raghunath thamatttur, 8th -9th may 2013 abb services & · pdf fileabb services &...

ABB Services & Products for MetalsServices & Products that add life toyour systems and processes

Raghunath Thamatttur, 8th -9th May 2013

© ABB GroupMay 10, 2013 | Slide 1


Facts about Global Product Group - MetalsEnergy efficiency and productivity

Over 1300 GPG Metals employees in morethan 40 countriesOver 100 years of process knowledge inmetals industryABB supplies the global metals industry inexcess of 1 billion $ per yearComprehensive automation,instrumentation and electrification productportfolioOne global sales force, one globaloperation and one global developmentteamWorldwide service organization

ABB Process Automation Services & Products

Improve efficiency and ProductivityCompanies are looking at improving the means to produce betterrather than how much , trying to improve efficiency and utilizationin existing processes , cut losses.

Reduce total Cost of OwnershipCompanies need to reduce total cost of owner ship by combattingoperational and maintenance challenges.

UtilizationInstalled system is either Over/ some times under dimensioned –and does not operate to full capacity resulting in under utilizationof equipment.Asset OptimizationCustomers have no clue on the amount of data generated by thefeedback devices , asset optimization is seldomly used! What to /how to exploit the Data is the common question we hear frommost of customers.


Primary Metals Hot Rolling MillsProfile & Tube Mills

Cold RollingMills

Processing Lines

SPOC( Single Point of

Contact)Energy Efficiency andoptimization solutions

in primary Metals

Plant safety Services

Down Streamoptimization services

Metals PortfolioExtending existing service scope

ABB Metals ServicesWe have scalable services that support your needs


Keep ProductionRunningRapid response fromtrained experts with uniquetools and services that payfor themselves in savings orimproved productivity.

Maximize SystemLifecycleMinimize downtime andexpenses by optimizingequipment lifecycle andutilizing remote enabledservices.

Deliver OperationalExcellenceEnterprise-wide processsafety management,energy efficiency andworld-class reliabilityprovide high return onyour service investment.

Optimize ProcessPerformanceImprove throughput andyield, reduce energy usage,raw material consumptionand cost with tighter,optimized control of yoursystem and equipment.

ABB Products


Optimization Services

FP -7

Optimization Services - Methodology

Diagnose

Measure Process

Detailed Scope with definedobjectives

Forecast Performance

Implement

Improve Performance

Apply corrective actions

Sustain

Maintain Performance

Preventative Maintenance

Sustain

Implement

Diagnose

Service

IncreasedPerformance

1

2

3

Pro-Active Solutions,not Re-Active

6-Sigma similarities

Why should you use Power NetAnalysis?

You will benefit!

Power Net-Analysis services were developed based onindustry needs

We can combine our production process knowledgewith your need to maximize production benefits

We have developed tools and quality standards formaking analysis’ and reports

Power NetAnalysis is based on our engineering tools

Many customers value these services …

Power Net Analysis ObjectiveUnderstand network disturbances caused by voltage drops

Increased wear of electrical equipmentTripping of under-voltage relaysIncreased standstill times for electrical reasonsProduction has to be reduced below the rated powerof the plantTrouble with the utility company or other consumerson the network.

Harmonicsprocess control systems and computers may haveerrorsmotors and transformers suffer from increasedtemperaturescables and capacitors warm up, can suffer dielectricbreakdownharmonics can influence ripple control frequencieselectronic devices synchronising circuits can bedisturbed

11/2012

ScopeModel of the power supply systemOn site measurement and adaptation of modelDesign of solutions

DeliverablesCalculation of net responses and suggested solutionsActual network conditions and load flowCheck of power quality, review of guidelines and limitsSuggestions for optimized network configuration(s)Licence proceedings documentation

Sum up

Increase plant availability by improving power quality

Decrease maintenance costs by reducing voltagedistortions

Planning a new plant or a revamp utilities often ask you foran experts opinion to avoid net disturbances

Reduce losses and load on the supply system bydecreasing of reactive power consumption

Reduced reactive power allows you to increase activepower consumption and productivity.

Case Story Schwermetall, Germany

The Need, a more reliable powersupply

ABB offers Power NetAnalysis.The order was placed end of 1998

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Case Story Schwermetall, Germany

Power NetAnalysis suggestsinstallation of dynamic filters

Order and commissioning ofdynamic compensation in 1999

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Today:

Electrical downtimes reducesby 20%

Costs for reactive powereliminated @ 6000 $ permonth

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Example @ Flat rolling mill:

7000 h operation per year

20KUS$ value added per hour

24 h • 365= 8760 h

1760 h for planed standstill timeslike maintenance, roll changes,public holidays...

Costs & Benefits

Price of PNA for a medium size plant = 50K US$

20 % network problems

42 h or 840K$ losses

3 % Standstill times causedby the electrical equipment

210 h or 4.2 MUSD losses

Costs & Benefits

Example @ Flat rolling mill:

7000 h operation per year

20KUS$ value added per hour

Life cycle ServicesParts & repair services

ObjectiveReviews effectiveness of parts management and identifiescost saving opportunities and potential risk associatedwith insufficient stock, over stock, out-of-date inventory,and end-of-lifecycle issues.

ScopeSpare parts inventory

Stock condition analysis

Part status, stocking levels, version management,warranty management

Parts criticality and historical parts usage reports

BenefitsOptimal spare part inventory

Less risk for insufficient stock, out-of-date inventory

DeliverablesFingerprint report with recommendations on partsmanagement

Life cycle servicesLife Cycle Audit

Highlight equipment:

general condition

criticality

life cycle status

Recommendation of appropriate maintenance

Recommendations of appropriate migration paths and upgrades

Cold Rolling Mill FingerprintLife cycle audit and process analysis

ObjectiveLife cycle audit of mechanics, motors and drives,automation platform, level 2 and technology

To analyze and identify opportunity for quality, productivityand yield improvements for CRM

ScopeInterview and discussion with key people

Collect measured data (mill speed, exit thickness etc) foranalysis

BenefitsOpportunity identification for better life cycle managementand increased efficiency

DeliverablesFingerprint report with improvement plan and associatedestimated ROI

12/2012

Optimize Process PerformanceMetals Life Cycle index- Essar Steel Algoma

ObjectiveAn audit was delivered to Essar Steel in Algoma the objective of theservice was to Understand and provide recommendations to address thefollowing:

Life cycle status of installed hardware and softwareProductivity, Quality and yield improvementsOptimizing in manpower

DeliveryOn site investigation resulting in a report which address key findings

of installed hardware and software (Mechanics, Motor & Drives andAutomation)in the area of Technologyin the area of Personnelregarding Prevention, Emergency and Life cycle strategy

Major findingsProductivity: potential of 20 to 25% productivity improvementpossibleQuality and yield: potential of 30% quality improvement possible


Profile Mill FingerprintLife cycle audit and process analysis

ObjectiveDetailed audit and advanced data analysis to capture thecurrent health of Drives, Motors, Automation & Process ofprofile mills

ScopeInterview and discussion with key people

Collect measured data e.g. temperatures, mill schedule,looper control, drives, hot metal detector etc. for furtherstatistical analysis

BenefitsOpportunity identification and improvement plan for betterproductivity, energy efficiency and quality


04/2013

Arcelor Mittal Contrecoeur East, Montreal, CanadaUpgrade of wire rod mill makes it more efficient

Customer’s requirementOld control and drive equipment need updatedue to spare parts obsolescence and highprocessor loadUpgrade must fit the limited budget andavailable maintenance stop timeA new platform allowing easier future upgrades

ABB:s supplyAll old MP200 controllers upgraded to AC450 forboth the mill and the furnaceOld HMI systems type MV850, MV830 andMV320 upgraded and integrated to one 800xAsystem via SentinelUpgrade of all remaining drives not yet upgradedto DCS800 or DCR800

Customer benefitsFull mill and furnace controlOne common HMI system allowing further futureintegration and additional functionsNew control platform allowing additional futurefunctionsPowerful maintenance and trouble shooting toolswith iba and Prilog logging systems

”We are very pleased with theoverall project. In particular with thesmooth startup after such a majorchange.”

Daniel SmithProject ManagerArcelorMittal Contrecoeur EastMontreal, Canada


Keep Production RunningScalable service agreements tailored to your needs

Drives Performance FingerprintDrives Dynamics Analysis (DDA)

ObjectiveAssess drive train performance and identify the causes ofpoor dynamic performance, determine correct parametersfor optimum drive performance and thereby improveproductivity and quality

ScopeTo analyze both the electrical and the mechanicalperformance of new and existing drive trains

BenefitsEnhance the drive performance and hence productivitythrough redesigning and/or tuning of the drive system

Reduce maintenance requirements and plant downtime

DeliverablesReport with recommend actions to improve the utilizationof drive systems, and to give optimal dynamicperformance

11/2012

Maximize System LifecycleSeveral retrofit solutions for all products

Benefits

Preventive maintenance

Restore of the original conditionExtended lifetime

Update of aging components:electrolytic capacitorsribbon cablescooling fans

Product replacement

Latest technology andfunctionality

Replacement of theold drive with thenewest drive productofferingReplace old SAFUI

inverter module by newACS800 invertermoduleskeep old cabinets,

existing supply partsand cablings

Retrofit

Reduced engineering costQuick project executionNo production losses

Totalinvestmentcost

Sapa Heat Transfer Cold Rolling Mill, SwedenRestore the damaged equipment in a record time

Customer’s requirementSapa wanted to restore thedamaged equipment as soon aspossible to ensure delivery ofproducts ordered by its customers.

ABB:s supplyRemoval of burnt materialsRepair of motors and gearboxesSupply of gauges and junctionsboxes and operator desksComplete electrical installation &commissioningAdjustment of control system, etc.

Customer benefitsDelivery of products ordered bySAPAs customers in timeA modern and fully repaired millwith safer operation

”We selected ABB’s for the ability toquickly set up a competentorganization since they have gainedknowledge of our plant rom theService contract we have with ABB.”

Tobias JanssonProcess Control TechSAPA HT Sweden


Maximize system Life CycleCrane Retrofits and modernizations

Restored availabilityDecreases downtime due to unreliable equipment

Minimizes lack of old spare parts

Shortens lead time on replacements and/or repairs

Decreases cost for replacement parts

Restored serviceabilityMinimizes risk of product obsolescence

Increases technical support

Enhancements by new technologyOptimizes productivityWe know what is important

Downtime is critical

Fast uptime

Knowledge of old products

Installation know-how

We have the experience toDeal with formalia and regulations

Do dimensioning with limited input data

Industrial Boiler FingerprintProcess and control performance audit

ObjectiveTo conduct process audit to identifyopportunities for boiler performanceimprovement

ScopeEvaluate boiler operation and control loops

Conduct dynamic response tests andevaluate disturbance rejection and loadchange recovery

BenefitsContinuous performance improvements byevaluation and benchmarking of controlperformance and boiler efficiency

DeliverablesFingerprint report with improvement plan andassociated estimated ROI

StepResponse

InspectionHardware and Software

BoilerStability

Poor regulation

Offset from setpoint

Good regulation

Slow response

Fast response

Cyclic response

BoilerLoad Test

Visually inspect andtest instruments,

valves, and controllogic

Check boiler air andgas flow curves

The Fingerprint analysis identifies where controlloops and hardware need to be refreshed orrepaired and invariably leads to significantreductions in energy bills and associated carbonemissions.

FP -27

Boiler Fingerprint: Service

Scope

Instrumentation & Actuators

Control Configurations

Steady State Performance

Dynamic Performance

Load Tests

On-site Tuning and Adjustments

One Week On-site

Analysis

Reporting

FP -28

Boiler Fingerprint : Value

Energy Savings

More Responsive to Process SteamDemands

Extended Operating Range

More Reliable

Improved Safety

Loop Optimization ServicesLoop Fingerprint, Loop Scan and Loop Track Services

ObjectiveTo audit and benchmark control performance

To implement services like loop tuning to improve performance

To sustain the performance by periodic scanning or continuoustracking of control performance

ScopeTo collect control data to analyze current performance

To identify improvement potential

To implement and sustain control performance

BenefitsControl performance improvement leads to productivity and qualityimprovement, energy efficiency, better reliability and safety

DeliverablesFingerprint report with improvement plan and associated estimatedROI

Cyber Security FingerprintProtect control systems against security threats

ObjectiveTo identify cyber security risks within a plant’s control systemsby gathering critical data and comparing them to ABB andindustry best practices.

ScopeCurrently designed for ABB System 800xA, Process Portal B,and Conductor NT version 6. Coverage for additional systemswill be made available.

BenefitsProvides a comprehensive view of your site’s cyber securitystatus

Reduces potential for system and plant disruptions

Security against computer worms such as Stuxnet that isknown to target SCADA systems

DeliverablesComprehensive report lists security strengths and weaknesses;risks; recommendations; and action plans

Cyber SecurityStuxnet: The first malware targeting industrial control systems

Remote Support ServicesRemote-enabled technical support

ObjectiveTo enter into service contracts with customers for remote-enabled technical support with guaranteed response time

ScopeABB automation system, drives

Utilize ABB’s secured remote access platform (RAP)

Centralized support team responding to global customers

BenefitsReal-time diagnosis and troubleshooting for customers

Faster response time from ABB

DeliverablesOn-demand 24x7 troubleshooting done remotely

Periodic audit (fingerprints) performed through remoteaccess

10/2012

Proven in P&P, Minerals

ABB ServicePortSecure, remote service delivery platform

ABB ServicePort is a service delivery platform throughwhich customers and ABB experts can securely access:

Diagnostic services

Improvement services

Performance-sustaining services

ServicePort lets you subscribe to channels of differenthigh-value services that are most important to you

If you want to ensure equipment runs well or optimizeprocesses, you can benefit from the latest diagnosticand improvement services – when you want them

ServicePort can also be a valuable on-site resource forvisiting engineers to perform advanced services


Early diagnosis of equipment problems and optimization ofmaintenance and operation activities are essential.

© ABB Group

Customer needReplacement of knowledge that left the companyExpert support for legacy control systemFast responses to production issues

ABB’s responseServicePort for onsite control system support

Delivers ABB expert resources remotelyProvides tech supportPerforms non-invasive checks on the operatingsystem

Temporary resident field service engineer

Customer BenefitReplaces lost expertiseSolves tech support issues immediatelyIdentifies problems before they occurProvides diagnostics to troubleshoot disturbancesDelivers ABB Optimization SolutionsReduces costsNeed-identification-to-resolution within 45 days

Site: Pulp Mill, AR, USAUnit: Pulp MillIssues:

Customer lost an important engineerINFI 90 system required upgradeSelf-maintenance no longer possible

Agreement:1-yr agreement + resident engineer

Customer Case StudyPulp mill, Arkansas, USA

ABB Products


Software Solutions,Energy Efficiency Solutions

Metallurgy products

Energy efficiency

ObjectiveTo make redundant non efficient equipment for example valvesin case of a pump application and reduce the power requiredbased on the flow.

60-65% of the electrical energy is consumed by motors, foreach 1 usd spent to purchase a motor 100 usd is spend to runit through out its entire life cycle. Today only 5% of thesemotors are controlled by variable drives , we see a possibility ofretrofitting at least 30% with these drives.

Process equipment runs at partial loads resulting in highenergy bills

ScopeReplacing all throttle valves for Pumps with variable speeddrives , initial low investment but increases Total cost ofownership. of the output immediately go to waste.

On an average almost 20% of energy consumed by motors arewaste because of throttling mechanism.

Fans Conveyors Roller tables

PumpsCranes Offshore

Winders

Paper machines

Debarking drums

Ski lifts

PropulsionCentrifuges

Spinning

DrillingWindmills

BenefitEnergy savings

Reduced equipment wear and Longer life timeof equipment

Soft start and stop reduce waste and save rawmaterial

Noise reduction

Improve efficiency

DeliverablesEnergy audit

Case Study – Metals Industry


Deliver Operational ExcellenceCase study: Industrial Energy Efficiency

ChallengeDevelop energy efficiency program for keyareas at this integrated steel mill

Results

53 energy saving opportunities identified

Total savings value €8.5M - €10.3M / year

3 wins saving €120K/year, payback <1year

4 projects fully developed

Each with savings > €1M/year; payback of ~1year

ABB installed new variable speed driveson a number of boiler fans with savings of€ 3M p.a

Asset life expectancy extended 10 years

A roadmap for improvement© ABB GroupMay 10, 2013 | Slide 39

ArcelorMittal FlatCarbonFos-sur-Mer, France

Scope

Study electricalsystems

Develop master planfor energy

Developspecifications for 5projects

“We are very pleased with theresults as ABB have defined very

clearly where energy can be savedand how to achieve it. The work isreally appreciated. It is better than

just an audit.”

J VAN LISHOUT

Byproduct Gas Energy FingerprintOptimal Gas Energy Utilization

ObjectiveAudit for evaluating effectiveness of management andutilization of energy-rich byproduct gases (blast furnace gas,coke oven gas etc.)

ScopeReview current gas management practices and examination ofscope for further improvements

Identification of appropriate optimization solutions for realizingthe improvements

Estimation of the economic benefits from the implementation ofthe solution

BenefitsIdentification of energy savings opportunities


Reduction inoverall

operation cost

Operatorindependentperformance

Betterenvironmental

impact

Higher EnergySavings

Tested with plant data but not sold

Adaptive Dimension Models (ADM)Profile Mill Setup Optimization

ObjectiveModel-based solutions for optimization of profile millproduction

ScopeMill setup optimization for profile mills

Optimization of production speed, interstand tension,groove utilization, roll load sharing and energyconsumption

BenefitsImproved mill utilization

Reduced set up time following size and grade change

DeliverablesOptimal mill setup parameters (roll gap, mill speed, groovefactor) for different product grades and size

InitialExploration

PilotEvaluation

Technical SolutionReady

ProductizationComplete

12/2012 02/2013

Shui Wing Steel Ltd., Hong Kong SAR, ChinaMass Flow Control makes the mill more profitable

Customer’s requirementIncrease mill yieldReduce the rolling tolerancePayback less than one year

ABB’s main supplyMFC, Mass Flow Control;U-gauge, Gateway, Ugtool;Operator and control software package.

Customer benefitsSimple installation during normalproductionOpen system, Easy to integrate into anexisting automation systemImproved yieldTighter tolerancesImproved performancePayback within one year

”The ABB, MFC & U-gauge configuration ishelping us to increase our yield and reducethe rolling tolerance when rilling single andwelded billets. The system is also givingvaluable online information to ouroperators. We expect a payback on theinvestment in less than one year.”

Mr Erik RaftsjöSenior EngineerShui Wing Steel Ltd.

Melt Shop and Hot Rolling Production SchedulingMSO & HSO

ObjectiveOptimal production scheduling of heats in a melt shop(MSO) and slabs (rolling programs) in rolling mill (HSO) toincrease the productivity

ScopeOptimal grouping and sequencing of heats to maximizecaster throughput

Optimal building of rolling mill programs and sequencing tomaximize throughput from rolling mill

BenefitsHigher throughput by reducing makespan time

Increased due-date reliability

DeliverablesStand-alone production planning tool customized tocustomer’s plant

InitialExploration

PilotEvaluation

Technical SolutionReady

ProductizationComplete11/2012


Optimize Process PerformanceOptimization solutions

Melt shop Scheduling Optimization (MSO)

Shortens waiting times inside the process = less heat/energy losses

Optimize the production by handing units that only can only in parallel in alimited way = Increased productivity

Determines equipment bottlenecks in a plant by simulated runs based onplant data

Energy management and Information managementPlant Information and Lab Information ManagementSystems (PIMS & LIMS)

ObjectiveProcess monitoring and reporting tool – can be used for energymanagement, lab data management and production datamanagement

ScopeVisualization, reporting and trending of relevant plant and labsignals. Interfaces available or can be developed for labinstruments for automatic or manual data logging

Automatic calculation of process and energy KPIs

BenefitsProduction tracking, production planning

Energy and emissions monitoring for compliance

Consolidated reports and analysis tools to enable managementdecision making

DeliverablesCPM solution deployed at customer site

Code Conversion from AMPL (AC70, MP200, AC400,etc.) to AC 800 with minimum impact on production


ObjectiveSafe and efficient application evolution from MP200/x, AC70/80and AC110/410/450 etc. based systems to System 800xAsolutions.

Automatic methods for controller application conversion to AC800 and reuse installed I/O.

BenefitsShort production stops and a fast production ramp up, oftenwithout any need for commissioning. Thus lowering the totalproject costs.

Reuse of the existing application software, ensuring that yourwell-proven functionality in the existing system will be retainedafter the upgrade

Scope and deliverablesConverted AMPL code ready for commissioning.

Required hardware and software for system 800xA (reusingmost of the I/Os)

Asset OptimizationImproving Plant Performance


ObjectiveReduce plant maintenance costs

By common understanding of maintenance strategies

Real time measurement of asset performance

One common view of asset performance

Seamless information exchange between operations andmaintenance

BenefitsDetect early warnings and prevent equipment failure with acomplete range of condition monitoring

Empower your maintenance users with the MaintenanceWorkplace

Reduce time to repair with seamless integration to CMMS

One common system platform for plant optimization

Unique industry know-how and wide engineering, service andconsulting offering

Scope and deliverablesAsset optimization as a software service combining 800 xAsoftware with service

800xA - The Power of IntegrationKey areas for Asset Optimization

Understanding condition monitoring of connecteddevices and equipment

Instrumentation, HV/MV/LV electro systems, vibrations, IT andprocess equipment

Device integration using fieldbus technologiesProfibus&HART, Wireless HART, FF, IEC61850

Maintenance WorkplaceConfiguration, monitoring and root

cause analysis tools

AM SDKCustom built Asset

monitors

CMMS integrationONE single maintenance

workflow from real timecondition monitoring to

CMMS

Calibration integrationDevice calibration

administration

One common system platformDirect access to all process and equipment dataNo time consuming system integrationComplete scope of condition monitoringPlant performance in real-timeTailored workplaces for different users

All tools to improve plant and process performanceOptimization and not system integration

Service AgreementsPackaged Services

ObjectiveService contracts lasting at least one year that generateguaranteed annual revenues

Tailored to meet the customer needs with regards tonumber of objects, type of service per object and servicelevel per object

ScopeDepends on customer requirements. Typically includesperiodic maintenance, troubleshooting, remote support,advances services etc.

BenefitsReduced total maintenance cost

Access to ABB’s expertise with guaranteed and fasterresponse resulting in less downtime, equipment reliability

One service agreement per customer reduces thecomplexity for both ABB and customer

02/2013


Metallurgy Products - Electromagnetic stirring forimproved quality, productivity and energy saving

Markets servedSteelmakingCastingAluminiumTreatment linesSolar siliconOther metals

OrganizationPart of ABB AB80 people wwMain center in Västerås, Sweden

Key deliverablesElectromagnetic stirrersElectromagnetic brakesEM Stablizers

http://www.baosteel.com/plc/english/indexe.htm

http://www.gerdau.com.br/ing/index.asp

http://www.corusgroup.com/

http://www.ussteel.com/corp/index.htm

http://www.alcan.com/

Our Electromagnetic Products

1. EMS for EAF and ladle furnaces

2. EMS for Slab casters

3. EMS for billet and blooms

4. AL-EMS for furnaces

5. EM-Stabilizer for galvanizing lines

Cost saving solutions for melt shops and castersReliable electromagnetic products for better quality & productivity

ABB Metallurgy – Electromagnetic stirring forimproved quality, productivity and energy saving

LF-EMS

•

AF-EMS

EMBR

SlabSEMS

FEMS

MEMS-Max MEMS-Mid MEMS-Dual MEMS-Mod MEMS

AL-EMS

EMStabilizer

A Ladle Furnace Stirrers 139B EM Mold – Flat 156C EM Mold – Profile 942D Al Furnace Stirrers 160E Arc Furnace Stirrers 149F Special Application EMS 28

Total 1574

References

SummaryTypical expected results with EAF EMS

Productivity + 5%

Electric energy - 5%

Yield + 0.5% to 1%

Less Alloy and Oxygen consumption

Improved Safety and Process stability

Force Measurement

Providing measurement solutions for Rolling Mill & Process Lineapplications in the Metals, Paper, Textiles and ConvertingIndustries

Force MeasurementUnique Sensor Technologies

Pressductor®

TechnologyPulsed Eddy CurrentTechnology

Plant Safety Fingerprint for MetalsSafety Audit

ObjectiveTo perform safety risk assessment as per EU legislationfor existing and new machinery with end-customer ormachine builder

ScopeHazard identification and risk assessment

Propose technical safety measures and safety solutions

BenefitsSafe and hazard-less work environment

Compliance to EU directives on safety

DeliverablesReport with assessment of current safety performancelevel and recommended measures and solutions toimprove safety levels

© ABB GroupMay 10, 2013 | Slide 58© ABB GroupMay 10, 2013 | Slide 58© ABB GroupMay 10, 2013 | Slide 58

Rigorous approachPHAs and health checksRegulatory compliance

Specify optimum solutionsConfirm residual risks aretolerablePrioritize actions

Program managementTrainingRegular assessments

Risk AssessmentAudit

Identify Risks

Process Safety Management

Optimize Risk Reduction

Plan Risk Reductions

Implementation andOn-going Support

Reduce Risks

Deliver Operational ExcellenceProcess Safety Management

© ABB GroupMay 10, 2013 | Slide 59© ABB GroupMay 10, 2013 | Slide 59

Deliver Operational ExcellenceCase study: Plant Safety

Customer’s requirementThe demand for state-of-the-art machinesafety solutions, living up to the latestEU Machinery DirectiveCutting-edge digital technology innew AC- and DC-drives

ABB:s supply1 x AC800M HI “safety-PLC” with PPAoperator stations5 x ACS800 AC-drives14 x DCS800 DC-drivesInstallation supervision and commissioning

Customer benefitsHigher operator safety in the production lineImproved accuracy and less need formaintenance for the drive systemsApproval for production by aNorwegian “Competent body”

”It was from the very beginning agood cooperation with ABB and awell performed project. We are verysatisfied ”

Helge EriksenSystem Engineer at Hydro Aluminium A/S

The AC800M-HI High Integrity SIL2 SafetyController and its associated safety I/Oround off the company’s safety portfolio.

raghunath thamatttur, 8th -9th may 2013 abb services & · pdf fileabb services &...

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