issue 3 / 2003 the abb india magazine · 2018-05-10 · hindustan zinc limited (hzl) in chanderia,...

Issue 3 / 2003

The ABB India Magazine

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CONTACTEditorial Team: Harmeet S Bawa, Vikram V Kanth, Namita Asnani,Pavithra Noel.

ABB Limited, GF-Corporate Communications, IndiaKhanija Bhavan, 2nd Floor, East Wing,49, Race Course Road, Bangalore - 560 001.

All trademarks acknowledged.Design: Shilahar Associates, Bangalore. www.abb.com/in

Issue 3 / 2003India Round-up

Dinesh Paliwal – A global perspective4

ABB India bags breakthrough export orders5for automation solutions

Sterlite Group opts for ABB’s state-of-the-art rectifier systems6Largest single drive system in India for Tata Steel

Indian Oil opts for ABB’s advanced automation solutions7

90 days to upgrade!

Rubber Mixer AC Drive System for Apollo Tyres – another first!8

New speed measurement system for slip-ring motors

TNPL – beyond ‘paper’ efficiency 9New life-cycle software for pulp & paper industry

Tata Steel and ABB – the partnership grows from 10‘strength to strength’

Q & A with Biplab Majumder 12

REL taps ABB’s domain expertise for improving 13power distribution in DelhiABB to execute Power Grid order in record time

Global Round-up

Lighting up Los Angeles 14

ABB’s quick response helps restore power in Rochester 14

Em‘Power’ing China 15Believe it or not!

Technology Digest

Winning the battle with downtime 16PsGuardTM – a protection and optimisation solution

Living our commitment to Sustainability 20

Channel Line21

Q&A22

Dear Friends,

In a fast moving, complex and increasingly

competitive business environment, it is not enough

to be ‘good’ or even ‘good enough’ – companies

need to exceed stakeholder expectations and

constantly strive to be better than the best! In order

to compete in an increasingly globalised market,

the Indian industry is making the transition from

a “chalta hai” mindset to an attitude of being

“truly world-class”. In this quest, it is important to

remember that it is no longer enough to “work hard” – we must also learn to “work smart”!

Technology and innovation have a key role to play in this journey and will be the key

differentiators between the ‘winners’ and the ‘also rans’. Some of the key drivers for businesses

to remain contemporary and relevant for the future, are efficiency and productivity, quality,

real-time integration of systems and information and asset optimisation. Processes across many

industries are already becoming less labour-intensive and more technology-driven, as we

realise and leverage automation for greater efficiency, productivity, quality and consistency.

For over 100 years, ABB has led the industry with state-of-the-art technologies and innovative

solutions. With IndustrialIT, ABB is now leading the industry into the ‘next way of thinking’ –

seamless integration of business and manufacturing processes in real time! Our customers

have always reposed their faith in ABB’s technologies and domain expertise and we look

forward to their ongoing trust and support. We, on our part, remain committed to continue

making our customers increasingly competitive by bringing them the latest technologies

through constant R&D and technology innovation.

In this issue of CONTACT, we focus on Automation Technologies. ABB Automation

Technologies offer a wide range of products, systems and services, based on cutting-edge

technologies, unparalleled domain expertise and global experience to deliver solutions for

control, motion, protection and plant integration across the spectrum of manufacturing,

process, consumer and utility industries. The standard product offering includes AC & DC

Drives, Motors, PLCs, Instrumentation, Controls & Analytics, Force Measurement Relays and

Low Voltage Products.

I hope you find this issue of CONTACT interesting and informative and we look forward to your

ongoing support, encouragement and feedback.

Yours sincerely,

Ravi UppalVice Chairman & Managing Director, ABB India

CONTACT – The ABB India Magazine 3

CONTACT – The ABB India Magazine4

On industrial trends...

As the world becomesincreasingly global andnetworked, attaining andretaining competitive advantageis becoming a greaterchallenge. Most industries haverealised that efficiency andproductivity are critical in thisendeavour. Labour and capitalare giving way to knowledgeand technology as the mainfacilitators. Manufacturingoperations are getting smarterand ever more integrated withthe business as a whole,entering the CEO’s domain!

In fact, automation technologiesare playing a key role inhelping operations becomeincreasingly productive,efficient and competitive acrossthe industry and geographicalspectrum. This has been myobservation across the worldand I believe it is relevant inIndia as anywhere else.

On technology & IndustrialIT...

ABB is a technologytrendsetter with an extremelyhigh intensity of innovation anda rich R&D pipeline.IndustrialIT is a commontechnology platform acrossABB. Simply put, IndustrialIT

is the enabler connecting themanufacturing world to thebusiness world, seamlessly andin real time. This facilitates‘shop-floor to top-floor’connectivity across a global

network of plants to enhancebusiness visibility, decision-making and financialperformance.

IndustrialIT is not just a newname for Distributed ControlSystems (DCS). It encompassesdesign, documentation,integration and connectivityand this common architectureapplies to products, systemsand services, both in powerand automation technologies.IndustrialIT is based on anopen architecture, “plug andproduce” philosophy, plusscalable product andapplication suites. IndustrialIT

is a key differentiator for ABB,and will play an important rolein reshaping manufacturingprocesses across industries.

On global manufacturingand focused factories…

We are focusing ourmanufacturing bases in countrieswhere we find the highestproductivity. This does notnecessarily mean just low costbut overall competitiveadvantage. ABB operates inaround 100 countries and ouraim is to optimise our globalpresence. Countries like Chinaand India have a key role toplay in this quest. We alreadyhave two focused factories inIndia - Vadodara and Nashik.We are moving away from theMade in India, Made in Chinaideology to Made by ABB, and

In his capacity as Head – Automation Technologies Division worldwide and member of theExecutive Committee, ABB Group, Dinesh Paliwal travels the world and meets customers acrossthe industry spectrum, understanding their business needs, sharing technology trends anddeveloping solutions through a collaborative approach.

As a member of ABB India’s Board of Directors, he recently visited India and we spoke to him ona variety of subjects. Here are a few excerpts…

Dinesh Paliwal – A global perspectiveIndia Round-up


ABB India has recently been awarded exportorders to provide automation solutions forsteel and cement plants located in China,Morocco, Turkey and Bangladesh. The scopeof these orders encompasses design, supply,erection, commissioning and service of Drives,Automation systems, Controls and Electrics forsteel and cement processing lines.

Commenting on the orders, Biplab Majumder,Head - Automation Technologies Division, ABBIndia, said: “These orders further reinforce ABBIndia’s strategic thrust on exports. Our solutionsare aimed at increasing efficiency and productivityat the above plants, thereby making our customersmore competitive in an increasingly networkedand globalised world.”

ABB is the technology leader for state-of-the-artautomation solutions and has unparalleled domainexpertise in the metals and cement industry acrossthe world. In line with ABB’s global optimisationphilosophy and the growing role of the Indianoperations, ABB India has been designated as theRegional Centre of Excellence for metals andcement across Asia in order to leverage the highcalibre of technical competence, domainexpertise, vast experience base and competitivemanufacturing presence.

ABB India recently commissioned the AutomaticGauge Control (AGC) revamp of the Davyreducing mill at Yieh Loong Enterprise Co. Ltd.,Taiwan. The scope of this cold rolling mill orderincluded a Level 1 Automation system, operatorstations & control desks and a Statistical ProcessControl system.

As part of Asia Metals, ABB India designed,engineered, supplied and supervised the erectionand commissioning of the reducing mill. Asia Metalsis an ABB Centre of Excellence, which is at thecentre of the fastest growing steel market in theworld. The Centre specialises in developing metalprocessing lines technologies for global usage.

our customers are starting to see the value ofglobal factories since they are assured of ABBquality and technology. Only a few years ago, itwas difficult trying to convince Indian orChinese customers to buy products made in theirown countries – so we have come a long way!

On working with customers…

I firmly believe that the success of anyorganisation depends largely on how closely itworks with our customers. I personally setaside time for meeting customers regularly,whether at home or during my travels. In fact,we need to go further. Some of our customers’customers are thinking even one step aheadof them, and we would like to bring that inputinto our offering. I will give you an example -the movies Mummy and Tomb Raider bothused ABB motors as part of their specialeffects’ systems. We worked with the filmproducers to find out what was most importantfor them in purchasing motors. They saidnoise reduction! So we concentrated onproviding them with the quietest motors!

On ABB India…

ABB has a long-standing and strong presencein India with extensive manufacturingoperations, and a very competentmanagement team. The workforce here ishighly committed with strong domaincompetence, technical expertise and a vastexperience base. Over the last couple ofyears, ABB India has embarked on anaccelerated growth path and today it is one ofour fastest growing operations in the Group.Customer confidence continues to be strong,and our visibility in India is high. Our Indianlisted stock has consistently beenoutperforming the market.

Our operations here have seen improvedproductivity and operational efficiencies, soundfinancial management, progressive HRinitiatives, IT assimilation, social and communityefforts and enhanced brand visibility. Besidesbeing a promising domestic market, where weare well positioned as market leaders both inpower and automation technologies, ABB Indiais also playing an increased regional and globalrole - be it in the form of projects, products,services and even in our global R&Dprogramme. I see the Indian operationscontinuing to grow from strength to strength.

ABB India bagsbreakthrough exportorders for automationsolutions

ABB India bagsbreakthrough exportorders for automationsolutions

The Sterlite Group has placedorders with ABB India to supplystate-of-the-art rectifier systemsfor their smelters at BharatAluminium Co. Ltd (BALCO),Korba in Chattisgarh andHindustan Zinc Limited (HZL) inChanderia, Rajasthan.

ABB will design, manufacture,supply, install and commissionthe entire system for BALCO’s2,45,000 tpa expansion projectat Korba. The rectifier systemwill form the heart of thesmelter used for the electrolyticextraction of primary aluminiumin the potlines. ABB will alsoupgrade the control systems forthe plant’s existing potlines.

As part of its 1,70,000 tpa zincsmelter expansion at Chanderia,Sterlite has once again reposed

Sterlite Group opts for ABB’sstate-of-the-art rectifier systems

ABB will supply a Variable Frequency Drive

(VFD) system for Tata Steel’s new sinter

plant # 3, part of their 1 mtpa expansion

project at Jamshedpur. This will be the single

largest drive system supplied in India.

The contract awarded through L&T includes

supply of 33 kV Vacuum Circuit Breakers,

8.4 MW synchronous motor, a Load Commutated

Inverter (LCI) drive, converter transformer,

Programmable Logic Controllers (PLCs) and other

auxiliaries.

Tata Steel will reap the benefits of higher energy

saving and reduced stress on mechanical

equipment resulting in longer operational life.

Largest single drive system inIndia for Tata Steel


its faith in ABB’s rectifiersystems. The scope of thisproject includes design,manufacture, supply, installationand commissioning of rectifiersystems, for electrolysis in thezinc smelter. The zinc smelterbeing set up is consideredamongst the largest in theworld.

Commenting on the projectsBiplab Majumder, Head –Automation TechnologiesDivision, ABB India, said: “ABBis a global leader in rectifiertechnology with systemsespecially designed to ensurethe highest standards ofreliability and efficiency forsmelters which operate round-the-clock. ABB’s unparalleleddomain expertise in the metals’industry, worldwide experienceand comprehensive productoffering have helped us insecuring these orders. This is agood example of how ABB isleveraging its global technologyadvantage and strong localpresence to help customers likeBALCO and Hindustan Zincoptimise their plant capacitiesand maximise efficiency.”

Indian Oil (IOCL), India’s largest oil company hasentrusted ABB India with the responsibility ofimplementing an Open Control System (OCS) withfield equipment for the Fuel Cracker Complexplant, at its Mathura refinery. The turnkey orderincludes the design, engineering, supply andinstallation of the system which is based on anIndustrialIT platform, to enable seamless real-timeintegration.

IOCL has also chosen ABB for upgrading theHuman Machine Interface (HMI) of the power plantcontrol system at their Noonmati refinery inGuwahati. This cost-effective upgrade will not onlyimprove the efficiency of the power plant but alsominimise maintenance costs and reduce downtime.

IOCL, a Fortune 500 organisation, is the country’sflagship oil company and a technology trendsetter.

Indian Oil opts for ABB’sadvanced automation solutions

ABB has partnered IOCL on numerous occasionswith state-of-the-art automation and controlsolutions at many of its installations.

ABB has successfully upgraded the existingMOD 300 Control System to an AdvantTM basedDistributed Control system (DCS) at NagarjunaFertilizers and Chemicals Limited (NFCL) Plant-1at Kakinada, Andhra Pradesh in a record 90 days!NFCL’s Plant-1 has a production capacity of950 tpd of ammonia and 1,650 tpd of urea.

ABB’s scope included design, engineering, supply,testing, FAT, erection, commissioning and SAT.ABB will also centralise the ammonia and ureacontrols by bringing them under a single umbrella.

90 days to upgrade!


The new system will offer:

Enhanced security

Advanced control features

Higher I/O handling capability

Improved reliability and availability in hardwareand communication redundancy

User-friendly, multi-window environment

Enhanced alarm management system


Apollo Tyres Ltd has commissioned ABBIndia to install a Medium Voltage AC drivesystem for their banbury (rubber) mixer,as part of the company’s expansionproject at Limda, Vadodara.

This will be the first AC drive system installation inthe Indian tyre industry for a rubber mixer.Traditionally, tyre manufacturers have been usingDC drive systems for such applications. However,Apollo Tyres was convinced of the efficiencybenefits of switching to AC drivesystems. As one of India’s fastestgrowing tyre manufacturers, Apollois known for its quality focus andbelief in innovativetechnologies for itsmanufacturing processes.

The scope of supplyincludes an ACS1000medium voltage AC

Rubber Mixer AC Drive System forApollo Tyres – another first!

drive for the mixer, a 1500 kW motor and aconverter transformer. The Direct Torque

Control (DTC) technology based AC drivesystem will help improve the powerfactor, reduce harmonics in the supply

network and enhance productivity and efficiency.Accurate speed control, low maintenance costs andreduced noise levels are Apollo’s other benefits.This IndustrialIT enabled drive will also allowconnectivity to the plant level automation systemthrough Profibus DP, enabling seamless plant

operations, control andmonitoring. ABB is thepreferred supplier andmarket leader for mediumvoltage drives in Indiabased on its superiortechnology, strong localpresence and well-acknowledged service andsupport.

New speed measurement system forslip-ring motors – greater dependability and accuracy

ABB has developed and patented anew system for measuring the speedof slip-ring motors that overcomesshortcomings of other traditionalmethods like tachometers andencoders that are difficult to install andcommission. The new technology isbased on the concept of measuring the frequencyof the rotor rather than using an electromechanicaldevice to directly determinethe speed of AC motors.The system includes a signalprocessor to suppress noiseand power semiconductorharmonics in the measuredvoltage signal prior to thecalculations. It also

transforms and filters the analoguesignal input. In addition, the signalprocessor includes an A/D converterto give a digital signal output.A mathematical algorithm is used inthe calculation unit to determine thevoltage frequency, slip and rotor

speed. A microprocessor enables calculation andother functions. The unit has a robust design with

no additional movable parts.With the introduction of sucha system, AC drives withslip-ring motors and theASTAT control system willprovide more accurate anddependable control of theload.


Tamil Nadu Newsprint Limited (TNPL), consideredthe largest producer of bagasse-based paper in theworld, has partnered with ABB to rebuild its PaperMachines (PM) 1 and 2 at its Kagithapuram plantin Pugalur, Tamil Nadu.

TNPL currently produces 1,80,000 tpa of newsprint,printing and writing paper primarily using bagasse,a renewable raw material. TNPL required an onlineprocess control system and an AC drive system foruniformity and consistency in the quality of itsproducts. With this in mind, the company investedin rebuilding its machines. ABB supplied anIndustrialIT based Distribution Control System alongwith ACS 600 sectional drives for PM 1. TheOperateIT automation solution from the IndustrialIT

stable enables dynamic real-time interactionbetween the operators and the plant systems.

TNPL – beyond ‘paper’ efficiency

In addition, ABB added new drives to the existingDC sectional drives in PM 2. A colour sensor wasalso added to the existing ABB Quality ControlSystem. ABB’s offering will serve as an integratedsolution to save energy, reduce maintenance andrunning costs, decrease downtime and ultimatelyimprove the productivity and efficiency of thepaper machines.

ABB’s new comprehensive life-cycle management software –StepUp and SoftCare will offerits pulp and paper customersmore flexibility for qualitycontrol while increasing thereturn on assets.

Life-cycle management is anoffering that keeps complexsoftware and hardware systemsup-to-date with rapidlychanging technologies. Insteadof letting the system age forseveral years before a costlyand risky upgrade is made, thisprogramme is designed toupdate the system inincremental steps for a fixedannual fee.

The StepUp programme updatesa customer’s existing solution toan IndustrialIT enabled solution.

New life-cycle software for pulp & paperindustry

IndustrialIT is ABB’s patentedconcept for linking products andsystems together with theinformation needed to run,monitor and maintain them.

Once the solution is updated tothe IndustrialIT platform, thecustomer can subscribe to theSoftCare programme thatcontinuously updates theirexisting solution. SoftCare offersthe combined benefits of atraditional upgrade programmeand web-based software support,

enabling customers to keep upwith changing industry standards.It includes new elements such asonline licence administration ordownloads of software revisions.

SoftCare protects the value ofour customers’ existing softwareinvestments by keeping themupdated on the latest industrystandards and customers will beable to maintain theircompetitiveness and rapidlyrespond to changing businessand technology environments.


ABB is recognised as the domain expert andpreferred partner by the metals’ industry and hasbeen providing leading-edge technologies, innovativesolutions, products and services across the world, be itfor ferrous or non-ferrous metals and even mineralindustries. With years of experience, thoroughknowledge and understanding of processes, ABBoffers complete solutions for electrification,automation, drives, process control and optimisationto make customers more competitive and help themreduce downtime, increase productivity and lowerenvironmental impact.

Tata Steel and ABB– the partnership grows from ‘strength to strength’

ABB has some of the biggest global names to itscredit - Ningbo Baoxin Stainless Steel Company inChina, Posco Co. in Pohang, South Korea and USSteel Co. in Koöice, Slovakia. ABB has alsopartnered with all the major Indian steelmanufacturers like Tata Steel, SAIL, JVSL andEssar, to name a few.

Tata Steel, the largest private steel producer in thecountry and one of the world’s lowest costproducers of steel has been reposing its trust inABB’s technology for decades. At Tata Steel’sstate-of-the-art steel manufacturing facility inJamshedpur, ABB has been involved in severalareas of its manufacturing process that include theContinuous Galvanising Line (CGL 1), Pickling andTandem Cold Mill (PLTCM), Recoiling Line(RCL-3), Electrolytic Cleaning Line (ECL), etc.

The Continuous Galvanising Line at Tata Steel’sJamshedpur facility is considered the most advancedgalvanising line built in India for production ofgalvanised strips. It incorporates the latesttechnology in AC drives, motors, instrumentation,automation and control – all designed, engineered,supplied and commissioned by ABB.

ABB has also implemented a complete DriveControl & Automation system for the RecoilingLine with Tension levelling and Trimming modesof operation along with automatic line operationfrom coil receiving at entry side to coil marking,

CGL-1: Technical data

Strip width: 800-1050 mm

Strip thickness: 0.18-0.8 mm

Line speed- process: 120 m/min

Entry and exit: 130m/min

Production capacity: 22.2 t/hr based onreference strip size of 0.38m x 1020 at 120 m/min,1000,000 t/year

Coating thickness: 60-400 gm/m2 (both sides)

Main features

Master Speed Control for the entire line

Tension control for pay-off reel, loopers, bridlesand recoiler

Entry/exit looper and synchronisation control

Generation of set points from look-up tables

All sequencing, interlocking and switching

Acquisition of actual technical data on processand equipment

Furnace closed loop controls andinstrumentation

Auto slow down of weld seam at shear, autodeceleration at coil end

Centralised supervisory and monitoring controland machine diagnostics

Fault/event logging production logs, reports, linestoppage information


motors, harmonic filters, a Static Var Compensation(SVC) system and SF6 circuit breakers.

ABB is implementing a complete Drive Control &Automation system for the Electrolytic CleaningLine including automatic line operation from coilreceiving at entry side to coil marking, weighingand taping at the exit side.

Cranes Controls for handling the billets/coils is yetanother area where ABB is working with TataSteel. The entire state-of-the-art Cold Roll Mill(CRM) complex is being driven with the help ofABB crane control drives, ACC600 drives for LT/CT motion and DARA 1000 drives for the hoistapplications. ABB has delivered a complete laserbased crane positioning system to locate andarrange the coil matrix in CRM complex. ABB’sAC drives are not only helping Tata Steel reduceenergy consumption but are also being used inprocess improvement for the HSM furnace bloweras a means to upgrade the furnace capacity.

ABB’s mission is to make its customers morecompetitive through enhanced productivityand efficiency. Companies like Tata Steel havecontinued to repose their faith in ABB’sinnovative, cutting-edge technologies over theyears. It is this common vision that is helping thepartnership grow from ‘strength to strength’ !

weighing and taping at the exit side. To meet thehigh standards for Line Automation, no less than28 different auto-sequences have beenincorporated for automatic line operation withminimum operator intervention. Co-ordinatedDrive Controls help attain a flutter-free lineoperation, perfect Tension levelling with stringentelongation control and closed loop tension controlswith very little tolerance. ABB has also installed astate-of-the-art system for logging surface defectsused in the manufacture of high quality steel forthe automotive and white goods industries.

ABB has carried out complete design,manufacturing, erection, commissioning andtesting of the 33 KV to 415 V power distributionsystems for the Pickling and Tandem Cold Millline including a substation automation system forcontrol and monitoring, as well as auxiliary drives/

Scope of supply for RCL-3

AC Multidrives

Level I and Level II automation

Coil Inspection & Defect logging system

Width Gauge and Thickness Gauge

Field devices

CCTV and Radio Communication system

Communication with other equipment, e.g. Welder

Plant electrics including LT distribution Standard Automation & Power Products

Low Voltage AC Drives

AC Motors Digital Cranes Control Drives

Gas Analysers

Transmitters

VCB/SF6 breakers

132 KV CT

CVT, RPC

Scope of supply for PLTCM

AC Multidrives (66 inverters line-up)

Level I and Level II automation

Cleaning Rectifier (6000A, 24V)

CCTV and Radio Communication system

Power distribution including SVC and substationautomation

ABB India continues on growth path with strong Q3 performance

Figs. in Rs. Million unless stated otherwise

Orders up

Revenues up

Order Backlog

34%

19%

MINR 11,442

Cum. Cum. % Q3 Q3 %Q3 2003 Q3 2002 chg 2003 2002 chg

Revenues 9,738 8,159 19.4 3,456 2,812 23

Orders 12,493 9,341 33.7 4,166 3,429 22

Profit After Tax 749 561 33.5 208 173 21

What are the current trendsacross the Indian industry?

India is one of the fastestgrowing economies in the worldwith a vast market and sourcingpotential. In an increasinglyglobalised and networkedworld, industries are striving forincreased efficiency andproductivity as there is agrowing need to be competitiveto keep pace with globalmarkets. Quality focus, leanerorganisations, outsourcing, masscustomisation, speed, world-class standards and value-addition are other key trends.Manufacturing processes arebeing streamlined throughincreased automation, focus onoptimisation, integration ofoperations and constantinnovation.

How is ABB helping theindustry?

For over a century, ABB haspioneered several technologies.Around 75% of ABB’s currentbusiness comes fromtechnologies developed duringthe past five years.

ABB’s vision is to make itscustomers more competitive inan increasingly networked andglobalised world by ThinkingGlobal & Acting Local ! We areleveraging our global presenceby optimising resources and

competencies, and developingregional and global factories andcentres of excellence.

Many Indian industry leaderslike Reliance, Tata Steel, JVSL,Hindalco, BALCO are workingto attain world-class standardsand become globallycompetitive. ABB India isworking closely with them inthis endeavour to help optimiseprocesses, increase energysavings, reduce input costs andenhance productivity andefficiency.

How is ABB looking at theIndia operations?

ABB India is playing anenhanced role in regional andworldwide Group operations,by leveraging its vastexperience, extensive localmanufacturing, technicalcompetence and domainexpertise.

Our strategic focus on exportsacross projects, products andservices is showing results. Wecontinue to book export ordersfor T&D and automationprojects. India has beenrecognised as the RegionalCentre of Excellence for cementand steel industries. Our state-of-the-art manufacturingfacilities in Vadodara and Nashikhave been designated as globalsourcing bases for 72.5 kV

outdoor circuit breakers, MVoutdoor circuit breakers andmagnetic actuators. Severalother products/components arealso being exported worldwide.

Could you briefly comment onIndustrialIT and its relevanceto India?

IndustrialIT is based on an openarchitecture, with a ‘plug andplay’ philosophy wheresolutions are being developedin the form of scalable andupgradeable functional productsuites enabling seamlessintegration of business andmanufacturing processes in realtime – closing the gap betweenthe ‘top floor’ and the ‘shopfloor’! Our Global R&D Centrein Bangalore, (the first of itskind to be set up outsideEurope and USA) focuses onIndustrialIT development anddeployment. Industry leaderslike ITC Bhadrachalam,Chettinad Cements, NagarjunaFertilisers, Tata Steel and IOCLare among those who arealready witnessing the earlybenefits of IndustrialIT .

Q & A with Biplab MajumderHead – Automation Technologies Division, ABB India


Cumulative


REL taps ABB’s domain expertise forimproving power distribution in Delhi

Reliance Energy Ltd. (REL) erstwhile BSES, hasengaged ABB as a consultant for NetworkOptimisation & Distribution Automation for theirtwo distribution companies in Delhi – RajdhaniPower Ltd and REL Yamuna Power Ltd.

ABB and REL will work together, studyingdistribution networks and evolving strategies andsolutions to provide consumers with reliable,uninterrupted and quality power at optimal costswhile minimising T&D losses.

ABB will also help develop a road map toachieve optimal network performance based onsolutions like SCADA, Automated Meter Readingsystems and integration of these with existingbusiness processes like billing solutions, CRM, ERPand GIS systems.

ABB to execute Power Grid orderin record timeABB has been awarded aturnkey project by Power GridCorporation of India Ltd (PGCIL)for setting up a 400 kV greenfieldsubstation at Vapi, Gujarat andextension of 400 kV bays of theexisting Padghe (MSEB)substation, Maharashtra. Thisproject will enable evacuation ofpower from the Tarapur AtomicPower Project in Gujarat. PGCILis the country’s leading powertransmission utility.

The scope of the project includesdesign, engineering, supply,testing and commissioning. Theequipment to be suppliedincludes six 400 kV bays andeight 245 kV bays; and theextension of the Padghesubstation will includetwo 400 kV bays.

ABB’s solutions are aimed at a12% energy saving in therunning of the air-conditioningand LT auxiliaries over theequipment lifetime.

ABB has already executedsimilar projects for PGCIL at

Jeypore, Vindhyachal (Satna &Bina substation), Jalandhar andTivim Ponda substations withothers currently in progress.ABB took up the challenge tocomplete the project in a recordtime of 18 months!

Global Round-up

When the first wave of statewide blackouts hitCalifornia in January 2001, it threw the mostpopulous state in the U.S. and the world’s fifthlargest economy into chaos.

Since then a lot of progress has been made andacross-the-board improvements have beenimplemented. The power supply system howeverremains vulnerable. With no significant generatorcapacities expected, the need to improvetransmission capacity between states and importmore power from neighbouring grids is crucial tomeeting daily peak loads of up to 45,000 MW.

In the neighbouring state of Nevada, NevadaPower Company has chosen an ABB FACTS

(Flexible AC Transmission Systems) solution toimprove the capacity of the McCullough-Crystal500 kV transmission line which is part of the LasVegas to the Los Angeles transmission system.

The technology series compensation will boostline capacity by 25% in time for the summer peakload of 2004.

This is the first time that Nevada Power, anesteemed customer of ABB, has chosen FACTStechnology from ABB. Pacific Gas and Electric,which serves northern and central California and isthe biggest utility in the state, has also recentlymade major investments in ABB FACTS’technologies.

Lighting up Los Angeles

ABB is increasing the capacity of the LasVegas–Los Angeles transmission corridorby 25%, helping to ease the power crisisthat has rocked California – in recent years.

ABB’s speedy response helped bring light back toover 2,40,000 customers of Rochester Gas &Electric (RG&E) after a devastating ice storm hitRochester, New York and enveloped the area indarkness.

ABB helped RG&E’s 900 odd crew who workedin 17 hour shifts to quickly restore power. Linepoles and damaged pole mounted transformerswere replaced with great speed.

Within 96 hours of ABB offering assistance,reviews and acceptance, inventory, manpowerand logistics were all put in place and RG&Ereceived the first consignment of pole mountedtransformers from ABB’s facility at Athens,Georgia. Dedicated teams were put in place toship over 280 odd transformers over the next fewdays to RG&E, almost a 1,000 mile journey north!

ABB’s quick response helped restore power in ashort span of time – a feat that wouldn’t have been

ABB’s quick response helps restorepower in Rochester

possible without ABB! The utility was quick toexpress its appreciation to ABB for its efforts inhelping them cope with one of the worst storms tohit Rochester, and in restoring power to the people!


ABB is building two of the world’s largest High-Voltage Direct Current (HVDC) transmission linksto transfer an annual 50 terawatts of hydel powerfrom the Western province of China to theindustrialised Eastern coastal areas of Shanghai andGuangdong.

The hydel power will be generated at the ThreeGorges dam and is slated for completion in 2009.It will be the world’s largest dam, spanning a

Em‘Power’ing Chinalength of 1.4 miles and a height of630 feet, and will feed power toEastern, Southern and CentralChina.

A vast majority of China’s powergeneration takes place in theWestern provinces but is used inlarge cities of the power-deficient Easternprovinces. ABB’s HVDC transmission link, part ofthe new Three Gorges transmission andconverting system will be a critical factor to helpbridge this deficit, while cutting the transmissiondistance from 2,552 km to 1,644 km. ABB’s firstHVDC power transmission link between the ThreeGorges dam and Changzhou has passed all trialsand is ready to set a new world record for powerlevels of 3,300 megawatts.

As China continues on its modernisation drive,ABB’s technology is playing a critical role infacilitating efficient power transmission.

VROOM... breaking the speed barrier

British designers Newby and Colin Fallows have designed abattery-powered car to break the current world record of247 mph. Dubbed “e=motion”, the dragster uses an invertorfrom ABB’s ACS 800 range of compact drives and two 40kW IP23 motors capable of reaching 9,000 rpm. Unofficially,the car has already broken the UK record of 139 mph andwill be taken to the Tunisian Sahara to attempt the officialworld record by becoming the first battery-powered car toexceed 300 mph.

BMW opted for ABB’s low-voltage drives at a new MINIpaint shop in the United Kingdom, and was rewarded withabout US$ 40,000 in annual savings on electricity.

Twelve low-voltage AC driveswere installed to run pumpsat the pre-treatment plant;regulating the pumps’ speedsaved by about 4,80,000 kWha year.

Maxi savings for a MINI plant

Success amidst failureABB’s state-of-the-art HVDC LightTM technology was

recently put to the test in the USA, when the28 mile long Cross Sound underwater cable was

energised overnight to supply 330 MW ofpower during the power failure on August

14, 2003.

ABB uses HVDC LightTM forunderground or underwater

transmission which has beendeveloped by ABB to

provide a high degree ofvoltage stability,

increasing gridreliability and

supportingfast network restoration.

Racing to meet Olympic deadlinesABB will supply products including control systems, mediumand low-voltage products and transformers to power thenew Beijing rail running from Xizhimen toDongzhimen to meet the needs of the29th Olympic Games in 2008.

In anticipation of the crowd during the Olympics,the Beijing Metro Group is increasing the lengthof the track to three times the current length,and they have chosen ABB to race ahead with!



In continuous manufacturing, 90% of all potentialfailures are likely to be caused by just 10% of theinstalled equipment. When planning preventivemaintenance, it therefore makes good businesssense to focus on this high-risk group. Risk BasedInspection (RBI) lets you do exactly that. Recentexperience has shown that customers can benefitfrom a dramatic saving in time and cost by usingthis tool.

Technology Digest

The principles of RBI

RBI is a knowledge-based method that uses risk asa basis for prioritising and managing an inspectionprogramme. In this definition, ‘risk’ is seen as theresult of the probability of future failure and thelikely consequence of that failure.

Generally speaking, the level of risk associatedwith the different pieces of equipment that makeup a plant is variable. However, this fact isseldom reflected in the inspection routinesapplied across the inventory of equipment. RiskBased Inspections focus the inspection andmaintenance effort on those areas where the riskand its potential effects are greatest.

The prime objectives of an RBI programme are to:

Focus effort on identifying and reducing thebusiness risks

Achieve increased plant availability

Reduce the maintenance costs

Improve safety

1)ABB Eutech is the process solutions centre of excellence within ABB’s petroleum, chemical, life sciences and consumer goodsindustries business area.

Typical recent results

Study A B C D

Average inspection intervalbefore/after RBI study (months) 31/ 44 No data 54/ 85 48/ 65

Vessels moved to non-invasive inspection 16 out of 26 76 out of 157 90 out of 179 41 out of 82

Reduction in inspection costs 58% 49% 61% 81%

Plant engineers fight a continuous battle withdowntime. Although key contributors, maintenanceand repairs are not the only cause for concern, it isthe threat of business interruption and its effecton output and profitability.

ABB Eutech1) has developed a Risk BasedInspection (RBI) method that enables companiesto substantially increase plant reliability, reduceplant failures and cut time inspection/maintenance. Recent results with four customers inthe chemicals and petrochemicals industry providecompelling evidence of major savings. The totalcost of inspection, for example, could be reducedby 49 to 80%. Average inspection intervals wereincreased by between 35 and 57%, with anaverage increase of 44%. And more than half theplant equipment could be removed from theinvasive inspection programmes.

The bottom line is that RBI reduces downtime,planned or unplanned, for a saving inmaintenance costs. The time and capacity/availability that is released as a result has a direct,positive effect on a plant’s output.

Winning the battlewith downtime


The ABB approach to RBI

ABB’s RBI process is built around an asset carestrategy that is designed to monitor the plantthroughout its life-cycle. This involves detailedknowledge and good understanding of thebehaviour of every component in the plant undercurrent operating conditions. It looks at parameterssuch as the design/construction quality, inspection/maintenance history, and the service conditions,including normal and abnormal excursions. Thereview identifies all failure mechanisms andassociated risks.

This accumulated knowledge and experiencehelps engineers decide what equipment needs tobe inspected and when, as well as to establishwhere failure would be least acceptable and causethe most problems.

Until now, ABB’s experience has been mainlywith pressure vessels. However, the sameapproach is adopted when assessing risks forrotating equipment, critical instrumentation andstructures.

ABB has refined its proven RBI approach into anefficient, streamlined solution called Risk BasedInspection. As a result of the experience gainedthrough hundreds of projects, it focuses ondelivering tangible results by:

Accumulating comprehensive knowledge of therisks associated with specific plant assets

Significantly reducing the total cost of inspections

Reducing maintenance and inspection time

Ensuring higher equipment availability andreliability, minimising unforeseen breakdowns

RBI for Victrex

An outstanding example of the success of RiskBased Inspection, implemented in closepartnership with a customer is a project ABBundertook recently for Victrex plc, a UK polymerproducer.

Victrex manufactures PEEK™ polymer, a high-performance thermoplastic with exceptionalchemical, electrical and temperature resistance.It is used in critical applications in the industrial,automotive, electronics, medical, aerospace andfood industries around the world.

Working with ABB, Victrex engineers wereaiming to break out of the vicious loop that hadalways linked higher output to investment innew plants.

Saving time, saving cost

Inspection and maintenance routines were a primetarget for close examination.

Before RBI, the inspection regime wasprescriptively invasive on all items, regardlessof the risks associated with them. It is a fact that,very often, extensive inspection during theshutdown periods reveals no deterioration.However, there are occasions when unexpectedproblems are found, and these can lead tounplanned repairs that increase the outage time.

All inspection and maintenance work on the mainpressure vessels must comply with PressureSystems Safety Regulations 2000. These lookmainly at how the safety performance andcondition of the vessels reduce workplace risksas far as is reasonably practical.

As a Victrex engineer puts it, “The total costof inspection includes decommissioning,

1. RBI risk matrix: moving the operating risk envelope to a safer region

2. Inspection life-cycle database


ABB Risk Based Inspection© in brief

ApproachWhat equipment should be inspected? Where wouldfailure be unacceptable?

Where should effort be focused?

Which techniques should be used?

How can the examination intervals be optimised?

BenefitsIncreased knowledge of the risk of operating assets

Significant reduction in the total cost of inspection

Longer turnaround intervals, and reduced turnarounddurations

Improved equipment availability and reliability, helpingto maximise uptime

Increased confidence in equipment integrity

Established path to regulatory approval

decontamination and preparation for internalinspection. All this time and effort just to find that,more often than not, everything is OK! This led usto question our approach.”

It was this questioning that steered the companytoward a knowledge-based approach tounderstanding the behaviour of the plant.

The RBI objective was to raise plant availabilityfrom 80 to 85% – from 290 days to 310 days peryear – which is the ‘world-class standard’ forsimilar batch speciality chemical processes.

It was concluded that the main contribution toincreasing plant availability would come from areduction in the annual shutdown time. This wouldneed to be cut from 35 days to 21 days.

The potential financial benefits realised fromreducing downtime was estimated to be runninginto millions of dollars. Such an amount wouldresult from an improved gross margin andreduction in short term investment needs.

None of this means that future plant expansion isruled out, but Victrex’ immediate priority was toget the most return from its existing facility beforeembarking on further major investment.

Both qualitative and quantitative, data historicalrecords of previous inspections and a thoroughanalysis of the causes of lost output in the last 12months, provided the basis for the knowledgebase on which the RBI plan would be developed.

A full understanding of the results of pastinspections of pressure vessels during shutdownswas vital, since preparing for and carrying outinvasive inspections account for much of the timeand effort involved in a shutdown. Knowing andunderstanding the failure mechanisms each item issusceptible to, and where to look for them,helped the team decide on the adequacy of non-invasive inspection. This proved to be a majorbenefit.

Thoroughly gathering and assessing salienthistorical data, plus the use of ABB advancedsoftware tools, enabled the team to develop aninspection routine that prioritises and responds torisks and foreseen failure scenarios. It alsominimises the risk of unexpected failure.

Having carried out the full review and created anRBI programme, the results have provedimmediate and impressive. The first shutdown tobe affected, in October 2001, required only ninedays. The necessary engineering and maintenance

work was completed in four days. The total costof the exercise was half the amount budgeted.

The next shutdown period, a little less than a yearlater, was cut from 35 days to 20 days. The teamexpects shutdowns to be kept to this level infuture years as some of the equipment gets olderand wear and tear increases.

Besides the time savings it facilitates, RBI has notonly met but exceeded expectations. Over thepart the gross margins have improved by millionsof dollars over eighteen months of operation andother savings on capital investment and associateddepreciation exceed several millions.

The Victrex experience shows quite clearly thatRisk Based Inspections can provide the benefitsbusinesses need to save on preventivemaintenance while minimising the risks of failure.

Source: ABB Review

3. The Victrex plant


End-user benefits:

Early recognition of instabilitiesand incipient collapses

Reducing likelihood forinstabilities to occur and forpower system to collapse

Increasing power systemavailability and decreasingoutages

Operate power systems closerto their limits

Increasing transmissioncapability while maintaining thesame system security level

Optimisation of powergeneration costs

PsGuardTM – a protection andoptimisation solution

Improved planning ofinvestments for newtransmission lines, capacitorbanks, etc.

Improve power systemoperation

Adapting power generationbased on availabletransmission capacity

Minimising the necessity forload shedding by early initiationof other counter measures

Optimisation of load to beshed, avoiding unnecessaryload shedding

The system description below gives an overview on architectureand technical features of the PsGuardTM, Wide Area Protection andOptimisation System.

ABB’s PsGuardTM is a solutionfor optimal monitoring and assetmanagement, fault evaluationand location, and incorporatesthe latest technologies appliedin wide area protection andoptimisation. It complements theexisting control and protectionsystems and provides wide areaprotection and optimisation.

Voltage Instability Prediction(VIP) implementation of phasormeasurement and VIP guidedcontrol actions provide thenecessary data acquisition andprocessing for issuance of mosteffective measures againstpower system instabilities.

The PsGuardTM system hasa modular architectureconsisting of the following maincomponents:

System Protection Centre(SPC) for network relatedapplications

Local Protection Centre (LPC)for station related applications

Phasor Measurement Units(PMU) for measuring ofvoltage and current phasors

Communication systemproviding links between SPCand LPC and PMU

Commercially availablehardware is used throughout thesystem in order to keepacquisition and stockholdingcosts low.

The PsGuardTM system could beextended by adding newstations to enlarge the protectedarea as well as in implementingnew applications andequipment to form a poweroptimisation system.


Living our commitment to Sustainability

ABB technology is harnessingthe elements in Nordic waters toproduce large-scale sustainableenergy. ABB will supply aSCADA system for overallcontrol and regulation, as well asthe collection grid between thewind turbines and the substation,and land cables for the nextlarge offshore wind farm inDenmark.

The Nysted offshore wind farm,located ten kilometers off thecoast of south Sealand,comprises 72 wind turbineswhich will generateapproximately 600 million kWhof electricity annually, sufficientto supply 1,25,000 single-familyhouses with renewable energy.

The 72 wind turbines will savethe environment from 300,000

Renewable energy – a new ‘sea wind’

ABB is ‘best in class’!ABB has emerged withremarkable scores in the2003 Sustainable AssetManagement (SAM) and DowJones benchmarking report.SAM, an independent assetmanagement and researchcompany, in co-operationwith Dow Jones Indexes,launched the world’s firstglobal sustainability index(Dow Jones SustainabilityIndex) in 1999. Theirsustainability database covers

companies worldwide, and theirbenchmarking system comprisesmore than 50 sustainabilitycriteria groups – including allthree dimensions ofsustainability - social, economicand environmental.

In this year’s report, ABB has notonly emerged ‘best in class’ forboth environmental and socialreporting, but has also scored a100% in these dimensions!Compared to the industry

average of 29%, these scoresreflect the combined effort andcommitment that has gone intoour sustainability efforts.

tons of carbon dioxide annually,and more than 400 tons each ofsulphur dioxide and nitrousoxide, which would have beenemitted from existing powerstations to provide the sameamount of electricity.

ABB and Prabhodini: An enabling partnership

In August 2003, ABB’s Nashik unit signed an MoUwith the NGO Prabhodini, which works withmentally challenged adult students. As per theunderstanding, ABB will help develop specialtools and provide vocational training to thesestudents. The training will include classes on theproduction and assembling of switchgear parts.

Apart from instilling a sense of self-reliance, theproject will also enable these individuals to earnan independent livelihood.

As part of our corporate social responsibility, thisproject explores new frontiers enabling thesedisadvantaged individuals, and taking us a stepfurther in our journey of living our commitment tosustainability.

Channel Line

Venture Control Systems become ABB’s first channelpartner to market Tensiometers

ABB’s channel partner in Noida (near Delhi),Venture Control Systems became the firstchannel partner to market Tensiometers in thecountry when Ispat Iron & Steel Ltd placed anorder for their cold rolling mill at Nagpur.

Munish Sharma of Venture Control Systemsremarks, “The performance of ABB’sTensiometers is unsurpassed for applicationscharacterised by heavy rolls, high speeds andsevere conditions. Customers stand to benefita lot from ABB’s superior technology.”

For accurate and reliable tensioncontrol in rolling mills, Millmate StripTensiometer offers a range of loadcells and control units that covermultiple needs.


Interview withMr. Uttamchand RatadiaCEO, Suman Electric Udyogs

Fastest growing channelpartner in Karnataka

Could you describe yourassociation with ABB over theyears?

Perhaps, it will not be out of placeto mention that we have beensupplying panel board accessoriesto ABB since 1995. We havealways been convinced of theunsurpassed technical know-howand superiority of ABB products.So when we got the chance topartner ABB to sell their range oflow voltage products, we gladly

On the fast track

accepted. Thus began anotherchapter in our relationship withABB as a business partner.

What were the main factors thatcontributed to your early success?

I would say, primarily, the quality ofABB products as well as theirservice and delivery commitmenthave helped ABB and us securethe position of a leading supplier oflow voltage products in this region.

What differentiates us is our long-standing and trusted relationshipwith end-users, OEMs, SBMs,panel builders and our keenknowledge of the project business.Added to this is our wide basket ofproduct offerings to help the

customer choose whichever rangeof products he desires.

What are your plans forexpansion in the near future?

We are contacting OEMs whohave traditionally used other lowvoltage products and explaining tothem the merits of ABBtechnologies. Also, we are nowrecognised in the market forquality, a fact reiterated by the ISO9000 – 2001 certification. We willcapitalise on our position as aleading switchgear supplier andmake greater inroads into anincreasingly quality consciousmarket.

You Ask – We Answer

I would like to have more information onMicroSCADA

Gautam K Chattopadayay, Oil India, Guwahati

MicroSCADA is a system for local and remotecontrol applications suitable for electrical and non-electrical process applications. In addition toelectrical processes, MicroSCADA is also well suitedfor other application areas. ABB has years ofexperience in supervisory network control andstation automation systems for utilities and industries

implementation times, and at lower investment costs- all compared to the alternative of building newtransmission lines or power generation facilities. ABBis the worldwide market leader in the field of FACTS.

The two main reasons for incorporating FACTSdevices in electric power systems are:- raising dynamic stability limits- providing better power flow control

ABB has the full FACTS portfolio and in-housemanufacturing of key components.

Thyristor Controlled Series Capacitors (TCSC) providea proven technology that addresses specific dynamicproblems in transmission systems. TCSCs are anexcellent tool to introduce if increased damping isrequired when interconnecting large electricalsystems. Additionally, they can overcome theproblem of Subsynchronous Resonance (SSR), aphenomenon that involves an interaction betweenlarge thermal generating units and seriescompensated transmission systems.

I would like to have information on healthassessment & remaining life of MV/HTSwitchgear in operation for over 25 years

P Sarode, Tata Steel, Jamshedpur

The health and remaining life of MV/HT Switchgearis dependent on various factors such as extent/type of usage, environment, etc. The assessmentneeds to be based on inspection and analysis by aspecialist engineer who will inspect theswitchgear andcarry out testssuch as: dynamicresistance of thecontacts, speedtravelcharacteristicsof the poles, di-electric strengthof gas sample andhigh voltage test oncubicle to inspectleakage current. Thiscan be arranged atyour request.


and is a leading supplier in this field all over theworld. MicroSCADA combines a user-friendly andconsistent operator technique with the capacity forextensive information processing, advancedcalculation and reporting and varied automaticfunctions. The operator supervises the processinteractively on full graphic monitor screens withschematic pictures which illustrate the real processstate and guide the operator to make the correctdecisions.

I would like to know more about ABB’s state-of-the-art FACTS technology

Rabindra Misra, Indian Aluminum Co., Orissa

The power industry term FACTS (Flexible ACTransmission Systems) covers a number oftechnologies that enhance the security, capacityand flexibility of power transmission systems. FACTSsolutions enable power grid owners to increaseexisting transmission network capacity whilemaintaining or improving the operating marginsnecessary for grid stability. As a result, more powercan reach consumers with a minimum impact onthe environment, after substantially shorter project

Communicating...

Efficiency and productivity continue to drive competitiveness, and technology has a key roleto play. In this issue we have focused on how automation is not just driving manufacturingprocesses but also integrating them with business processes to provide managers with real-timeinformation to enable speed of decision-making! We hope you enjoy the issue and lookforward to your continued feedback and support.

Harmeet S. Bawa, Head GF-Corporate Communications, ABB India


Standard Products LV Capacitors CLMD CapacitorsTechnical Specifications

InstrumentationMotor Starter Selection Chart

Brochures Mailers

High Voltage Machines Outdoor Circuit Breaker – Live TankModel EDF SK

AT Installations PT Products

Posters

Some recent media coverage

AT and PTInstallations

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For the complete picture in cutting-edgeautomation technologies...

ABB is a global leader in power and automation technologies that enable utility and industry customers toimprove performance while lowering environmental impact. ABB Automation Technologies offer a wide rangeof products, systems and services, based on unparalleled domain expertise and global experience to delivercutting-edge solutions for process automation, control, motion, protection and plant integration across thespectrum of manufacturing, process, consumer and utility industries.

...look no further!

Control Platform &Enterprise Products

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issue 3 / 2003 the abb india magazine · 2018-05-10 · hindustan zinc limited (hzl) in chanderia,...

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