Integracion de Procesos

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© ABB / PA / Control Systems May 12, 2014 | Slide 1

Electrical Integration with System 800xA

Integrated Process and Power Automation

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© ABB Group May 12, 2014 | 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

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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 Consumption Power

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 Integration Traditional approach

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Integrated Process and Power Automation Electrical Integration with System 800xA

Electrical

Integration

Based on Open

Standards

Full Plant

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

Historian and

Data Archiving

Common asset

management

Common

system

architecture

Common engineering Common

operations

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Integrated Process and Power Automation Electrical 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 Automation Complete Portfolio from ABB

Main Electrical

Contractor Main Automation

Contractor

Integrated Process and Power Automation

Control

Systems

LV

Power

Distri-

bution

Intelli-

gent

Switch-

gears

Drives Motors Safety

Systems

Telecom

Systems

Intelli-

gent

Field

Instru-

ments

Analyzers

Expertise and

Consulting services

Consulting

Services

HV/MV

Power

Distri-

bution

Bridging two worlds together with Electrical Integration

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Integrated Process and Power Automation Complete 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

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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

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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 Benefits Reduced Investment Cost

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Customer Benefits Reduced 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 Benefits Improved Operator Effectiveness

Power group Process group

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Customer Benefits Improved 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

Low Value

Turbines

Compressors

Fans Blowers

Mechanical Equipment

Electrical Equipment

Control Valves

Centrifugal Pumps

Field Devices

Customer Benefits Reduced Maintenance Costs

Extending Asset

Management into

electrical equipment

*Survey completed by ARC Advisory Group

Typical Asset

Management areas*

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Customer Benefits – Reduced Maintenance Costs Single 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

http://www.sap.com/index.epx

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Customer Benefits Increased 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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2.2 1.8 1.8 2.1 3.3

2. 50.1

1.5

7.2

5.7

MW MW MW MW

MW

MW

MW

Hz

kV

Generator trip

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0.0 1.8 1.8 2.1 3.3

2. 50.1

1.5

4.8

3.9

MW MW MW 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 Automation Electrical Integration with System 800xA

Electrical

Integration

Based on Open

Standards

Full Plant

Integration with

System 800xA

Reduced Investment Costs

Improved Operator Effectiveness

Reduced Maintenance Costs

Increased Plant Availability

Reduced Energy Costs

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Outline



Customer benefits

References

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Integrated Process and Power Automation References

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 Automation REPAR Refinery, Petrobras, Brazil

Customer’s need:

Refinery process control and power management

Single plant interface, integrated operations and maintenance

ABB solution:


Integrated Process Automation and Power Management System


IEC 61850 integration of ABB and Schweitzer Protection & Control

IEDs


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 Automation Flasjo 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:


Integrated Process Automation and Substation Automation System


IEC 61850 integration of ABB Protection & Control IEDs


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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Integracion de Procesos