This document discusses electrical integration using ABB's Integrated Process and Power Automation solution. It defines electrical integration as integrating process automation and power automation into one system. ABB's solution provides full plant integration using System 800xA with electrical integration based on open standards. It offers a complete portfolio from ABB and customer benefits like reduced costs, improved effectiveness, availability, and energy savings. Example references of installations are provided.

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© ABB / PA / Control Systems
February 12, 2015 | Slide 1
Electrical Integration with System 800xA
Integrated Process and Power Automation

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February 12, 2015 | Slide 2
Outline
 What is Electrical Integration?
 ABB’s solution: Integrated Process and Power Automation
 Customer benefits
 References

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Outline
 What is Electrical Integration?
 ABB’s solution: Integrated Process and Power Automation
 Customer benefits
 References

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What is Electrical Integration?
A hot topic – Larry O’Brien, ARC

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What is Electrical Integration?
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
 What is Electrical Integration?
 ABB’s solution: Integrated Process and Power Automation
 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
Ce
ntra
lize
d
Com
mon
asset
mana
Common
system
architecture
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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© ABB Group
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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
 What is Electrical Integration?
 ABB’s solution: Integrated Process and Power Automation
 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
 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

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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 groupProcess group

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Customer Benefits
Improved Operator Effectiveness
Process OperatorPower 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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Customer Benefits
Reduced Maintenance Costs

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Customer Benefits
Reduced Maintenance Costs
Process
Instrumentati
on
Substatio
n
Equipmen
t
Process
Electrificatio
n 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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Customer Benefits
Reduced Maintenance Costs
 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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Customer Benefits
Reduced Maintenance Costs
 Maintain only one interface to CMMS
 Maintenance planning more efficient
 Single source for maintenance analysis

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Customer Benefits
Increased Plant Availability

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Customer Benefits
Increased Plant Availability
 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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February 12, 2015 | Slide 32© ABB Group
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Customer Benefits
Increased Plant Availability
2.2 1.8 1.8 2.1
3.3
2.50.1
1.5
7.2
5.7
MW MWMW MW
MW
MW
MW
Hz
kV
Generator trip

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February 12, 2015 | Slide 33
Customer Benefits
Increased Plant Availability
0.0 1.8 1.8 2.1
3.3
2.50.1
1.5
4.8
3.9
MW MWMW MW
MW
MW
MW
Hz
kV
Fast load shedding
 Avoidance of black-outs with System 800xA
based Power Management Systems
 Faster load shedding than hardwired with IEC
61850 high speed protocol
 Quality monitored load shedding signals
 Reconfiguration without rewiring

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Customer Benefits
Reducing Energy Costs
 Improving visibility into power consumption
 Understand and easily access power usage information
 Explore energy saving opportunities
 Enhance existing energy usage reduction program
 Track and trend power consumption
 An increase in power consumption can indicate
equipment malfunction and wear
 Integrate equipment and systems to make energy
efficient decisions
 Centralized control of power consumption
 Plant personnel will have complete visibility and
control of a situation regardless of where a problem
originated (i.e. an electrical glitch, process control
problem, or a failing IT asset)

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Customer Benefits
Motivation for Reducing Energy Usage
 Issues
 7 – 15% of energy does not leave the fence
 Increase in operating costs
 Plant net and gross heat rates gradually deteriorate
 CO2 emission costs
 Cap and trade in US and Canada
 $15 to 30/ton of CO2?- emissions are no longer going
to be free
 Defacto moratorium on new coal plant
construction?
 Need to increase output of existing plants
 Need to extend lifetime of existing plants

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© ABB Group
February 12, 2015 | Slide 36
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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© ABB Group
February 12, 2015 | Slide 37
Outline
 What is Electrical Integration?
 ABB’s solution: Integrated Process and Power Automation
 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:
 Full Plant Integration with System 800xA
 Integrated Process Automation and Power Management System
 Electrical Integration Based on Open Standards
 IEC 61850 integration of ABB and Schweitzer Protection & Control
IEDs
 Complete Portfolio from ABB
 DCS, PMS, IEDs
 Customer’s benefits:
 30% less engineering hours due to reuse of engineering data
 15% savings in installation time with standardization of
solution
 20% savings in training costs with improved visibility of one
system

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Integrated Process and Power 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:
 Full Plant Integration with System 800xA
 Integrated Process Automation and Substation Automation
System
 Electrical Integration Based on Open Standards
 IEC 61850 integration of ABB Protection & Control IEDs
 Complete Portfolio from ABB
 DCS, SAS, LV Switchgear, IEDs
 Remote Diagnostic Services
 Remote troubleshooting and fewer trips to site
 Customer’s benefits:
 Cost effective solution, short installation time
 Standardized concept for coming hydro power renewals
 Reduced maintenance costs with remote access to plant data

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