each power and water cus-tomer their own ABB site representativefor each plant a single person , whoseface and phone number is known to thecustomer and through whom they direct

all their service projects and enquiries.Also, our ser vice eng ineers are tra inedto understand that when they enter acustomers plant, their mission is to en-sure that they find the optimal solution toeach case, and that their ultimate objec-tive is to maximize the customers returnon the plants assets.

"For a power or waterplant, service is mission-critical. As a service-provider you have to beclose to the plant."

Stefan Hatt

Head of global service for ABBs power generation and water business

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Application focus

Remote monitoring of PVpower plantsABB has developed a remote operation, monitoring and managing service forunattended photovoltaic power plants. Currently installed in 18 PV power plantsin Europe, the service collects process data in real time, handles alarm and failuredetection, provides data reporting and ensures among many other things - thatthe plant is meeting its performance ratio target.

R

emote operation and mainte-nance of plants is an importantpart of ABBs overall service of-

fering for the power generationand water industries.

ABB has been providing remote serv-ice and support for thermal power plantsfor more than 10 years from a dedicatedcontrol and operations center in Genoa,Italy. The service has grown rapidly yearby year, and now monitors several hun-dred generating units all over the world.

As a result of its increasing activi ty inthe solar power market - as a turnkeysupplier of photovoltaic (PV) and concen-

trating solar power plants - ABB has de-veloped a dedicated operation and main-tenance solution for PV power plants.

The solution is geared specifically forthe needs of PV plant owners, and hasproved immensely successful within avery short time, says Guido Rossi, headof ABBs power generation service busi-ness in Italy. Within the first nine monthsalone, weve been awarded contracts toprovide full-scale remote operation andmaintenance services for 18 PV plants.

The plants range in size from a 0.86MW roof-top PV plant to a 24.2 MW planton a 95-hectare site. The plants are oper-ating with a performance ratio of between80 and 87 percent, which is determined bythe customer and guaranteed by ABB forat least the first 12 months of operation.

Rapid market impact

In addition to guaranteeing the plantperformance ratio, the ABB solution hasa number of compelling benefits, which

explain its rapid impact on the PV market.Like ABBs remote monitoring for

thermal power plants, the PV plants aremonitored from either of two dedicatedPV control centers in Genoa and Ma-

drid, which use high-speed and securedata transmission connections and aremanned solely by accredited technicians.

Besides collecting and storing real-time and historic data on all the criti-cal equipment at the plant, the solutioncontinuously analyzes the data to ensurethat the plant is operating at its stipu-lated performance ratio. If the plant isntmeeting its production target, the solu-tion notifies the ABB technician who thenperforms a detailed diagnosis to identifythe cause of the problem. The techniciancan then rectify the fault by remote, ordispatch a service team to the plant if

necessary.In addition to monitoring energy pro-

duction at the plant, the solution alsoforecasts energy production over thenext 24 hours. The solutions advancedself-learning algorithms combine historicweather data and next-day meteorologi-cal forecasts with the plants configura-

tion to calculate the following days en-ergy production.

ABBs remote operations and mainte-

nance solution is available to solar powercustomers worldwide.

Forecast algorithms

2500

2000

1500

1000

500

0

Actual produc tion

Neural network algorithm (plant)

Neural network algorithm (Epson Meteo)

Data: 10/03/2011

Customer: Satel Srl Plant: Macchia Rotonda 2

22.00

21.00

20.00

19.00

18.00

17.00

16.00

15.00

14.00

13.00

12.00

11.00

10.00

09.00

08.00

07.00

06.00

The solution is gearedspecifically for the needsof PV plant owners, andhas proved immenselysuccessful within a veryshort time.

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Application focus

Software service programsImproving resource optimization and productivity requires systematic analysis,performance prediction and automation.

K

nowledge is 50 percent ofwinning a battle. Knowing theplausible dangers can help

one to prepare and overcomethem. The other 50 percent to winningthe battle is strategy having a frame-work for action.

A study on operations reveals that thescenarios which rank high in the list ofconcerns are increased failure rates, lostopportunities to grow the business, andobsolescence. One single scenario thatkeeps an operation manager awake atnight is production loss, especially whenhe knows that his system is working be-

yond the recommended life cycle. Afterall, this is a reality in all things, includingsystems: failure rates run high as theybecome older.

The DCS (distributed control system)

+ Advantages Telephone support forupgrades

Electronic notif ication ofupdate availability

Assured system reliabil ity Maintain optimum

productivity levels

was first introduced in 1975. More thanthirty years later, many of these systemsare still operational , as they are designed

and meant to be. They are a testamentto the high pedigree that has spawnedthe new technologies and functionalitiespresent today. Upon closer inspectionthough, one will see that many of thesesystems are made of sedimentary layersof old and off-the-shelf components. Thismay be the secret to their long life. Theyare made of spare parts that ensure themechanical operation of the hardware.

One should still be prepared for pro-duction loss when working with mature

systems spare parts notwithstanding.This is because software is the brain

behind the 'mindless hardware.' Com-ponents can only function based on thedictates of the software. We cannot over-

estimate the consequences of neglectingsoftware updates. It leads to a contagionof events leading to system failure.

Automation Sentinel is an ABB serv-ice program that looks after the softwareon several levels.

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Application focus


Service levels andinclusions

MaintainUpdates on software maintenance, de-vice library management and technicalor product release; Technical phonesupport for troubleshooting; Softwaresecurity management; Online accessto KnowledgeBank, among others.

Maintain Plus

Same as the Maintain level, with theaddition of Software Evolution to new-er system family software and newproduct licences.

Maintain & Evolve

Same as the Maintain Plus level, withthe addition of System Evolution tonewer control system technologywhich includes System 800xA.

Contact ABB for details of full package

inclusions.

Maintain and Maintain Plus levels

Both levels address a straightforwardneed: that the automation system contin-ues to run optimally due to the continualupdating of the software. These levels ofSentinel service are appropriate for busi-nesses and operations looking to sustainproduction at status quo, the median ofproductivity.

Maintain & EvolveThe path of technologica l advances

is not linear. It is a curve. There are in-

novations that have been termed as 'dis-ruptive technologies because they have,quite simply, caused shifts in the way wedo business.

In production, the path of technologi-cal advances is also a curve. Innovationsin production are transformational or ev-olutionary, which means new features orfunctionalities.

In terms of practical application inautomation, this means businesses arelooking for automation solutions that will

allow it to add functionalities in the fu-ture, when business conditions and oth-er metrics require.

The Automation Sentinel program hasanticipated this. It has a service levelcalled Maintain & Evolve, which looksto building the foundation for evolutionsthat will give operations the capacity tostep up to these new functionalities attheir own discretion.

Automation Sentinel is an ABBservice program that looks after theDCS software on several levels.

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Application focus

Service in SingaporeABB is providing electrical balance of plant service for the Changi WaterReclamation Plant, the world's largest covered wastewater treatment plant and oneof the most visionary and innovative water projects on the planet.

The Changi Water ReclamationPlant (CWRP) is one of thelargest water reclamation fa-cilities in the world. Along with

the Deep Tunnel Sewerage System, theCWRP will collect, treat and purify everydrop of wastewater produced by Singa-pore over the next 100 years, replacingall existing local plants in Singapore.

Located at the eastern edge of Singa-pore, the plant is mainly underground andis built in a stacked arrangement, thus

occupying a land area less than one-thirdof a conventional layout.

The plant produces cleaned waste-water to the highest international stand-ards, suitable for deep sea discharge inthe Straits of Singapore. On the rooftop,CWRP incorporates an operational facil-ity capable of reclaiming potable waterthat is fit for human consumption or forhigh-requirement industrial use.

CWRP was crowned the Water Projectof the Year at the prestigious Global Wa-

ter Awards 2009 in Switzerland.

Powering Singapore's water super-

highway

Amounting to a project cost of US$3billion, the CWRP uses the most ad-vanced technology available to treat two-thirds of the 1.3 million cubic meters ofwastewater Singapore generates daily.

The plant is being extended to a dailymaximum capacity of 2,400,000 cubicmeters - sufficient to accommodate the

entire needs of Singapore.Building the CWRP threw up many

technological challenges and ABB playeda prominent role in its construction byproviding advanced power and automa-

tion expertise and products, such ashigh-efficiency motors and medium-volt-age drives that enable critical parts of theprocess to operate at the highest levelsof energy efficiency and reliability. In fact,throughout the entire Changi water treat-ment process ABB products and systemspower, monitor, measure and speed-con-trol crucial process equipment in the liq-

uid and solids treatment modules, sludgedrying systems, centrifuges and turbinegenerators, and effluent pumping station.

Water service for CWRP

After the Changi Water Reclama-tion Plant went into full operation inJune 2009, ABB was following up withthe customer when it was noticed thatCWRP had a demand for a completeservice package. The customer had beencontacting various ABB departments re-garding service requirements, so ABBcoordinated a response across several ofits divisions and created a single compre-

hensive service contract offering.With its wide range of products, sys-

tems and services, ABB follows the wholelife cycle of Changi Water ReclamationPlant, from engineering to construction,

and now, service and maintenance. ABBsupports CWRP in identifying the bestsolutions for their specific needs, includ-ing maintenance and asset optimization.

The service contract from the Pub-lic Utilities Board, valued at just underUS$2 million, is a three-year service andmaintenance agreement for the electricalbalance of plant (EBoP), which will help

ensure reliable and ef-ficient operations atCWRP. The service

package includes themaintenance of criti-cal ABB equipmentsuch as high-efficiency,medium voltage mo-tors and water-cooled,medium-voltage drivesthat power and controlthe huge pumps at ex-

ceptional levels of energy efficiency.Also covered are high-voltage distribu-

tion boards and transformers; medium-

voltage switchgear; low-and medium-voltage transformers; and low-voltageswitchboards, switchgear, motors anddrives.

Under the service contract, ABB pro-vides, 24/7, certified standby engineersand response to site within four hours forcritical equipment. A key engineer is as-signed to support the customer and in-ternally coordinate various service groupsto establish a single point of contact.

Through this contact, ABB helps

CWRP to plan and execute regularmaintenance. Other value-added aspectsof this comprehensive service contractinclude access to ABB's Web-basedParts OnLine spare part information and

"ABB engineers have been very

responsive, accommodating andhelpful to our maintenance team.For that, we are very grateful andappreciate their efforts and diligencein keeping our critical equipment ingood working order."

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Application focus

ordering system, maintaining the failurelog book and supplying basic trainingand refresher courses for ABB equipmentoperation.

With ABBs Logistics Center Asia(LCA) located in Singapore, local fast re-sponse on spare parts is available, thusallowing CWRP to minimize their spareparts inventory.

Last but not least, and viewed by thecustomer as very important, are the lo-cal Drive Service Workshops and Motor

Service Workshops led by ABB factorycertified personnel.

Key success factors in service

Despite the wide range of ABB equip-ment involved in the service contract, thecustomer perceives just one ABB entity.

This exceptionally easy interfacemakes it simple for CWRP to run andmaintain its equipment. The CWRP main-tenance team has peace of mind as ABBpersonnel will always be there to support

and resolve any issues concerning criticalABB equipment. For full clari ty, the cus-tomer has easy access to ABB's salesand service engineers via a clear and sim-ple contact chart.

Changi Water Reclamation Plant hasrecognized how ABB's service can helpincrease the reliability and efficiency oftheir operations.

"We thank ABB for the service provid-ed so far, and also for assigning proficientand efficient engineers to support CWRP.ABB engineers have been very respon-sive, accommodating and helpful to ourmaintenance team. For that, we are verygrateful and appreciate their efforts anddiligence in keeping our critical equip-

ment in good working order," said Mr. LimSwee Sen of Public Utilities Board.

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Component monitoringimproves plant ef ficiency

Centricas South Humber Bank PowerStation in the UK is equipped with an ABBSystem 800xA distributed control systemand ABBs Power Generation InformationManagement plant and enterprise informa-

tion management system. The plant oper-ates on combined cycle and has a gener-ating capacity of 1,266 MW.

Recently, Centrica added OPTIMAXPlantPerformance software to the systemin order to monitor and improve the plantsprocess efficiency.

OPTIMAX PlantPerformance is a soft-ware package that monitors the perform-ance of plant components, such as gasand steam turbines, the heat recoverysteam generator, condensers and heat

exchangers.It provides early warning of equipment

degradation and performance deviation,indicates the resulting financial impact ofthe deviation to the operator, and providesdecision support for predictive mainte-nance and energy trading.

The UK energy market is constantlychanging and a greater emphasis is beingplaced on running costs. OPTIMAX pro-vides us with a tool to monitor, analyze andimprove the plants efficiency, thus driving

down our production costs. With increasedefficiency we can ensure the longevity ofthe plant, with OPTIMAX at the center ofour strategy. Antony Cooke, automationengineer, Centrica

Extending the life of a40-year-old steam turbine

ERZ is a municipality-owned com-pany responsible for waste managementin Zurich, Switzerlands largest city. Thecompany manages about 100,000 tonsof waste a year, some of which is inciner-

ated at two waste-to-energy plants, oneof which is Josefstrasse.

The steam turbine at Josefstrassewas 40 years old and in need of modern-ization. ERZ selected ABB to replace theexisting relay-based steam turbine con-trol system with a state-of-the-art ABBcontrol system. As part of the turnkeycontract ABB provided a new governor,new steam extraction control, new motorcontrol center, new control and protec-tion of the turbine hydraulics, and instru-

mentation.With this solution the turbine is well-

equipped for several more decades ofhigh-performance operation.

ABB was awarded this project be-cause they listened carefully to ourneeds. We have clearly seen that ABBknows what they are doing and the of-fer fitted well with our needs. During asite visit to a recently modernized plantto see a reference of the ABB solution,we received very positive feedback from

the plant manager. This convinced us tochoose ABB for the modernization of ourplant as well. Erich Zuest, ERZ

Projects


Rehabilitating the Ingahydropower plants

The Inga 1 and 2 hydropower plantsare located on the Inga Falls of the CongoRiver - the worlds largest waterfall by vol-ume and the worlds second largest river interms of the volume of water discharged.

Inga 1 and 2 represent the first modestattempt to harness this potential. Built in

1972 and 1982 respectively they have acomparatively small generating capacity of351 MW and 1,424 MW. Due to wars andlack of finance the two plants have neverreceived maintenance and many of the 14units are no longer working.

The objective of the rehabilitationproject is to return the plant's low poweroutput to 1,300 MW.

ABB was selected for the project bySNEL (Socit Nationale dlectricit), thenational power company in the DR Congo,

on the strength of its technical solution andextensive global experience of executingsimilar hydropower and electrical projects.

ABBs scope of supply includes dis-mantling and replacing the medium andlow voltage systems, transformers andsupply lines, as well as the integration ofa new distributed control system for theauxiliary systems. ABB is also responsiblefor engineering, supply, installation, com-missioning, final tuning and power-on.Completion is scheduled for 2012.

In a separate contract ABB has alsobeen selected by SNEL to upgrade theconverter stations at either end of theHVDC (high voltage direct current) trans-mission link between Inga and Kolwezi.The 1,700 km power link was originallydesigned and delivered by ABB in 1982.At the time it was the longest power trans-mission link ever constructed.

Case studiesA selection of ABB service solutions for power generation and water customers invarious applications and all parts of the world.

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Projects

Upgrading an 1,800 MWpumped storage plant

The Tianhuangping Pumped StoragePlant is one of the largest pumped stor-age facilities in China. It is owned by EastChina Electric Power Group Corporation

(ECEPGC).Located 175 km from Shanghai, theplant plays a vital role in stabilizing theentire East China power grid and themanufacturing hub around Shanghai andthe Yangtze Delta. The first of the six 306MW units was commissioned in 1998and the remaining five in 2001.

ABB equipped the entire plant withan INFI 90 distributed control system.In 2010, ECEPGC selected ABB to up-grade unit 1 to the latest ABB DCS tech-

nology.

Improving fleetreliability and reducingmaintenance costs

ABB is contracted by IPR GDF Suez toimprove reliability and reduce mainte-nance and support costs at four com-bined cycle power plants in the UnitedStates. The four plants comprise 14 gen-

erating units and have a combined gen-erating capacity of 3,700 MW.

ABB provides modular and flexibleservice and maintenance solutions en-compassing preventive maintenance,24/7 support line, remote connectionservice, training, spare parts, repairs andconsulting.

Principal customer benefits includequick return to normal operating condi-tions in the event of a disturbance; relia-ble budget forecasting thanks to predict-

able costs; and remote connectivity forimmediate response to support needs.

Retrofitting staticexcitation systems

The Alicura Hydroelectric Power Plantin Argentina comprises four 250 MWunits, which were originally commis-sioned in 1987. The Toshiba generators

were equipped with BBC static excitersystems which, after more than 20 yearsof reliable operation, were in need of re-placement.

ABB is currently retrofitting its state-of-the-art UNITROL 6800 static exci-tation systems and automatic voltageregulators to the four generators atAlicura. ABB is responsib le for projectmanagement, engineering, installationand commissioning over a two-year pe-riod between 2011 and 2013. The plant

is owned and operated by AES Alicura.

Improving power anddesalination plantperformance

The Doha East Power Station andShuwaikh Desalination Plant in Kuwaitproduce 1,158 MW of electric powerand 90,000 tons/day of water. They areowned by the Kuwait Ministry of Electric-

ity and Water.ABB provides a full range of life cy-

cle services for both plants. The solutionincludes consulting, spare parts, repairs,system and product evolution, trainingand technical support.

The five-year contract is designed toimprove the performance and reliability ofboth the power and desalination plants.Doha East is one of Kuwaits five majorbase load power plants, and Shuwaikhproduces 6 percent of the countrys de-

salination capacity.

Drive system upgrades forEskom

ABB was selected to refurbish theexisting variable speed drive systems forthe boiler feed pumps at three Eskomcoal-fired power plants in South Africa.The plants have a combined generating

capacity of more than 12 GW and areamong the largest in Eskoms fleet.

ABB was able to provide a standardvariable speed drive solution for all threeplants and for the drive systems of vari-ous OEMs. The solution includes stand-ardized dry-type transformers designedto operate both with the existing andnew drives.

With extensive local resources inSouth Africa, ABB was able to assessand refurbish the motors locally and pro-

vide fast delivery and the requisite sup-port, including a variable speed drivesimulator for training.

Kendal Power Station

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Projects

DCS upgrade of 1,260MW plant in India

ABB was awarded an $18 million con-tract by Gujarat State Electricity Compa-ny Limited in April 2011 for a completeinstrumentation and control solution for

the Wanakbori Thermal Power Station,which is one of the largest in Gujaratstate.

ABB is upgrading the distributioncontrol system for the plants six 210MW units to Symphony. The solutionincludes diagnostics and optimizationpackages, turbine controls, steam gen-erator control, station controls and in-strumentation, a steam and water analy-sis system, flue gas analyzers, controlvalves, actuators and positioners. The

project is scheduled to be completed by2013.

Securing water distributionin Western Australia

The Water Corporation is one of Aus-tralias largest and most successful wa-ter providers, and the principal supplierof water, wastewater and drainage serv-

ices in Western Australia. Its activitiesspan across an area of 2.5 million squarekilometers.

After 15 years of successful col-laboration, Water Corporation and ABBformed an Integrated Control Engineer-ing Alliance to enhance their partnershipand secure water distribution across thestate.

ABBs network control system is in-stalled at Water Corporations StatewideOperations Centre in Perth, from where it

monitors and controls more than 300 re-mote sites and over 25,000 physical I/Opoints.

ABB to upgradeIndonesian power plantwith Symphony Plus

ABB has been awarded a contractfrom PT Pembangkitan Jawa-Bali(PT PJB), a subsidiary of PT PLN, toupgrade its installed base at the Gresik

coal fired power plant in East Java,Surabaya, Indonesia.

ABB wi ll replace the existing MOD300control system with SymphonyTM Plus.The system is integrated wi th a conditionmonitoring system to monitor, protectand diagnose the turbosupervisory pa-rameters in the plant. ABB will also pro-vide an integrated historian for reliabletotal plant diagnostic and operations op-timization as well as business data stor-ing and archiving for the power plant.

By upgrading their control system toSymphony Plus, PT PJB is able to pro-tect its intellectual capital investment byreusing existing plant operation codes.

This wil l be the fir st Symphony Plusproject installed in Indonesia. Theproject is scheduled to be completed byMarch 2012.

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ABB tops DCS and EAMmarket rankings

ABB has been ranked the worlds leading supplier of distributed control systemsand enterprise asset management systems for 2010 by ARC Advisory Group

In its annual studies of the distributedcontrol system (DCS) and enterpriseasset management (EAM) markets,ARC Advisory Group, the leading

research and advisory company, hasranked ABB as the worlds leading sup-plier in both sectors.

According to the latest version of ARCAdvisorys Distributed Control SystemsWorldwide Outlook, which was releasedin September 2011, ABB increased itsmarket share and retained its leadingworldwide market position in the globalDCS market in 2010.

In addition to being the overall mar-ket leader, ABB was also the rankedleader in several regions and industryverticals.

Innovation, quality products, exten-

sive industry knowledge and applicationexpertise has enabled ABB to establisha large and loyal customer base, saidBarry Young, principal analyst at ARCand author of the report. ABB bringstogether a product, system and servicecapability that allows them to delivercomplete automation and productionsolutions across a broad range of indus-tries.

The study corroborates an earlierreport published by Frost & Sullivan in

June this year. The report, entitled Stra-tegic Analysis of the World DistributedControl Systems Market, gave ABB amarket share two-thirds greater thanthat of its nearest competitor.

Strong EAM offering

In the second ARC Advisory report Enterprise Asset Management and FieldService Management Solutions World-wide Outlook ABB was ranked globalmarket leader in power generation, power

transmission and distribution, and themining sectors, as well as in the Asia andLatin America regions.

ABB has recently strengthened its po-sition and offering in the EAM sector with

the acquisitions of Mincom in July 2011and Ventyx in June 2010. The reportranked Ventyx as the worlds largest EAMvendor in the power generation, waterand wastewater industries, and Mincomas the leading global supplier EAM vendorin power transmission and distribution.

Mincom and Ventyx have comple-

mentary strengths across many key in-dustries and geographies, said Ralph Rio,author of the ARC study. The combina-tion of these two impressive vendors hascatapulted ABB into a leadership positionfor EAM solutions across many significantsegments.

EAM solutions facilitate the manage-ment of an organizations fleet of physi-cal assets over their entire life cycle, fromdesign and production, through commis-sioning, operations and maintenance, to

decommissioning and recycling.ARC Advisory Group is a recognized

thought leader for industrial and supplychain needs, offering market research,advisory services and consulting.

In brief

ABB brings togethera product, system andservice capability thatallows them to delivercomplete automation

and production solutionsacross a broad range ofindustries.

ARC Advisory Group

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Technology and innovat ion

Plant owners make significantcapital investment in the sys-tem hardware, engineeringtools and application software

that together comprise their initial dis-tributed control system (DCS) installa-tion. Upon commissioning, plant andcorporate personnel add to the invest-ment by enhancing control systemcomponents, tuning and refining con-trol application code and developing

knowledgeable staff who operate andmaintain the plant and control system.

The result of these investments is ahighly trained and experienced staff ofengineers, technicians and operators, aswell as the creation of site-specific con-trol strategies, procedures and graphicsthat enable the plant to maintain highunit availability and excellent operationalperformance.

ABBs evolution strategy aims at sup-porting those customers who wish to

protect and enhance their investmentsin both the control system hardware andtheir valuable intellectual property.

ABBs life cycle management strategy

The Symphony family is a provenautomation control system used for de-manding applications in various indus-tries. For more than 30 years, ABB hasevolved the Symphony family, ensuringthat each new generation enhances itspredecessors in accordance with its

industry-unique life cycle policy of Evo-lution without obsolescence. All told,this family of systems represents one ofthe largest installed bases of distributedcontrol systems in the world. The ma jor-ity of these systems are in operation inthe power generation and water sectors.

With Symphony Plus, ABB has takenthe Symphony success story to the nextlevel. Like its predecessors, SymphonyPlus is designed to meet the require-ments of plant owners in all geographic

markets and for all types of power gen-eration and water treatment. It meets theperformance objectives of its varioususers in maintenance and operations,engineering, IT and management. And

it addresses all the key focus areas ofthe power and water industries plantproductivity, energy efficiency, opera-tion security, plant safety, and cost ofownership.

Symphony Plus includes the latestproducts and services from the worldslargest automa-tion supplier. Themain componentsinclude state-of-the-art HMI offer-ings that suit dif-ferent customerneeds, dependingon their require-ments and pref-

erences. Othernew functions andtechnology up-dates include rack and DIN rail-mountedI/O modules, process controllers, com-

munication modules, and system con-figuration tools.Evolution versus Rip and replace

ABBs commitment to Evolution

without obsolescence provides plantowners with the ability to extend the op-

erating life of theircontrol systems andimprove the profit-ability of their in-vestments throughseamless evolu-tion, thus avoidingthe costs and risksassociated withrip-and-replace

upgrade methods.ABBs evolution ap-proach offers plant

owners the flexibility to upgrade theDCS in accordance with their business

System evolutionABBs life cycle commitment extends the operating l ife of plant control systemsand improves profitability through evolution

ABBs evolution strategyaims at supporting thosecustomers who wish toprotect and enhance theirinvestments in both thecontrol system hardwareand their valuable

intellectual property.

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Rip-and-replace risks

Risk unnecessary plant trips and production downtime due to:- errors creating a familiar controller strategy- errors recreating a familiar HMI strategy- operational errors due to unfamiliar system or control philosophy- unfamiliar documentation and troubleshooting procedures

Risk cost escalation and schedule delays due to:- executing a large engineering development project- implementing retuning efforts- retraining for plant operations, engineering and maintenance

- installation wiring efforts and missed scope- construction change requests- extended checkout and startup (I/O checks, logic checks, graphic checks)- reimplementation and troubleshooting for third-party interfaces

ABBs evolut ion approach

Retain proven control application software for:- calibration and control tuning- permissive and interlocks- startup/shutdown, automatic load runbacks- signal scaling and failure modes- alarm setpoints and alarm conditioning logic- simulator tuning and fault scenarios

Process control remains same as before

Retain plant knowledge base, operations and mainte-nance philosophy.Upgraded engineering tools include documentation thatis the same as existing upgraded HMI and affords famil-iar operational philosophy for:- user interface to control action

- situation handling and SOPs- graphics display and navigation- system diagnostics- alarm, event handling, logs, reports, SOE

Upgraded system hardware affords familiar mainte-nance procedures for:- control system maintenance- diagnostic and troubleshooting procedures- engineering and online change procedures- maintenance and tag out procedures

Preserved investment in control system I/O

- hardware upgrades can be easily implemented, atopportune times, by plant personnel

- offers significant cost savings, less work, lessdemands on plant resources

Minimal commissioning and startup (no retuning ofloops)

Results in:- minimal loss of production- minimal risk- lower project costs

The table be low highlights the advantages of ABBs evolution approach compared to the rip-and-replace alternative

Rip-and-replace alternative

Control code re-engineering or translation is required. Newalgorithms result in different process control behaviors andrequire retuning

Plant personnel need to learn a new system. New docu-mentation and new C&M procedures are different and un-familiar to plant personnel that are supporting:- troubleshooting for process control- troubleshooting for system hardware- operations look and feel

- maintenance procedures

Requires massive change-out of system hardware (I/O,

controllers, communication infrastructure, HMI and, as aminimum, specialty I/O terminations)

Long commissioning and startup periods (reconfigurationand retuning of loops)

Results in:- greater loss of production- increased risk- higher project costs

Evolution advantages versus Rip-and-replace risks

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and plant operational needs rather thanon component obsolescence.

ABBs evolution program suppor ts astepwise approach in which componentsor process areas are upgraded individu-ally as required during either normal op-erations or as part of scheduled mainte-nance activities, while leaving the rest ofthe system undisturbed.

These options utilize the system to itsfull potential. Evolution alleviates the need

for large capital investment and the resul-tant cash flow impact associated with afull-scale rip-and-replace approach thatrequires a major outage and cost-inten-sive engineering, design, and construc-tion efforts. Perhaps the most significantbenefit of ABBs evolution concept is tomitigate the risks associated with rip-and-replace, such as poor design quality,resource allocation, plant trips, lost gen-eration, project overruns and commercial/legal issues.

Collaborative evolution planning

processA successful evolution program

begins with a solid plan driven by theowners business goals. Good planningis critical for any incremental, stepwiseevolution and can minimize the negativeproduction impact of the actual upgradeprocess. It can simplify and improve theyearly budgeting process and facilitatebetter system upgrades and planned

plant shutdowns.Individual planning is essential. Dif-

ferent industries invariably have differ-ent strategies and business issues goingforward. At ABB, account managers andtechnical experts work with system own-ers individually to address their uniqueneeds. The collaborative relationship re-sults in the best strategies for each indi-vidual site. After a comprehensive audit ofthe existing system, and with an under-standing of the business drivers, ABB will:

Submit a 3-5 year plan to be reviewedand revised as necessary. ABBs in-cremental approach supports flexibil-ity, and allows for changes to the planas required over time

Identify and target which plant areasare at greatest risk for productionloss and those that have the greatestpotential for increased production. Aseach phase is identified, ABB will pro-vide value assessments and return-on-investment support for consider-ation in order to facilitate successfulproject appropriation requests

Review the long term plan periodi-cally and update as required to reflect

changing business needs and newABB solutions. This approach takesthe guess work out of the budget-ing process. As part of this planningprocess, specific projects are identifiedand implemented

Regardless of whether that invest-ment was 1, 5, 10 or 15 years ago, theinstalled automation system is a vitaland sustainable part of the business andmanufacturing strategy and can be en-

hanced and extended for years to come.ABBs strategy of Evolution without ob-solescence provides its customers witha platform to help maintain and enhancethe existing automation system. Thisstrategy of seamlessly integrating newtechnology with the existing system low-ers the cost of ownership, increases thevalue the system provides, and extendsthe life of the system.

The collaborativerelationship results in thebest strategies for each

individual site

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Contact

Subscription

For a printed or electronic subscription, please contact theeditor or subscribe online at www.abb.com/powergeneration

Publisher

ABB Ltd

Business unit Power GenerationP.O. Box 81318050 Zurich / SwitzerlandPhone +41 (0) 58 585 39 56

Circulation

Electronic issue 3,500

Printed issue 5,000

In Control is published three times a year by ABB PowerGeneration in English and is available in printed and electronicversions. In Control is free of charge to those with an interest

in ABBs power generation and water business.

Disclaimer

The informati on contained herein re flects the views of the authors and i s for in for-mational purposes only. Readers should not act upon the information containedherein without seeking professional advice. We make publications available withthe understanding that the authors are not rendering technical or other profes-sional advice or opinions on specific facts or matters and assume no liabilitywhatsoever in connection with their use. The companies of the ABB Group do notmake any warranty or guarantee, or promise, expressed or implied, concerningthe content or accuracy of the views expressed herein.

Upcoming events 2012

Total plant automationfor the power

generation and waterindustries

Application focus in the next issue:

ABB Power Generation is a leading prov ider of integratedpower and automation solutions for conventional andrenewable based power generation plants and waterapplications like pumping stations and distribution plants.The companys extensive of fer ing inc ludes turnkeyelectrical, automation, instrumentation and control systemssupported by a comprehensive service portfolio to optimizeperformance, reliability, and efficiency while minimizing

environmental impact.

2012 Event City Country06.02.2012 08.02.2012 Power-Gen Middle East Doha Qatar

07.02.2012 08.02.2012 CSP Today South Africa 2012 Johannesburg South Africa

23.04.2012 25.04.2012 ABB Automation & Power World Orlando, FL USA

23.04.2012 27.04.2012 Hannover Messe Hanover Germany

08.05.2012 10.05.2012 VGB KELI Conference 2012 Karlsruhe Germany

12.06.2012 14.06.2012 Power-Gen Europe Cologne Germany

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Clean power from coal?

Certainly.

With more than 125 years of technology innovation and experience in power generation,ABB is a partner you can rely on. Our port folio includes integrated electr ical, automat ion,instrumentation and control solutions that help optimize performance, improve reliability,enhance efficiency and minimize environmental impact. A worldwide service capabilitysupports the plant throughout its life cycle. Whether it is thermal, nuclear or renewablessuch as hydro, wind, solar or biomass, ABB has the know-how and track record toserve all types of power generation needs. www.abb.com/powergeneration

ABB Ltd.

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