issue 1 / 2003 the abb india magazine · issue 1 / 2003 the abb india magazine abb wins overall ......
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Issue 1 / 2003
The ABB India Magazine
ABB wins overallWall Street JournalTechnology award
ABB India wins singlelargest export order
ProductivityEnhancement throughAutomation –The Industrial IT way
CONTACT – The ABB India Magazine2
CO
NTE
NTS
CONTACTEditorial Team: Harmeet S Bawa, Vikram V Kanth, Antaash Sheikh.Correspondents: Manish Bhargava, Namita Asnani.
ABB India, GF-Corporate Communications2nd Floor, East Wing, Khanija Bhavan,49, Race Course Road, Bangalore - 560 001.
All trademarks acknowledged.Design: Shilahar Associates, Bangalore.
www.abb.com/in
A new simpler ABB 4
ABB to implement Industrial IT solution for 5the world’s longest oil pipeline
ABB’s first Industrial IT factory goes online 6
Building knowledge capital through training 9and empowerment
Welcome to the world of IndustrialIT 10
Channel Line 20– ABB India’s B2B portal crosses Rs. 120 million mark
during first 6 months of operation
ABB and Sustainability 21– Rain water harvesting– A ray of hope
Q&A 22
More options with ABB’s Industrial IT fieldbus solution 14
Exploring the value of Industrial IT enabled products 18from ABB
Productivity Enhancement through Automation, 19The Industrial IT way
Putting Industrial IT to the test 4
Issue 1 / 2003
CONTACT – The ABB India Magazine 3
Dear Friends,
Thanks to the continued support of our customers and the effortsof our employees, ABB India registered a strong performance forthe year ending 2002 despite a challenging and competitivemarket environment. Order intake for the year was up 20% andRevenues grew by 14%. In addition to the continued confidenceof our domestic utility and automation customers, we also brokenew ground in international markets with the companywinning several turnkey export projects and we also increasedour global product exports and services.
We re-entered the market for HVDC and reactive power compensation, winning significant orders in theseareas, after a long gap. We made excellent progress with our strategic focus on standard products anddeveloping our channel partner business. This included the addition of over 120 channel partners, acrossthe country, several brand initiatives, the successful launch of our e-portal, which got off to a flying start,resulting in significant e-channel business. Several new products and applications were introduced, bothin the power and automation technologies arena, including 400 kV power transformers, new range of LVproducts and drives, flame proof and higher frame size motors, to name a few.
Our continued focus on improving productivity and efficiency helped us deliver greater value to ourcustomers and other stakeholders. We implemented several new IS and HR initiatives including thecompletion of SAP implementation. We stepped up our communications’ activities and enhancedcompany visibility considerably thereby strengthening our brand equity. Besides the ongoingconfidence of our customers, these efforts were also widely acknowledged by the media, investors andthe communities we operate in.
ABB, as you know has been recognised as a technology leader for over a century, with many pioneeringbreakthroughs to its credit. We invest around 7% of our Group turnover in research and order relateddevelopment, which is weaved into the fabric of our business strategy and product portfolio. We have avery high ‘intensity of innovation’, with around 75% of our present business being based on productsdeveloped in the past five years.
In today’s highly competitive business environment, all businesses are seeking radical productivity andefficiency improvements. ABB is spearheading this effort through its open architecture basedIndustrial IT platform aimed at real-time, seamless integration of plant operations and business processesacross the entire value chain. In keeping with this vision, ABB is also ‘Industrial IT enabling its ownproducts to facilitate a scalable ‘plug and produce’ architecture based on ‘product suites’ to suit specificprocesses and requirements. Over 35,000 ABB products have already been Industrial IT enabled to date.Our global R&D centre in Bangalore is also facilitating the development of Industrial IT . In this issue ofCONTACT you will read more about Industrial IT, which we have termed ‘the next way of thinking’.
In the year ahead we will continue to focus on our strategic initiatives aimed at creating value for ourcustomers and other stakeholders by leveraging our domain competence and vast manufacturing andmarketing presence in the country and applying our business philosophy of “thinking global-acting local”.I look forward to the continued confidence and support of all of you in this endeavour.
Ravi UppalVice Chairman & Managing Director, ABB India
CONTACT – The ABB India Magazine 3
CONTACT – The ABB India Magazine4
Business Area
High voltageproducts
Medium voltageproducts
PowerTransformers
DistributionTransformers
Utility AutomationSystems
Power Systems
ABB’s new simplified structure
will help focus on core
businesses and make response
times faster, making it easier for
customers to transact with ABB.
A new simpler ABB
Power Technologies Automation Technologies
Business Area
Control PlatformProducts
Drives & Motors
Low Voltage Products& Instruments
Robots, Automotive &Manufacturing
Paper, Metals, Marine& Turbocharger
Petroleum, Chemical& Consumer
7 Divisions
AutomationTechnologies13 Business
Areas
3 Divisions
6 BusinessAreas
Powertechnologies7 Business
Areas
6 BusinessAreas
Novartis, one of the world’s leading pharmaceutical
players has chosen ABB to upgrade the first of its
pharmaceutical and biotech plants to 21 CFR Part
11 regulations and other U.S. Food and Drug
Administration (FDA) requirements. The plant,
located at Torre Annunziata near Naples in Italy,
is a key facility in Novartis’ global network of
production centres for finished pharmaceuticals
and active ingredients.
The upgrade has four main aims – facilitating 21
CFR Part 11 compliance, renewing an outdated
control system, increasing the number of products
from one to three and raising production capacity.
ABB has tailored a solution based on its Industrial
IT platform to meet these objectives. The solution
consists of Operate IT operator stations, Control IT
AC800F controllers and Produce IT Batch software.
ABB is also responsible for engineering,
configuring and validating the entire system to 21
CFR Part 11 and other FDA standards, and this
state-of-the-art solution will enable the plant to
Putting Industrial IT to the test
operate as a paperless environment, in which the
vast amount of paperwork required by law to
record and verify each operation in the production
process is replaced by a more efficient,
computerised system of electronic batch records
and electronic signatures.
Based on its success, the Industrial IT solution
being implemented, could become the preferred
platform for other Novartis’ plant upgrades
worldwide.
CONTACT – The ABB India Magazine4
CONTACT – The ABB India Magazine 5
ABB is to supply control and safety systems for the
world’s longest oil pipeline, running from Azerbaijan
to Turkey. The new system is based on ABB’s
Industrial IT technology, which links products and
services with the information needed to run, service
and maintain them. The construction consortium,
BTC, will be able to control operations at both ends
of the pipeline, which are 1,760 kilometres apart and
in different countries. Construction of the US$ 2.9
billion underground pipeline will start next year and
is due to be completed in 2005. When commissioned,
it is expected to carry one million barrels of oil a day
from Sangachel on Azerbaijan’s Caspian coast,
through Georgia, to a new marine terminal at Ceyhan
on Turkey’s southern Mediterranean coast. ABB will
supply, install and commission integrated control and
safety systems to provide operational control,
emergency shutdown options, and fire and gas
monitoring of the pipeline, a marine terminal and two
offshore production platforms.
The work includes remote-controlled subsystems to
isolate sections of the pipeline for regular
“A cross-border technology solution is
needed to make sure this extremely complex
pipeline runs efficiently. Our Industrial IT
platform is unique in that it handles both
process and safety control in one system,
rather than with separate systems as is done
traditionally. This is important to ensure
pipeline efficiency, as well as environmental
and personal safety.”Dinesh Paliwal
Head – Automation Technologies
inspection and maintenance. The pipeline will be
linked over its entire length by a fibre optic
telecommunications backbone. Associated field
instrumentation includes transmitters and ultrasonic
flow metering for the terminal, valve and pumping
stations.
ABB to implement Industrial IT solutionfor the world’s longest oil pipelineABB to implement Industrial IT solutionfor the world’s longest oil pipeline
ABB Industrial IT keepsthe beer flowingABB is set to help Warsteiner breweryflow into the future by implementingstate-of-the-art Industrial IT technologyat two of its production plants inGermany.
At the Warstein site, more than 42,000I/O points will be coupled with 37 Control ITcomponents via Profibus, operated from 17operate process stations. And at the Paderbornbrewery, the system will be expanded to morethan 12,000 I/O’s and 13 controllers. The twoinstallations will not only replace nine existingsystems, but the entire revamp, includingInform IT Production Manager, will integrateall operations at the breweries – from batchlogging to filtration, from central power supplyto refrigeration.
“ABB’s Industrial IT solutions are thetechnology of the future,” said Ulrich Brendel,technical director at Warsteiner. “WithIndustrial IT, we have access to the wholeproduction process and, thanks to objectorientation, all production parameters aretransparent,” he added.
CONTACT – The ABB India Magazine 5
CONTACT – The ABB India Magazine6
ABB’s first Industrial IT factorygoes onlineNew technology at the Lodz distribution transformerfactory in Lodz will increase speed and efficiency
ABB’s focused factory, in the city of Lodz,
Poland, which manufactures distribution
transformers between 250 and 2000 kVA is the
first ABB factory to go online using Industrial IT.
Industrial IT will now drive the entire production
process leading to significant increase in speed
and efficiency, shorter delivery times and
accurate delivery schedules.
With Industrial IT in place, customers will be
able to get quotes, confirm product delivery
dates, configure the technical data for a
transformer and automatically enter the order
into the Enterprise Resource Planning (ERP)
system of the factory. Very soon, the new system
will also provide information about plant
capacities, and which ABB factory can carry out
an order in the shortest possible time; work can
then be done in a single factory, or spread across
multiple factories within a region or globally.
ABB’s unique Aspect-Object technology provides
a simple and intuitive way for Lodz management
and supervisors to monitor and control factory
operations. Every user desktop can be
customised to meet individual job needs and
requirements, while retaining a common ‘look
and feel’. In addition to the planning and control
functions, the Aspect Integrator provides instant
access to a wide range of user-defined reports.
Management can view current job status, quality
and test results, as well as historical performance
information, with a simple click of a mouse.
This ‘virtual‘ global factory concept will be an
important breakthrough for ABB in the drive for
improved speed and full utilisation of capital
resources. For the first time in ABB and the
industry as a whole, control and business
information will be accessible on one screen -
drawings, bills and machine maintenance
information. Apart from improving cycle times
and machine use, such electronic information
transfer will ensure accuracy and consistency in
manufacturing leading to quality improvements.
The Industrial IT set-up in Lodz can be deployed
in discrete manufacturing elsewhere in the
world.
Industrial IT technology and solutions have been
introduced at every stage of the business in Lodz
– from online ordering and planning, through
the manufacturing process to final product
shipment. “Industrial IT is highly beneficial and
profitable for customers. It radically increases
speed, cuts total cycle time by more than 50%
and consistently ensures a high-quality product,”
said Peter Smits, head of Power Technologies
division. “The usual delivery time for a
distribution transformer is five weeks. However,
the actual production time is only five days.
Time is lost through many interfaces causing
waiting time and double-checking of
information. Real-time applications and the
integration of all systems within the factory cut
that time drastically,” he added.
CONTACT – The ABB India Magazine6
CONTACT – The ABB India Magazine 7
New alliance to enable ‘shop floor to top floor’ connectivity
ABB, Accenture, Intel and Microsoft have formed analliance to help manufacturers bridge the gapbetween plant floor operations and enterprise ITsystems. The alliance aims to help manufacturers bysimplifying integration, gaining greater visibility intotheir businesses, making informed, real-time businessdecisions and enhancing their financial performance.
The four companies will provide a full range ofcomputing diagnostics, solution design,development and integration services formanufacturers. The team’s joint development workwill help customers gain access to manufacturing
Stop press!
Markus Bayegan receivingthe award at the EuropeanInnovation Award ceremony
ABB wins overall Wall StreetJournal Technology award
ABB won the gold award for technology in theEuropean Innovation Awards held by The WallStreet Journal, Europe. ABB received the accolade,ahead of 190 individuals, organisations andcompanies in 20 countries, for its development ofwireless sensor technology.
ABB unveiled its award winner “Robbie” at thetechnology fair in Hanover, Germany, earlier thisyear. Robbie is an assembly line robot fitted withwireless sensors that allow performance data to besent to a central computer. The data is sent usingradio waves rather than being transmitted via aheavy cable. Robbie also has a wireless powersupply rather than a conventional cable withenergy from a magnetic field being converted intoelectrical power.
ABB’s award winner ‘Robbie’
automation technology that will work seamlessly ina plant environment and integrate with a widecollection of enterprise IT systems.
The collective resources of the alliance membersbring automation and power products,manufacturing solution expertise, robust computingand networking, and programme management andintegration skills together to support a powerfulopen architecture for enterprise solutions.
“It shows that the quality of our research anddevelopment and technology-based innovation ishigh, contributing to significant value creation inour business areas. It is also very well received byour customers,” said Markus Bayegan ABB’s ChiefTechnology Officer.
Reporting on the technological advance representedby “Robbie”, The Wall Street Journal said that itpromises to make cabling, including power cables,on electronic equipment a thing of the past.
Optimize IT receives Editor’s Choice Awardfrom Control Engineering Magazine
The magazine chose Optimize IT Real TPI for multiplereasons – the product helps manufacturers determineand improve the performance of their factories. It helpsplants run smarter and better with substantial costsavings; it automates data collection and analysis andprovides customised reports tailored to address theneeds of plant management. The product has been
successfully adopted by customersacross industrial segments includingseveral Fortune 100 companies who areusing it to improve their competitive advantage on adaily basis. The product has enabled manufacturers toimprove productivity, reduce costs and improve returnon assets through capital cost avoidance.
CONTACT – The ABB India Magazine8
ABB India wins single largest export order
ABB India has been awarded its single largestexport order to date by Public Establishment ofElectricity for Generation & Transmission (PEEGT),the Power Generation and Transmission Utility ofSyria. The turnkey order includes six new 230/66/20kV substations for Dera, Al-Fayha, Bebila,Telhamis, North Aleppo and Sarakeb and will helpin substantially improving power supply to thesetowns. The project is scheduled for completion inabout 24 months. This is a fitting example of ABB’sglobal optimisation philosophy and reinforces ABBIndia’s growing reputation in the internationalmarket.
“We are already working on projects with
PEEGT Syria and this order reflects the
customer’s trust in our capabilities. It is an
endorsement of ABB’s leadership in power
and automation technologies and recognition
of its unparalleled domain expertise”.
– Ravi UppalVice-Chairman and Managing Director, ABB India.
The scope of the project includes design,procurement, manufacture & supply of equipmentfor all the substations. ABB’s multi-productequipment supply will include Power & InstrumentTransformers, Outdoor Circuit Breakers, MVSwitchgear and Control & Relay Panels from itsstate-of-the-art manufacturing facilities at Vadodara,Nashik and Bangalore.
“ABB’s cutting-edge power technologies and
local manufacturing capabilities combined
with our proven engineering and project
execution competencies have been decisive
factors in this success”.– Inder Sadhu
Head-Power Technology Systems
Expanding horizonsAs part of its focuson exports, ABBIndia has beenrapidly expandingits geographicalfrontiers andrecently broke newgrounds by winningsignificant orders inBhutan and Iceland.
ABB India secured a turnkey substation order fromthe Bhutan Power Corporation Development &Construction Department for supply andconstruction of 220kV and 66kV substations atRurichhu & 220kV bay extension at Semtokha.
Rurichhu, a greenfield substation, at an altitude of900m will evacuate power from Basochhu lowerstage Hydro Electric Project. It is proposed to be an
unmanned substation and will be controlled fromthe main control centre through OPGW/ PLCC linkand fibre optic terminal equipment. Semtokhaextension substation, located near Thimpu, is at analtitude of 2,300m. The project is scheduled forcompletion in 15 months.
The breakthrough Iceland order is for 6 nos.indoor 66kV SF6 EDI circuit breakers from NationalPower Company, Iceland. This is the first time thatcomplete EDI breakers will be sourced from India.The EDI circuit breaker is part of the ED series ofcircuit breakers for which ABB India is the globalsourcing base within the Group.
These orders bear testimony to the high quality andadaptability of ABB products, which can beinstalled in countries with diverse climatic andtopographical conditions. It is also proof of theability of the ABB India team to tap new businessopportunities anywhere in the world!
CONTACT – The ABB India Magazine8
CONTACT – The ABB India Magazine 9
Building knowledge capital throughtraining and empowerment
ABB India has recently set up a new customer
training centre at Vadodara. This is in addition to
similar centres at Bangalore and Nashik. The main
objective of this centre is to enhance technical skills
and develop competencies of personnel across
functions and levels. The training modules, designed
by ABB’s expert team of trainers with unparalleled
domain knowledge and experience, are structured
to provide in-depth information on ABB’s wide
range of products, systems and solutions for power
transmission and distribution including the latest
technological developments. The programme
curriculum addresses the needs of all levels of
management, engineers, supervisors, technicians
and operating personnel and creates opportunities
to learn, grow and reach higher performance levels
through knowledge empowerment.
Trainees will have access to world-class
infrastructure like sophisticated learning aids,
multimedia presentations, simulations and product
cut-outs, practice benches for hands-on training
and well-equipped class rooms with instant access
to ABB university e-learning modules.
Some of the chief benefits of the ABB training
programme are:
! Better return on training investment by
maximising productivity and performance
! Reduced life cycle costs thereby increasing
return on investment and return on assets
! Maintaining products and systems at a high level
of readiness, so as to minimise downtime and
mitigate the need for equipment repair
The training initiative is a major step in building on
the company’s long-term relationships with its
customers to provide them with effective and
customised solutions that address their specific
business needs. ABB’s training programme aims at
giving customers the knowledge advantage to
enable them to ‘power’ ahead and maintain their
leadership edge in their respective market space!
Maneja, Vadodara
Peenya, Bangalore
Nashik
CONTACT – The ABB India Magazine 9
CONTACT – The ABB India Magazine10
=
IndustrialIT
Technology Digest
Welcome to the world of
Compatible enterprisebuilding blocks
Through the broadest technology initiative in its
history, ABB is “information enabling” every
product – bundling documentation, configuration
and connectivity tools, life-cycle support, and more
in consistent electronic format.
Using patented ABB Aspect Object™ technology,
these electronic characteristics are built into a
powerful software shell which represents the
physical object in every sense. Simply copy and
paste the Aspect Object into your automation
platform, then point and click for faster installation,
operation and asset management!
! Consistent, electronic asset information in every
box
! Plug-and-Produce installation and integration of
enterprise objects
! Compatible ABB products for every
link in the enterprise value
chain
An open, enterprise-widearchitecture
Meet the ABB Aspect Integrator Platform™ – a
revolutionary, open architecture for managing and
optimising every link in the enterprise value chain.
This powerful Microsoft® Windows-based architecture
sets the standard for every Industrial IT product from
ABB and its partners. The Aspect Integrator allows
grouping of devices and their associated Aspect
Objects in easy-to-navigate structures tailored to the
needs of operations, maintenance or management
personnel. Real-time interaction between these
Industrial IT Enabled products means configuration,
operation and evaluation of each takes place within
the context of its larger system. The result: Fast
installation, logical navigation and more intuitive
enterprise management!
! Monitor, control, optimise and maintain from
one powerful, open platform
! Evaluate and deploy plant components - just
like browsing the files on your PC
! Attach data just once, for automatic installation
across multiple system structures
Imagine a business where your systems for power, automation, and information are
seamlessly integrated. Every component in the enterprise value chain has the built-in tools
necessary to install, operate, optimise and maintain across its total lifecycle. A compatible, open architecture
reaches from plant floor to top floor. Faster system design, deployment, asset management, optimisation and
collaboration are just a mouse click away.
CONTACT – The ABB India Magazine10
CONTACT – The ABB India Magazine 11
A personalised enterprise workspaceto fit each user’s responsibility!
Control LogicHierarchy
Physical LocationHierarchy
MaintenanceHierarchy
YourHierarchy
Asset information thatfollows the asset
Physical installation of system devices has long
been the easy part. The difficult part is collecting
the information to install, operate and maintain
each component – then keeping it up to date.
Industrial IT from ABB changes all this. No matter
where each real object – or its asset information –
is deployed, one “click” on the Aspect Object
opens the links necessary to configure, optimise,
analyse and influence the real object.
The list of dynamic device characteristics (Aspects)
begins with complete electronic documentation,
drawings and instructions. Depending on the
product and its level of Industrial IT Certification
additional Aspects may include integral
configuration and maintenance tools, control
faceplates and graphic symbols, communication
protocols, on-line service, and more. The result:
“Plug-and-Produce” installation, operation and
asset management – just a mouse click away from
each device!
Customising your view ofthe business
To help every user find and act on the right
information, ABB Aspect Objects may be organised
in a variety of logical structures. Depending on
your interest, these might relate to process flow,
control logic, physical location, maintenance status
or others. Regardless of the arrangement, each
Aspect Object maintains its dynamic links to the
real device and its associated information.
This capability allows creation of secure
“workspaces” for each type of user, accessing the
same portfolio of Aspect Objects through various
navigational options, shortcuts and favourites.
Imagine performing the following sequence for
any device with just a few clicks of a mouse...
! Search the object library for devices of desired
capacity
! Select the asset that meets your needs, then
copy and paste its Aspect Object into the
process flow
! Call up the device faceplate to configure
setpoints and communications
! Open a live video link or diagnostic tool and
admire your work!
Zoom in to any enterpriselevel for fast answers, action,or asset management!
CONTACT – The ABB India Magazine 11
CONTACT – The ABB India Magazine12
ProfileIT
DriveIT
MeasureIT
OptimizeIT
OptimizeIT
SustainIT
SupportIT
PlanIT
ProduceIT
AdviseIT
DriveIT
FieldIT
ControlIT
ProduceIT
ProcessIT
FulfillIT
RoboticsIT
ProcessIT
SimulateIT
MeasureIT
ProcessIT
ProduceIT
PowerIT
ProtectIT
InformIT
PowerIT
ProtectIT
CollaborateIT
EngineerIT
OperateIT
OptimizeIT
ControlIT
Compatibility across theenterprise value chain
The “Plug-and-Produce” ABB Industrial IT
architecture sets the stage for real-time interaction
across the enterprise value chain – from eBusiness
order input, to just-in-time procurement and
production, to logistics and distribution of highly-
customised end-products. Drawing from a vast library
of dynamic enterprise objects, the Industrial IT
architect deploys repeatable power and automation
scenarios to fit a wide variety of business objectives.
Just as one would browse the files in a PC directory,
the user navigates among multiple structures of
enterprise assets – assigning each to the most
productive and profitable task at hand!
! Faster systems engineering with compatible
Industrial IT building blocks
! Improved maintenance and asset management
within a logical systems hierarchy
! Intuitive access to just-in-time business analysis
and planning functions
! Reduced time-to-market through “copy and
paste” configuration of new systems
! Improved real-time plant information, for pass-
through to business IT systems
! Compatible information across the enterprise –
tailored to each job responsibility
ABB software tools forevaluation of processparameters, productquality, equipmentcondition monitoring, plusdiagnostics andrecommended actions.
AdviseIT
Systems and software formeasurement and analysisof product composition,including gas and liquidanalysis, spectrometry,chromatography andmore.
Software solutions toimprove interactionamong suppliers,manufacturers and endcustomers for maximumvalue in the eCommerceage.
CommunicateIT
Connectivity andnetworking tools to ensuregreater capacity, reliabilityand securityfor enterprisecommunications.
Monitoring and reportingsolutions to speedcompliance withqualitative regulatoryagencies such asenvironmental health andsafety.
ComplyITCollaborateITAnalyzeIT
FieldIT
Intelligent field devicesand software formeasurement oractuation, includingfieldbus-compliantcommunicationssolutions.
Financial services tosupport the procurementand lifecycle managementof Industrial IT systems orother business assets.
FinanceIT
CONTACT – The ABB India Magazine12
CONTACT – The ABB India Magazine 13
PlanIT
InformIT
ConsultIT
SupportIT
RoboticsIT
ProduceIT
FulfillIT
CollaborateIT
ConsultIT
FulfillIT
A diverse portfolio of ABBconsulting services to helpmake the most of humanresources, physicalassets and groupprocesses.
ConsultIT
ABB hardware, software,and systems for real-timecontrol, supervision andmanagement ofoperational variables.
Software and services tooptimise the designprocess for end products,primary equipment,process trains orcomplete manufacturingplants.
DriveIT
ABB motors, drives, andsoftware solutions toprovide and improve theefficiency of motion,torque, speed andposition.
Powerful ABB softwaretools for faster configura-tion of automationsystems and processequipment, includinggraphics, physical layoutand documentation.
EngineerITControlIT DesignIT
ABB sensors, scannersand imaging products tomonitor variables includingweb and sheetcharacteristics, force,torque, stress, proximity,voltage, and more.
MeasureIT
A compatible range ofmetering and remotereading solutions formeasurement ofelectricity, gas and waterconsumption.
ABB solutions andservices to optimiseproduct fulfillment, fromorder entry andproduction planningthrough logistics anddistribution.
InformIT
Data recording, tracking,integration, and historiansolutions for improvedenterprise information anddecision support.
Technologies to supportintegration or connectivityof multiple products orsystems, featuring theABB Aspect IntegratorPlatform.
IntegrateITMeterIT FulfillIT
ABB products andsolutions to supply,regulate, convert anddistribute electrical poweracross the full range ofvoltages and applications.
PowerIT
Value-added ABB tools forancillary processing of end-products or sub-productsthrough material handling,assembly, mixing, metal-working, finishing andmore.
Console, handheld, panel,and wireless solutions fordynamic, real-timeinteraction between plantsystems and humanoperators.
OptimizeIT
ABB software tools fortuning, tracking, andoptimising of automationand power systems, plantassets or end-productquality.
Software and services toimprove plant andbusiness efficiencythrough forecasting,capacity planning,scheduling and logistics.
PlanITProcessIT OperateIT
Source: ABB Review
CONTACT – The ABB India Magazine 13
CONTACT – The ABB India Magazine14
More options with ABB’s Industrial IT fABB embraced fieldbus technology from the
beginning and has made it an integral part of its
Industrial IT architecture. A complete fieldbus
automation solution is now available that fully
exploits the benefits of synergy between the fieldbus
and other key Industrial IT features. This solution
includes innovative products that offer customers
complete freedom when choosing communication
protocols, plus standardised engineering, high
system availability and asset optimisation. What is
more, it can be installed without risk in hazardous
areas.
Historically, communication between field
devices and a control system has been over
analog, 4–20 mA current loop interfaces. This
widely used technology works well and allows
accurate transmission of process variable
measurements as well as effective closed-loop
control.
Fieldbus technology, however, is digital. This
brings remarkable simplification to system
architectures, with a corresponding saving in field
cabling, equipment room layout, marshalling racks
and safety barriers. Further, when digital field
instruments are used, significantly more data
becomes available; ‘smart’ transmitters with
powerful microprocessors and memory chips,
manage valuable device configuration and status
information. Significant gains come from making
the data available to the automation system for
remote engineering and maintenance.
Technically Fieldbus is a digital, bi-directional,
multidrop communication system for instruments
and other plant automation equipment, put more
simply, a single-cable network that can replace
conventional means (eg, a 4–20 mA current loop)
of transporting data between field devices and a
control system. Devices which can be connected
to fieldbuses include flow, pressure, temperature
and level instruments, analysers, switchgear,
programmable logic controllers, process
controllers, remote I/O stations, drives, motors
and human-to-machine interfaces.
Fieldbus architectures consist of field instruments
connected to local, low-speed segments linked
together by a high-speed communication backbone.
Fieldbus communication is bi-directional over a
single cable, and a high-speed Ethernet-based
broadband network can easily accommodate
hundreds of devices at fast scan rates. The simpler
wiring and consequent saving in material and
installation costs, is obvious, at least in theory. So, in
practice, the number of low-speed segments needed
could be high, with each one requiring a linking
device, power supply, connectors, terminators, etc.
With traditional technology, each signal sent to the
hazardous area requires an IS barrier to filter out
dangerous current and voltage peaks. IS barriers are
usually located on the I/O marshalling racks in the
equipment room. The additional equipment
footprint required can be expensive.
Fieldbus I/O connections are made in software,
which eliminates marshalling panels altogether.
Additionally, only one IS barrier is required per
low-speed segment, so the number of IS barriers is
greatly reduced. A smaller footprint and less
material translate into a significant saving, and this
is confirmed by experience [1].
[1] Typical traditional automation architecture
Field devices connect to the marshalling racks and safety barriersover 4–20 mA current loop interfaces. Controllers then transferinputs/outputs to the Distributed Control System (DCS).
CONTACT – The ABB India Magazine14
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IT fieldbus solution
Remote engineeringThe greatest benefit of fieldbuses lies in theadditional data communication they makepossible – Reduced commissioning effort. Theadvantage of using fieldbuses is especiallynoticeable during commissioning. Instead of thetwo men (one in the control room and one in thefield) often needed to configure a loop intraditional systems, one engineer can single-handedly commission each loop. The saving intime and cost is dramatic, 10–15% having beenachieved in one application [2].
Single-loop integrityIn the early days of process automation, one fielddevice was connected to one controller and manysuch independent loops operated in parallel. Amajor advantage of this architecture was that afailure in one loop did not degrade others (‘single-loop integrity’). Distributed control systems laterconcentrated the I/Os and control functions intoever more powerful controllers and I/O modules.But this came at the expense of single-loopintegrity; failure of one component could nowimpact several loops and have a catastrophic effect
on operations, so expensive redundancy schemeshad to be incorporated into the architecture. Thefieldbus restores single-loop integrity.
The Foundation fieldbus protocol, for example,enables control functions to be distributed amongthe field devices. Peer-to-peer communicationbetween the devices ensures autonomy of thisfunction from the rest of the architecture.
Now, a control loop can be assigned to one low-speed segment, ensuring that it will keep runningeven if there is a failure somewhere in the rest of thenetwork. Additionally, the fieldbus checks the statusof the network elements. Failure of a component isimmediately detected and reported. Field devices canbe substituted on-line, without having to cut off thepower or interrupt normal network operation. TheHigh-Speed Ethernet components used in the fieldbusare mass produced and typically redundant andrugged; this drives down the cost of, and need for,redundant architectures.
The predicted saving is diminished by thelimitations in low-speed segment capacity, addedengineering complexity and extra demands madeon the hardware.
‘Smart’ devices contain valuable status andperformance information that cannot be accessed viaan analog link. When a fieldbus is used, thesevariables can be retrieved and a whole new world ofpossibilities opens up for predictive maintenance,advanced diagnostics and asset optimisation. Thefollowing two examples serve to illustrate this.
Fieldbus status signals allow operators to immediatelyidentify the malfunctioning device, obtain anindication of the cause and significantly acceleraterepair operations with on-line substitution.
When a fieldbus is installed, maintenance engineershave access to internal valve parameters, such as stemtotal travel length, number of strokes, total operatingtime, etc. These parameters are indicative of valveperformance and they can reveal degradation.Maintenance need now only be carried out whenrequired. This all adds up to less plant disruption andshorter downtime. Besides the lower maintenancecosts, there are big gains in plant availability, higherproduction and higher productivity.
[2] Fieldbus architecture
The controller (A) interfaces between the DCS and the fieldbus. Thefieldbus servicing the high-power devices (PLC, drives, analysers,MCC, safety, condition monitoring) is connected to the fieldbushandling the devices with lower power requirements (instruments,valves) via a linking device (B).
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ABB’s fieldbus solution has significantdifferentiating features
ABB saw the potential of the fieldbus for processautomation early on and soon began to participatein various fieldbus organisations, making significantcontributions to the technology specifications (HighSpeed Ethernet and Profibus) as well as playing aprominent role in the pilot tests.
ABB has made fieldbus technology a requirementfor its control products and offers a completefieldbus solution that fully leverages the innovativeaspects of Industrial IT, such as Object Aspects.
Indeed, fieldbus has been made an integral part ofthe ABB Industrial IT architecture. The ABBfieldbus solution has several key differentiatingfeatures, including the following.
ABB’s Control IT AC800 controllers acceptsimultaneous inputs from all these different protocols.The unique ABB Fieldbus Plug allows a product tobe simply and quickly connected to any bus.Selection of automation solutions is no longer subjectto protocol constraints; they are all accepted in theIndustrial IT architecture. The end-user is free tochoose the technology that best fits his requirements,regardless of the communication protocol.
Standardised engineering using AspectObjectsIn a typical process industries automation project, itis not unusual to find field devices from as many asfive or even ten different suppliers – each with aproprietary engineering tool. These have to be allmastered by the configuration engineer, a tedious,cumbersome and expensive process.
Here again, ABB leads the market with aninnovative solution: the Field Device Tool (FDT).The FDT is a software application, based onMicrosoft technology, that resides in the systemengineering tool and provides a standardisedengineering interface. Each device comes with asoftware ‘driver’ (Device Type Manager, DTM) thatwill be accepted by all FDT compliant engineeringtools. The device is then configured (eg, setting ofthe transmitter parameters) via a standard interface,irrespective of the device engineering environment.This makes engineering as simple as loading theprinter driver on a PC. ABB further exploits this
feature by making the DTM an Aspect of thedevice. ABB’s Industrial IT architecture then letsusers access the device configuration anywhere inthe system – a single mouse click is all that isneeded.
Secure communication
ABB also has some unique products that ensurecontinued communication should a networkcomponent fail:
The Redundancy Link Module (RLM01) duplicatesthe communication path over two redundant high-speed PROFIBUS DP segments, thereby ensuringcontinued communication in the case of failure inone line.
The Linking Device LD 800 connects the high andlow-speed segments. It offers I/O interfaceredundancy, whereby failure of one linkingmodule is automatically backed up and access tothe low-speed segments continues uninterrupted.
Increased capacity in hazardous areas
One of the unique devices offered by ABB is theMultibarrier MB204, a low-speed multiport junctionbox that provides spurs to four devices. It increasesthe capacity of a low-speed segment by up to afactor of four, while preventing short circuits in asingle spur from affecting the rest of the segment.
[3] ABB’s Industrial IT fieldbus solution lets end users selectautomation solutions without regard to the communication protocol,simplifies engineering, secures communication and supportsinstallation, operation and repair.
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Asset optimisation
The maintenance trigger is a system-residentsoftware that collects selected status inputs fromequipment and processes them in a predefinedmaintenance logic. All inputs are accessible,irrespective of their communication protocol. Uponreaching one of the predefined maintenanceconditions (for instance, a maximum number ofstrokes in a control valve), the trigger is activatedbefore the valve performance degrades. A faultreport is presented at the operator station and theoperator can send a maintenance work orderrequest to the Computer Managed MaintenanceSystem (CMMS). Root cause analysis is greatlyfacilitated by a detailed audit trail giving thecomplete device event history while repair,installation and operation are supported byextensive electronic documentation.
Mysore Paper Mills Ltd
Industrial IT Quality Control System (QCS), Measure IT ScanningPlatform SP700 with basis weight, moisture and caliper measurements, aswell as a Profile IT Calender Profiler to be installed on the third papermachine (PM3) of the mill. ABB will also provide engineering,commissioning and training.
ONGC’s WIN – Northern offshore fields fire and gas systemto be upgraded to SafeGuard Industrial IT platform
ABB will upgrade the existing fire and gas safety
system for Oil & Natural Gas Corporation Limited
(ONGC) to the SafeGuard Industrial IT platform
for their WIN-Northern offshore fields at Mumbai.
This follows a similar fire and gas safety system
revamp by ABB for ONGC BHN Platform.
“The BHN Platform revamping job was the first
of this nature and magnitude executed by an
Indian Company,” said Vijoy Kumar, DGM
(E&T) at ONGC. “We appreciate the effort put
in by the ABB team to complete this project
well in time.”
ABB’s offering for the
WIN Project includes
fire, gas, smoke and
heat detectors in
addition to a TUV AK-6 (SIL-3) certified dual
modular redundant SafeGuard PLC-based fire
and gas system with Operate IT operator
stations. ABB’s scope of supply also includes
surveying of the existing facilities at the
platform along with the design engineering of
the entire fire and gas system.
Some recent Industrial IT applications in India
All these features are Industrial IT Object Aspects,accessible by a mouse click. Further, a CMMSresident Maintenance Order Manager helps track theWork Order through scheduling, resource allocation,execution and closure. Spare parts inventorymanagement and automatic web-based partspurchasing can also be incorporated, depending onthe sophistication of the CMMS package. Provisionsare also made for interfacing to established CMMSpackages, such as PSDI Maximo, IFS and SAP.
ABB has fully embraced this technology, embeddingit in the ABB Industrial IT architecture and making ita prime feature of its control products. Fieldbustechnology will continue to evolve and ABB willcontinue to exploit the synergy between it andIndustrial IT to bring exciting products that make lifeeasier for everyone.
Source: ABB Review
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Exploring the value of
products from ABBImagine a situation where the main circuit breaker
in your company’s distribution station has tripped
and there is no power for your machines.
Production has ground to a standstill. Neither
automatic nor remote manual reset works. You’ve
got just 15 minutes before your financial baseline is
affected. The technician you dispatch to the station
regrets, but he hasn’t trained on this type of circuit
breaker. The only person who really knows this
particular breaker is off-duty, and the manuals are
locked in his office.
Enter Industrial IT
Fortunately, there’s a
better way to run a
business – and avoid
the nightmare
described above.
Look again. You’re in
luck. Your circuit
breaker is Industrial
IT Enabled and
certified, like all other
enabled products, to
carry electronic documentation as an integral part
of it. No need to look in a separate system, or for a
locked-up binder. And there’s no more reliance on
that key information that your chief engineer – and
only he – carries around in his head.
Thanks to Industrial IT, all the documentation and
drawings you need are at your fingertips. And not
only now. Any time, from purchasing to the breaker’s
ultimate de-installation, the essential information you
require is made immediately available.
This is what the ABB certification programme
called Industrial IT enabling is all about – ensuring
that every Industrial IT Enabled product supports
and adds value to its key lifecycle processes.
Enabled breaker – Empowered technician.
Returning to the industrial crisis described at the
beginning, what would our technician have done
with an Industrial IT Enabled circuit breaker?
First, he would have clicked on the breaker icon on
his plant overview – opening up all the
documentation and drawings, plus a technical
reference manual. Looking at these, he would see
that the rod that moves the auxiliary switches was
deformed, probably concluding that it had
happened during a violent storm the day before. As
a temporary measure, he might quickly fabricate a
makeshift rod from some spare metal lying around
his office, getting the plant back on line in five
minutes. And just another five minutes is all he
would need to order a replacement part from the
supplier via the eCommerce web link built into the
documentation. A plant back on line and a problem
solved ... thanks to an Industrial IT Enabled product.
And some ingenuity on the part of the technician.
PS1 modular substation. ABB has developed a comprehensiveproduct information environment for this substation, comprisinga complete Industrial IT based model with all the documentationembedded in a collection of Aspect Objects.
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ABB India Automation Division hosted a three day
conference from 20th - 22nd Feb, 2003 in
Bangalore, for large and medium size end user
customers titled Productivity Enhancement
through Automation, The Industrial IT way. The
aim of the conference was to increase awareness
of ABB’s Industrial IT initiative alongwith the
product and solution offering with emphasis on
how Industrial IT can help enhance productivity
and efficiency, thereby making customers more
competitive.
The conference was attended by over 90
customers across India representing companies
from a wide range of sectors, including Cement,
Metals and Mining Oil, Gas & Petrochemicals,
Refining, Pharmaceuticals, Pulp, Paper, among
others. It provided an ideal platform for
showcasing ABB’s Industrial IT portfolio through
presentations, customised breakout sessions,
videos, posters and kiosks. The main focus of the
conference was on explaining the concept, uses &
benefits of Industrial IT for the industry at large.
More than 10 experts representing the ABB Group
from various centres of excellence made
presentations on technological developments and
were extremely well received by customers across
the spectrum.
One senior customer from Tata Iron & Steel
Company (TISCO) commented: “Nowadays we
don’t get many opportunities to see new
technologies all under one roof in a forum such
as this. We are extremely delighted to see ABB’s
vast product and solution offering for its
customers in India, especially, the technical
advances made possible using the IndustrialIT
platform.”
These sentiments were reaffirmed by another
customer who remarked, “I am delighted to see
the technological capabilities of ABB. I never
imagined that the portfolio was so vast. I am sure
that by using ABB’s Industrial IT platform, we canovercome the biggest paradox we face as
customers - The push for standardisation coupled
with the ever growing need for technological
upgradation.”
On the final day of the conference, customers
were invited to see live product and solution
demonstrations at ABB’s Peenya manufacturing
facility at Bangalore. Customers evinced keen
interest in the products & solutions on display,
such as Operate IT, Knowledge Manager, Pocket
Portal, Process Portal, AC450 RMCs, 800 M,
Control Valves, Instrumentation products and
Robotics. They showed keen interest in energy
saving possibilities with AC Drives.
Johan Bjorklund from ABB Singapore, one of thepresenters, observed, “Customers liked the variousproducts range and demos that they could have afirst-hand look. The interactive sessions enthusedcustomers and they look forward to exploring thepossibility of implementing Industrial IT solutionsin their plants. The end-users’ perspective of theirneeds and expectations from automation vendorsgave us an insight into how customers perceiveautomation today and how they would like tohave it in the future.”
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Channel LineABB India’s B2B portal crosses Rs. 120 millionmark during first 6 months of operation
Channel partners who deal with ABB’s wide range
of automation technology standard products (like
LV products, electric motors and machines, drives
and control automation products) all have one
answer about ABB’s B2B portal – “Fantastic!”
Over 300 trained Channel partners have been
accessing the site since June 2002, placing and
tracking orders, looking at inventory levels,
viewing receivables status and lots more - all in
real time, thanks to the full integration of the portal
with the ERP system. With total transparency,
privacy and security built into this B2B portal,
orders over Rs. 120 million have already been
logged in - opening a whole new way of doing
business.
Before the launch of the portal, business was
conducted in a highly conventional manner –
Channel partners created their offer along with
sales engineers, who would further clear them with
their managers. After getting the consent, channel
partners would place their orders, often through
the sales engineer responsible, who would then
feed the order into the ERP system. All enquiries
related to the availability of stock, delivery period,
receivables and other transaction details were
earlier routed through sales engineers, losing
valuable time and hampering speed of response.
“This initiative is aimed at reducing the
order to delivery time for automation
product lines. In addition, apart from
keeping channel partners abreast with
latest developments in the company, it
allows them to directly create offers, place
and track their order & payment status as
well as view inventories and swap or sell
inventories between themselves.”
Subir PalHead – Channel Management,
Automation Technologies
“This is an incredible tool, we can now
directly see the availability of stocks, create
our own enquiries and place as well as
track our orders through the Net. This
system has helped us cut through put time
between placing of an order to the delivery
of products. When stocks are not available
in the company, we now have an option to
pick the required stocks from one of the
other channel partners who have opted to
display their inventory on the site. We are
excited by the various prospects available to
us through this site.”
Mr. Agarwal – ABB channel partner
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ABB and SustainabilityRain water harvesting
ABB’s Peenya facility has taken a
major step forward in water
conservation through the
process of rain water harvesting.
Simply put, this involves
collecting and utilising rain
water, water flowing out of
drains, overhead pipes and other
such sources, which are
generally ignored leading to
tremendous wastage of this
precious resource.
Being a company with a strong sense of social
responsibility, ABB has always been very active in
fulfilling its commitment to the communities in
which it operates. As part of its sustainability
initiatives, ABB’s Peenya unit in conjunction with
the HOPE foundation runs a weekly health
programme in the village of Nelagadaranahalli,
located at the outskirts of the factory. This
programme provides free weekly medical
consultation to the inhabitants of the village. Apart
from dispensing medicines, qualified doctors also
address other health issues like immunisation,
cataract operations and tuberculosis awareness.
The popularity of this health camp has spread far
and wide with villagers travelling miles to avail of
its services. The doctors and nurses treat about 150
patients on each weekly visit. It is heartening to
see so many people of all ages gathering there to
seek medical attention. This is only the beginning.
A ray of hope
Villagers attending the health camp
To ensure that the project runs
smoothly, the team responsible
for implementing the scheme
first conducted a feasibility
survey which involved
identifying collection points
from where water could be
easily collected during rains. The
other collection points included
tapping rain water from roofs
and roads, spots marked around
wells and bore wells. In total,
5 main collection pits were
made with 3 subsidiary pits.
The whole exercise proved to be
a big success as during periods
of heavy rainfall a minimum of
1.5 lakh ltr of water is collected,
which is used for watering the
gardens at the Peenya facility for
at least 10 days. These efforts
have therefore resulted inconserving water and preserving
nature at large.
Novel methods of water conservation at ABB’s Peenya facility
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You Ask – We AnswerQ
&A
Q. We would like to know
when the entire range of
MCBs and RCDs along
with distribution boards
will be launched
– Nikhil Oza, Santosh Agencies, Hubli
We will be launching these
in the 2nd quarter of 2003
nationwide in a phased
manner. A brochure for the
same is available with our
channel partners.
Q. Can you share with
us the basics and
fundamentals of HVDC
transmission and
distribution?
– PK Jain, VP, Aarti Steels Ltd., Ludhiana
to-Point, back-to-back and
multi-terminal systems.
The development of HVDC
technology dates back to the
late 1920s with the first
commercial line operational
in 1954. Significant
improvements in HVDC
technology came around
1970 – one of the more
recent being HVDC
convertor and DC cable
technology called HVDC
light - from ABB! In India
ABB has already
implemented three HVDC
projects – Vindhyachal back-
to-back – Interconnecting the
Northern and Western
regions, Rihand-Dadri and
Chandrapur-Padghe bipole
long-distance transmission
links located in the north and
west respectively.
Q. What is a residual
current operated device?
Where are they used?
– LJ Joseph, Exec. Engineer, TNEB, Chennai
In electrical
installations
where neutral
connections
are commonly
used, there are
occasions
when the current flows from
the line conductor to earth
and hence back to the current
source. Such currents are
usually caused by some kind
of defects and are termed as
earth fault current. There is
nothing to prevent an earth
fault from occurring. However,
such faults can be quickly
isolated if Residual Current-
operated Devices like RCCBs
& RCBOs are installed. The
ABB range of RCCBs makes
use of the well proven
principle of utilising core
balance transformers with
permanent magnet trip
devices. They are able to
detect earth fault current and
disconnect at the shortest time.
RCCBs are commonly used for
protection against electric
shock on account of direct
contact with live parts and
current flows through the
body that has to be
disconnected at the shortest
time or in the event of touch
voltage being too high for the
body in contact with exposed
metal parts, protection against
fire hazards and against the
occurrence of electrically
ignited fire due to earth fault
current.
Q. Is there any test for
assessing the life of
clophen (askaryl) filled
transformers? Can ABB
retrofit clophen Trafo with
oil-filled Trafo?
Mohan Jha, DGM (Elec) Hindustan Paper
Corpn. Ltd., Assam.
– We have no test for
assessing the life of clophen
(askaryl) filled transformers
and ABB has not started to
retrofit clophen Trafo with
oil-filled Trafo.
HVDC stands for High
Voltage Direct Current and is
today a well proven
technology used to transmit
electricity over long distances
by overhead transmission
lines or submarine cables. It
is also used to interconnect
separate power systems,
where traditional AC
connections can not be used.
There are different types of
HVDC transmission – Point-
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Communicating...
As always we have endeavoured to bring you the latest in technology development at ABB. Thisissue is dedicated to Industrial IT, which is ABB’s common technology platform aimed at makingcustomers more efficient and competitive by empowering them with real-time seamlesslyintegrated information. We hope you found this issue interesting and look forward to yourfeedback in ensuring that we remain in CONTACT.
Harmeet S. BawaHead GF-Corporate Communications, India
Power Technology Products Brochures Industrial IT Brochure Power Technologies Training Programme Folder
Corporate posters Wind power poster STATCON poster
CONTACT – The ABB India Magazine 23
www.abb.com/in
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