ganesh kamath, surabaya, 30 october 2014 one abb seminar ...€¦ · one abb seminar surabaya 2014...

One ABB Seminar Surabaya 2014Ganesh Kamath, Surabaya, 30rd October 2014

Advanced Services – Powered byServicePortTM

© ABB GroupNovember 3, 2014 | Slide 2

Process AutomationServing a full range of processes . . .

§ Cement

§ Food and Beverage

§ Life Sciences

§ Marine and Cranes

§ Metals

§ Minerals

§ Oil, Gas and Petrochemical

§ Printing

§ Pulp and Paper

§ Specialty Chemicals

§ Turbocharging

§ Additional industries via channelpartners and other ABB businesses

§ Developing Markets

Control Room

Control System

Control

Process

Protection &Control IEDs

Promoting CollaborationIntegrated Process and Power Automation

Controller

Plant Network

Controller

Profibus/Profinet

SubstationAutomation

Process ControlServer

IEC 61850

Process & Power Workplaces

Instruments

LV SwitchgearDrivesMotor starters

ProcessElectrification

ProcessInstrumentation

Plant-wideSequence of

Events for betterroot cause analysis

Same operationsinterface and

engineering for sharedinformation and

knowledge

CentralizedHistorian and

Data Archiving

CentralizedHistorian and

Data Archiving

Common, integratedasset management

strategy

Electricalintegration based

on Open Standardssuch as IEC 61850,Profinet/Profibus…

Electricalintegration based

on Open Standardssuch as IEC 61850,Profinet/Profibus…

Common systemtherefore reduced

spare parts, trainingetc…

Standardized procedures,settings, control logic and

libraries

Standardized procedures,settings, control logic and

libraries


ABB Life Cycle ServiceComprehensive Service Portfolio

HV & MV SwitchgearRelay protection

• Testing• Calibration• Coordination• Upgrades

Transformer• Oil Testing• Assessment• Periodic maintenance• Repair• Refurbish

Motors & Generators• Preventive kits• Periodic Maintenance• LEAP• Repair• Refurbish

LV and MV drives• Preventive kits• Periodic Maintenance• Repair• Refurbish

Automation• Preventive kits• Repair• Refurbish

Control Optimization• Fingerprint• Implement• Scan• Track

Industrial Energy Efficiency Reliability and integrity

Full Service ®

© ABB GroupNovember 3, 2014 | Ver. 1.1 Slide 5

ABB ServiceServices Portfolio

§ Over 22,000 service people in100 countries

§ Integrated solutions forreliability, productivity andenergy efficiency

§Optimization Services

§Full Service (Maintenance Outsourcing)

Training

Installation & Commissioning

Remote Services

Spare Parts

Condition Monitoring

Preventive Maintenance

Evolution Services

Repairs & Interventions

Upgrades & Retrofits

ABB Process Automation ServicesWe address your entire asset lifecycle

§ABB Service Portfolio

§Front-endengineering

DetailEngineering

Equipmentselection &

procurement

Construction Commissioning Start-up Operation

Design & Construction Warranty & Post-warranty

Lifetimeextensions

Installation & Commissioning

Decommissioning

§Consulting (Energy Efficiency, Productivity, Reliability, Safety)

§© ABB Group§November 3, 2014 | Slide 6

§© ABB Group

§November 3, 2014 | Slide 7

Certification

LeverageServiceKnowledge

Skill Requirements

IncreaseDeliveryEfficiency

Service Products

Solution

IdentifyServiceNeed

ABB Service Activity Process

ServicePoint

LCS

KeepProductionRunning

DeliverOperationalExcellence

OptimizeProcesses

MaximizeSystems

© ABB

Early days of automation

§03 November 2014 §| Slide 8

Few units§ Data collection difficult§ Range of control limited§ Troubleshooting very hands on§ Space defines number of controllers

© ABB

Modern Day Automation


We can not use yesterday’sservice methods to solvetoday’s problems§ Data is easily accessible§ Range of controllers extensive§ Hard drive defines number of controllers§ Troubleshooting is digital

© ABB

Goal: Continuous Improvement


1234

1234

1234

1234

Stand Alone Tools§ Signal Analyzer§ Loop Tuning§ Loop Analyzer

Continuous Tools§ Service Portal§ CMMS System§ Certification and Training

Action plan

Tuning

Actuator

Signal

Logic

Impl

emen

t

© ABB

Automation System Performance


Prod

uctio

nan

dQ

ualit

y

Goal

Problem

Operatorsdon’t turn offfeatures that

work!

System Utilization0

Manual

100

Auto § Control is only used during upsets§ A few shifts tried to use control§ There is an inverse correlation between

production and control utilization§ No service done in over 5 years!!!

Production

SystemUtilization

Case Study: High systemutilization is cutting production!

A well tuned control loop will improveperformance and production when utilized

© ABB

Industrial Trends in Control Performance


Manual OperationOutput out of rangeIncreasing variabilityImproving process

30%

15% 30%

25%

Half life of process controllersGiven: 100 PID loops tuned at onceThen: Within 6 months, performance

of 50 of these loops will degrade

100

Loop

perfo

rman

ce

degr

adat

ion

50

06

Simple PID utilization

PID Controllers are designed to:§ Regulate the process§ Reduce product instability§ Improve operations

However, customer data shows:§ PID loops are not being maintained§ PID loops have degraded§ PID loops are standing in the way of

production and performance


Advanced Services: Performance MigrationMaximum Off Specification

Diagnose: Current

Implementation: Corrective Action

Sustain: Improvement Projects

Optimal: Mechanical Constraints

Reduction in Variability=

• Less Raw Material Usage

• Improved energy consumption

• Wider Operating Window

• Increases in production, quality, and product purity

• Faster troubleshooting time

• Advanced Automation Solutions

Goal


Optimization Services - Methodology

§ Diagnose

§ Measure Process

§ Detailed Scope with definedobjectives

§ Forecast Performance

§ Implement

§ Improve Performance

§ Apply corrective actions

§ Sustain

§ Maintain Performance

§ Preventative Maintenance

Sustain

Implement

Diagnose

Service

IncreasedPerformance

1

2

3

Pro-Active Solutions,not Re-Active

6-Sigma similarities


Advanced Services powered by ServicePort™Make more of a better product for less

Performance Channels

§Higher productionefficiency

§Reduced downtime

§ Improved system stability

§Maximized asset lifecycle

§Better processperformance

§Faster, more flexibleservice

Work smarter, not harder


Advanced Services powered by ServicePort™What are ABB Advanced Services?

0102030405060708090

100Control System

Equ

ipm

entP

erfo

rman

ce

Time

Traditional system approach

Performance peaks,then degrades

0

20

40

60

80

100

Ser

vice

Per

form

ance

Time

Traditional service approach

Performance depends onavailability

Advanced Servicespowered byServicePort

0

50

100

Ove

rall

Per

form

ance

Time

Consistentperformanceimprovement


Advanced Services powered by ServicePort™Secure, remote Advanced Services delivery

§ ServicePort is a servicedelivery platform throughwhich customers receiveAdvanced Services for§ Process§ Equipment§ Industry

§ Services are deliveredthrough channelsubscriptions

§ ServicePort is a on-site tool

Advanced Services powered by ServicePort™Proven process

Diagnose§ Measure performance gap§ Forecast benefits (ROI)§ Deliver action plan

Implement§ Fix performance gap§ Define monitor plan

Sustain§ Manage performance gap§ Schedule maintenance§ Define condition triggers§ Maintain to conditions

Service

IncreasedPerformance

Diagnose§Measure performance gap§ Forecast ROI§Deliver action plan

§1

Implement§ Fix performance gap§Define and monitor plan

§2

Sustain§Manage performance gap§Schedule maintenance§Define condition triggers§Maintain to conditions

§3


Advanced Services powered by ServicePort™Advanced Services value areas

Sustain

Implement

Diagnose Assess

Action

Repeat

Assess

Action

View Scan Track

Fingerprint ServicePort


Advanced Services powered by ServicePort™Monitoring Service based on channels

Channelline-up


Advanced Services powered by ServicePort™Types of channels

Cyber Security Channel

Harmony Performance Channel

Hoist Performance Channel

Loop Performance Channel

QCS Control Utilization Channel

QCS Sensor Stability Channel

QCS VPA Channel

System 800xA Channel

Channel Lineup

EquipmentChannels

ProcessChannels

IndustryChannels


Advanced Services powered by ServicePort™Equipment Performance Services

Help improve equipment availability, prevent equipmentdeterioration and extend asset life.

800xA Performance Services help customersmanage 800xA control systems, improve systemperformance and extend asset life.

Harmony Performance Services help customersmanage Harmony control systems, improve systemperformance and extend asset life.


Advanced Services powered by ServicePort™Process Performance Services

Help improve process performance, prevent processdisruptions and protect assets.

Loop Performance Services identify and correctcontrol loop performance issues.

Cyber Security Performance Services identifystrengths and weaknesses for defending againstcyber attacks within a plant’s control systems.


Advanced Services powered by ServicePort™Industry Performance Services

Applying industry-specific knowledge to help improveequipment performance and extend asset life.

Quality Control System Performance Servicesevaluate current QCS performance levels andprovide a basis to evaluate and identify opportunitiesto improve measurement and control utilization.

Mine Hoist Performance Services evaluateperformance levels of ABB or other mine hoists andprovide a basis to evaluate and identify opportunitiesto improve mine hoist utilization.


Advanced Services powered by ServicePort™Secure, remote-enabled access to service experts


Advanced Services powered by ServicePort™How to find needles in a haystack?

Few units§ Not difficult to find

issues.Many units§ Much harder to find

issues.§ Time to find with simple

tools is not practical.§ Avoiding false positives

is essential

Few

Many

Represents one unit

300 units are shown here.This represents a small areaof an industrial process.


Advanced Services powered by ServicePort™View, Scan and Track

Math

Rules

raw data associated witheach channel

presents KPIs generated from raw datathrough periodic diagnostic monitoring

generates notifications based onpredefined KPIs

View

Scan

Track

Goal Present

Gap>rule = Alarm

KPI(s)

Sev

erity

Raw Data

Trends for Experts


Advanced Services powered by ServicePort™View the raw data

Time Events

Data View – Aligned to visibly show issues


Advanced Services powered by ServicePort™Scan the status

Identifies, classifies and prioritizes issues


Advanced Services powered by ServicePort™Track changes


Advanced Services powered by ServicePort™Channels produce reports that guide improvements

Advanced Services powered by ServicePort™Expected financial results

Typical Savings for process areas with 250 control loops

Energy

Raw materials

Product change

Reduced off-spec

Production

100 200 300 400 500

Quality

Target shift

Energy

$225,000 per year

Raw Materials

$ 75,000 per year

Quality

$ 50,000 per year


Advanced Services powered by ServicePort™Example of how services are deployed over one year

Initialization, Baseline Setting, Training

View (performance) Calculations / evaluations /daily usage

Scan (scheduled): Scan analysis / report /implementation planning / notification validation

Track (event-triggered): remote troubleshootingassistance

Customer (on demand)

Mon

th1

Mon

th12

ganesh kamath, surabaya, 30 october 2014 one abb seminar ...€¦ · one abb seminar surabaya 2014...

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