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Innovation in production Refined integration State-of-the art electrical integration for a refinery utilizing System 800xA and IEC 61850 Antonio Carvalho, Johan Hansson A reliable and dependable energy supply is vital for the functioning of any industry. Managing and controlling this supply is thus as important as managing and controlling any other significant process parameter. The inte- gration of the electrical control system into the process control system increases productivity and availability by permitting a single strategy in the areas of engineering, maintenance and operations. ABB has taken the lead in the domain of electrical integration with its award-winning Extended Automation System 800xA, enabling intelligent electrical devices to be integrated utilizing the global IEC 61850 standard for control and protection of substation equipment. The adoption of a global standard based on state-of-the-art technology enables lower installation and operational costs, as well as enhanced asset management capabili- ties. ABB is providing process control and power management systems based on System 800xA to nine of Petrobras’s 12 Brazilian refineries – solutions that will help increase production by a massive 40 percent. In this article, ABB Review takes a look at the project in Petrobras’ REPAR refinery.ABB Review 4/2009 47
Refined integrationInnovation in productionE lectrical integration is not a new concept. Low-, medium- and high-voltage devices have been integrated 1 Separate process and power automation systems using hardwired integrationinto process control systems (PCSs)for many years. Traditionally, the Process Electrical Control roomsystems that serve process automation workplace workplaceand power distribution within thesame plant are separate, but are cou- Plant network Plant networkpled by extensive hardwired interfac- Control SCADA server Control system system serveres. Due to cabling and engineeringcosts, the bandwidth and cost efficien- Control networkcy of this approach is very limited. Gateway/protocol converterThe introduction of intelligent electri- Control Controller Controller Protocol 1 Protocol 3cal devices (IEDs) and serial interfacespermitted much more information Protocol 2 Fieldbusfrom the electrical system to be uti- Local I/O IEDslized. This approach is commonlyused today in industrial and power Marshalling Rackgeneration applications. Turbine, Water + steam cycle, Generator protection, Transformer protection, Process Unit control, Boiler, FGP, … MV/HV switchyard, Excitation, SynchronizationA large variety of protocols and stan-dards are used in substation automa-tion, including IEC60870-5-10x, DNP3.0, Modbus and various legacy proto- Factbox 1 Mapping of data model to protocols according to the IEC 61850 standardcols. The multitude of interfaces re-quired lead to a broad variety of engi-neering tools, protocol converters and Applicationgateways, and hence additional hard- Data model (objects, services)ware, maintenance and increasedengineering costs. This could result in Client-server Sampledsolutions having to be implemented Abstract communication GOOSE Values (SV) communicationon a project-by-project or even a services interfacedevice-by-device basis. 1 illustrates (ACSI)a scenario that has different serial Stackprotocols for communication with the interfaceIEDs, as well as a hardwired interface MMS Realtime –between the electrical and process priority communication Stackcontrol system. TCP IPIEC 61850 Ethernet link layerThe 2004 introduction of the global * Generic object oriented Ethernet physical layer with priority tagging (100 Mbit/s)IEC 61850 standard for substation substation eventautomation represented a huge stepforward in simplifying the integration IEC 61850 communication mapping from the data model to the fullof IEDs. The standard ensures the IEC 61850 uses mainstream communica- MMS stack (left-hand side of figure).interoperability between devices and tion technology MMS (Manufacturing Mes- GOOSE (Generic Object-Oriented Substa-is capable of replacing all the various sage Specification) over TCP/IP and Ether- tion Event) and Sampled Values (SV) areprotocols in the substation-automation net. The data model and the communica- further communication services, both useddomain. tion stack are linked by means of standard- for real-time high-priority data – achieved ized mapping. This mapping is the only by direct mappings into the Ethernet linkAt the core of the IEC 61850 standard item that needs adaptation should the layer and eliminating any middle-layer pro-is a complete object-oriented model of communication technology be changed. cessing. GOOSE is used for horizontalthe IED, its data and supported com- Such an approach ensures long-term sta- communication between IEDs, where it re-munication services. These are mod- bility in the face of future developments. places the traditionally hardwired signals.eled in a form that is consistent across The adopted mapping from communication Sampled values are used for sending cur-all types and brands of IEC 61850 services to the communication stack is rents and voltage measurements in a high-compliant IEDs. Interoperability is shown in the adjoining figure. Client-server priority fashion, mostly used in high-voltagefurther supported by the use of a communication (vertical communication applications.common XML-based substation con- from the IEDs to the control system) uses afiguration description language (SCL)Factbox 1 .48 ABB Review 4/2009
Refined integration Innovation in productionIEC 61850’s integration in System 800xA 2 Integrated process and power automation using System 800xA with IEC 61850ABB’s System 800xA is the first pro-cess-control system on the market tosupport the IEC 61850 standard. The P Process Electricalimplementation is shown in 2 . Both Control room w workplace workplacevertical communication (using the full Plant networkMMS stack) and horizontal communi-cation (using GOOSE1)) are supported. Aspect Server Connectivity Server incl Control system IEC61850 OPC ServerThe vertical integration is implement- Control networked using an IEC 61850 OPC server2),which transfers the MMS data to Sys- AC 800M AC 800M controller Vertical integrationtem 800xA in the form of regular OPC Control controller incl. IEC 61850 interface IEC 61850 MMSdata items. This means System 800xA Fieldbus IEC 61850 Networkhas direct access to all selected IED Horizontaldata such as current and voltage mea- integration IEC 61850surements, status, interlocking, time- GOOSE IEDsstamped alarms and events, and can Turbine, Water + steam cycle, Generator protection, Transformer protection,also send open and close commands Process Unit control, Boiler, FGP, … MV/HV switchyard, Excitation, Synchronizationto the IEDs. All System 800xA displaycapabilities, such as freely configu-rable graphics, faceplates, alarms and Factbox 2 What is power management?event lists, and historian capabilitiesare available. Furthermore, IED para-meter reading and writing can be per- The supply of power and energy is vital to control (including integration with the gover-formed remotely, as can the transfer every industry. The management of that nor and excitation controller).of disturbance recording files to Sys- supply is just as important. Industry’s de-tem 800xA. pendence on scarce energy resources, the ABB’s Power Management System (PMS), volatility of energy costs, growing environ- an offering based on System 800xA meetsThe horizontal part of the integration mental concerns and more stringent legisla- the requirements of industries in whichis achieved with the AC 800M control- tion are just a few of the factors influencing power management is a vital topic in termsler utilizing GOOSE communication. the global drive for improved energy man- of costs and an important prerequisite forBy equipping the AC 800M with an agement. reliable operation.IEC 61850 interface, horizontal com-munication is made possible with all Power management has been designed ABB’s System 800xA PMS is a state-of-the-other IEDs on the same IEC 61850 specifically for the most energy-intensive art solution with advanced features that sur-network in a real-time fashion. Exam- sectors in which industries operate, such as pass the capabilities of traditional automa-ples of application areas are fast load- in oil and gas and petrochemicals. In many tion systems. These include:shedding signals, interlocking, or even areas around the world, operations face an Extensive scalability in size, performanceanalog values needed in the controller insufficient or unreliable public power sup- and functionalityapplication. ply. Such industries must therefore largely Redundancy at all levels depend on their own generation and distri- Support of multiple programming lan-By utilizing both vertical and horizon- bution capabilities. Power management guagestal communication, System 800xA is schemes manage energy vulnerability and Support of legacy, standard and ongoingequipped to use the latest state-of the ensure sustainable energy for plant opera- developments in the area of communica-art technology to communicate with tions by reconciling efficiency, and econom- tion protocols, including OPC, Modbus,IEDs according to a global standard. ic, health, safety and environmental consid- Modbus TCP, Profibus DP, Profinet, TCP/This means seamless integration of erations. IP, IEC 60870, DNP3, IEC 61850 andsubstation equipment, enabling true othersintegrated process and power automa- The power management system controls High-speed communication capabilitiestion with a single-system solution. The and supervises power generation and sup- Support of IEC 61131-3 programmingmain benefits are: ply. One of the most important functions is languages load shedding, which requires fast network Integration with process control systemsFootnotes determination and energy balance calcula- Integration with subordinate systems, in-1) GOOSE: Generic Object-Oriented Substation tions. The protection/control units can also cluding GPS, meteorological stations and Event monitor and, if necessary, invoke frequency- motor control centers and CMMS2) OPC is a standard for real-time communication be- based load shedding. Another important Asset Optimization tween control devices from different manufacturers. function in power management is generator Extended security and access control Today, OPC is officially a name and not an acronym, but originally stood for OLE for Process Control. OLE stands for Object Linking and Embedding, a document embedding and linking technology.ABB Review 4/2009 49
Refined integrationInnovation in production One user interface ensures consis- about 40 others using the IEC 61850 new turbo generators. The project tency in data presentation, data standard. almost tripled the energy available for access and operating procedures – the REPAR refinery from 26 MW to meaning a significant improvement ABB’s System 800xA is ideally suited 76 MW and included the building of a in operator effectiveness for such large-scale plant-wide proj- new power house and 12 new substa- Data recording and archiving onto ects: In addition to being the leading tions and the modernization of eight one single database for faster error automation platform in a wide range existing substations. analysis and capturing plant-wide of process industries, it has the sequence of events unique capability to integrate the The REPAR refinery adopted the Lower cost of ownership due to process, electrical and safety systems IEC 61850 standard as the communi- fewer spare parts, less training, into a single system. system administration and docu- Factbox 3 Petrobras mentation being required This, among other things, enables Enhanced asset-management capa- refinery operators to monitor and con- Petrobras (short for Petroleo Brasileiro bilities using the electrical diagnos- trol the systems from a singleinterface S.A.), is a semi-public Brazilian multina- tic data and connection to enter- and run power management applica- tional energy company headquartered in prise level systems such as comput- tions and intelligent IEC 61850 substa- Rio de Janeiro. In terms of market capital- erized maintenance management tions in the process-control system. ization and revenue, it is the largest com- systems (CMMS) pany in Latin America, and the largest The operational and cost benefits of company headquartered in the Southern such an integrated system are huge, Hemisphere. The company was foundedThe REPAR refinery is including optimization of all auto- in 1953, and while it ceased to be Brazil’sone of Petrobras’most mation and electrical assets, simplified legal monopolist in the oil industry inimportant downstream engineering, streamlined maintenance, 1997, it remains a significant oil producer, improved energy efficiency, and lower with output of more than 2 million barrelsproduction units. initial investment costs compared with of oil equivalent per day, as well as a ma- running non-integrated systems. jor distributor of oil products. The compa-Power management for Petrobras ny also owns oil refineries and oil tankers.ABB has a large installed base of Petrobras is planning to further Petrobras is a world leader in the devel-power management systems Factbox 2 streamline its processes in operation, opment of advanced technology forin Petrobras refineries Factbox 3 . Of the maintenance, training, optimization deep-water and ultradeep water oil pro-12 refineries owned by Petrobras on and quality control. System 800xA can duction.Brazilian territory, ABB has installed provide data and resources to supportthe PMS in nine of them and the such improvements. Today, Petrobras operates in 27 countriesprocess control system in seven. in the energy sector, primarily in the areas of exploration, production, refining, trad-Three years ago, as part of their stra- ABB’s System 800xA is ing and transportation of oil and its deriv-tegic growth plan, Petrobras decided the first process-control atives in Brazil and abroad. Its currentto invest in increasing its production system on the market to motto is “An integrated energy companyand in improving the quality of its that works with social and environmentalproducts – mainly in the areas of die- support the IEC 61850 responsibility.” The company is fourth insel and gasoline – through the addi- standard. the ranking of the largest publicly held oiltion of new production units and the from the world, is the third largest in themodernization of others in existing REPAR Project Americas in market value and occupiesrefineries. In February 2008, Petrobras The REPAR refinery is one of Petro- the sixth place among the world’s largestthus signed a frame agreement with bras’ most important downstream pro- companies in terms of market value.ABB for the supply of PMS and PCS. duction units. It is located in Brazil’sThe agreement had a value of 61 mil- Parana state, one of the most industri- Areas Quantitylion and covered the supply of hard- alized and most populated regions of Market value – August/2009 $ 173.59 billionware, software and technical services the country. Consequently, REPAR is Service stations More than 8,000including specialized training. The among the refineries to receive a larg- Employees – June/2009 $ 75,242contract forecast implementation of er investment in the Petrobras strate- Production platforms 112around 70 projects on nine refineries gic plan. Thermoelectric plants 10in which ABB has installed base. Refineries 16 The implementation of the growth Average oil & natural gas 2,505,379The scale of the modernization pro- plan of the REPAR refinery included production – June/2009 barrels/daygram is immense. In addition to build- the installation of the new PMS. This Total investments – $ 174.4 billioning new units for hydro treatment, encompassed several new substations 2009/2013cooking, desulfurization and other including a 230 kV intake substation, a Investment in biofuels – $ 2.8 billion 2009/2013processes, Petrobras is constructing 69 kV GIS3) distribution substation and50 new substations and modernizing 12 process substations as well as two50 ABB Review 4/2009
Refined integration Innovation in productioncation technology for its substation PCS, REPAR built a new centralized data model to permit a perfect inte-automation and PMS. ABB’s System control room where a total of 56 Sys- gration with System 800xA PMS.800xA was ideally suited to meet tem 800xA operator stations are beingREPAR’s PMS needs. The new PMS installed. Four of them will be exclu- Benefitswas required to integrate the function- sively used for the monitoring of elec- Some of the benefits for Petrobas are:ality of its predecessor system in terms trical operations. One of the most im-of using the same database of key portant projects was the 69 kV GIS, Standardizationcontrol features such as load-shedding based on ABB’s 670 series of IEDs – The adoption of IEC 61850 technologyresponses and reactive-power control the substation is already working us- and System 800xA permitted Petrobrasin a single and centralized solution. ing the new technology. to standardize various procedures inThe old PMS thus saw its Advant substation configuration, control logic,stations upgraded to System 800xA, The rigorous studies connected to the control libraries and operation proce-while retaining its Advant Master introduction of IEC 61850 network ar- dures. These translated into savings incontrollers. The new substations use chitecture Factbox 4 brought automation commissioning time and configuration.System 800xA from the start 3 . engineers and substation engineers The object orientation of IEC 61850 together to the same “project table”. supports standardized device modelsThe new substations use redundant ABB is supporting the integration ef- using names instead of object/registerAC800M controllers that have IEC61850 forts by guiding substation engineers numbers and indexes. System 800xA,interfaces and Profibus DP fieldbus in the correct usage of the IEC 61850 through its IEC 61850 compliance,network to connect to intelligentMCC4) and drives. The IEC 61850 net- 3 PMS REPAR simplified architecture integrated with existent systemwork is used in the following voltagelevels: 69.0 kV GIS substation, 13.8 kV Workplace Workplace and asset Engineering stationswitchgear, 2.4 kV medium-voltagedistribution-center panels and 0.48 kVdistribution-center panels. Thus ABB’s Client/Server networkPMS is used to control all voltagelevels of the electrical system of therefinery. The operation of System CS AS IM 61850 OPC Advant connect800xA is supported by ABB’s PMSLibrary, whose implementation builds Control network GPSon 24 years of experience with AC800M S800 I/Opower-management systems in ABB. SOE IEC 61850 ModulebusWhen this project is complete, the IED IEC 61850 IEDSystem 800xA system will have 16 re- IED IEDdundantly fitted AC800M controllers MB300installed in 10 substations interfacing Profibus DP Modbus RTUwith around 460 IED‘s in total.For the operation of the new PMS and Synch Rectifiers batteries charger MCC AVR AC400 controllers auxiliary services DRIVESFootnotes3) GIS: gas insulated switchgear4) MCC: motor control centerABB Review 4/2009 51
Refined integrationInnovation in productionwas able to fully support this redundant control network, Factbox 4 Architectural analysisstandardization. a redundant IEC 61850 OPC interface, and other arrange- Shielded cable – 1 GBpsLower investment cost Fiber optic – 1 GBps 61850 OPC server ments in which System 800xAThe use of IEC 61850 com- Fiber optic – 100 MBps was tailored to meet Petro-bined with System 800xA bras specifications. This andPMS brought simplicity to Switch IEC61850 other mechanisms of avail-many phases of the project ability improvements helpedimplementation. This was deliver a system to REPARnoticed in the definition, that reduced unscheduleddesign and engineering phas- downtime.es through the common userenvironment, use of the A digital system integratedEthernet standard, the single with a powerful IEC 61850tool for the engineering inte- network allowed use ofgration of all devices, less remote maintenance tools, Substation 1 Substation 2 Substation nwiring and more advanced access to device diagnosticsprotection capabilities thanks and reporting, increasingto the use of horizontal Aspects that were jointly analyzed by ABB and REPAR engineers system reliability.GOOSE messaging for direct for the achievement of a robust IEC 61850 network include suchexchange of data between choices as what network topology to use, star versus ring, single A successful integrationdevices. versus redundant, what should be programmed in the IEDs, what ABB has recognized the im- should be programmed in System 800xA, how the IEC 61850 net- plementation of an integratedLower-lifecycle costs work should be segmented. After detailed evaluations, a single-ring process-control and powerOne of the main benefits de- topology was favored for every substation to connect switches, and management system basedlivered to REPAR was optimal a star topology was chosen between switches and IEDs. A redun- on System 800xA for thelife-cycle management and dant star topology was used to connect all rings to a common OPC Petrobras REPAR refinery aslow life-cycle cost through IEC 61850 server and an engineering station. one of its top innovations ofthe use of a future-proof 2009.5) The REPAR projectsystem with IEC 61850 in- will be completed in 2011,teroperability. The reuse of with the other Petrobras proj-engineering data and the use of a integrated system. The control of ects following later. The integration ofstandard language for programming drives, intelligent MCC’s, medium- PMS and PCS will enable higher pro-highlighted the power of IEC 61850 voltage switchgear, protection and ductivity through more far-reachingfor REPAR projects and the associated control IEDs were all integrated on optimization of plant operations andcosts savings through less need for the same system. Improvements will represent a model for future proj-training and reduced staff require- directly perceivable by REPAR include ects worldwide.ments. increased visibility of the process, the possibility of asset management ofThe adoption of System 800xA also electrical devices, improved interface The photographs used in this article are of the REPARprotected past investments: The exist- with process control and improve- refinery and copyright of Petrobras.ing system, based on Advant Master ments in operation procedures.controllers, could be fully integratedwith the new. Furthermore, the newPMS has structures ready to receive The adoption of Systema future replacement of the legacy 800xA protected pastsystem controllers. investments: The existing Antonio CarvalhoIntegrated process and power system, based on Advant ABB Process Automationautomation Mastercontrollers, could São Paulo, BrazilA unified system for process and email@example.com automation was used to com- be fully integrated withbine power management, process the new. Johan Hanssonelectrificatio, and process control into ABB Process Automationa single control environment in the Reliability and availability Västerås, SwedenREPAR Refinery. Benefits that REPAR System 800xA allows the implementa- firstname.lastname@example.org valued with its existent PMS, tion of a PMS in a DCS platform. Thesuch as reduced energy costs through use of this platform gives the systempower management, were transferred the highest levels of availability and Footnoteinto the new system and strengthened reliability. The REPAR Project is based 5) See “An innovative 2009” on pages 6–11 of thisthrough the implementation of a fully on redundant AC800M controllers, a edition of ABB Review52 ABB Review 4/2009