MMEA seminar 8.9.2015 ABB/A. Alalääkkölä Automation ...mmeafinalreport.fi/files/WP5 Automation Benefits from Measurement... · Automation Benefits from Measurement to Optimization

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Automation Benefits fromMeasurement to Optimization

MMEA seminar 8.9.2015 ABB/A. Alalääkkölä

© ABB GroupJanuary 27, 2016 | Slide 1


ABB Group

ABB in Finland

Automation system 800xA – benefits from measurement to optimization

Examples of mine solution – AEF, Kittilä Mine

Future trends

Content

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ABB GroupPower and productivityfor a better world

Power and productivity for a better worldABB’s vision

As one of the world’s leading engineering companies, we helpour customers to use electrical power efficiently, to increaseindustrial productivity and to lower environmental impact in asustainable way.


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A global leader in power and automation technologiesLeading market positions in main businesses

§ Nearly $40 billion in revenue (2014)§ 140,000 employees in over 100 countries on all continents§ Annual R&D investments more than $1.5 billion USD

ABB in FinlandWorking for a sustainable world

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ABB in Finland

5,200employees

in R&D

1/5Formed in

1889merger of Swiss (BBC, 1891)and Swedish (ASEA, 1883)engineering companies

In revenue(2014)

billion2.1€

of employees


ABB Finland’s global product responsibilities

Globally10,1 bn USD

Globally7,5 bn USD

Globally7.9 bn USD

Globally10,3 bn USD

Globally7,0 bn USD

Induction machines,synchronous machinesDiesel generatorsWind generatorsWind convertersSolar invertersLow voltage frequencyconvertersLow voltage motors,motors for explosiveatmospheres (Vaasa)

Low voltage switches(Vaasa)

Paper machine drives

Process industryelectrifications (Vaasa)

Collaborative ProductionManagement

Energy managementsystems

Azipod®

EMMA™ - energymanagement system

Special transformers(Vaasa)

Protection relays fordistribution networks(Vaasa)

Power distributionproducts and solutions(Vaasa)

MicroSCADA Pro controlsystem (Vaasa)

MicroSCADA Prooperation supportsystem (Vaasa)


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Planning and production in Finland


VaasaMotors, special transformers, LVproducts and switchgear, powertransmission and distribution systems,distribution protection & control, powergeneration systems, turnkey projects forprocess industry

PorvooWiring accessoriesPitäjänmäki, Helsinki

Motors, generators, frequencyconverters, CollaborativeProduction Management(CPM) and Paper MachineDrive solutions

Vuosaari, HelsinkiHaminaAzipod® electricpropulsion systems

ABB Country Service

© ABB GroupJanuary 27, 2016 | Slide 10© ABB GroupJanuary 27, 2016 | Slide 10

Change +5.9 %

ABB in Finland: Key figures 2014Research and development 204 million €

State-of-the-art technology and solutionsfor global business

§ New member to the Relion® product family:Relion 620 series

§ Clionet®-Data Care, an advanced data-sharingand backup service to secure technicaldocumentation of protection and control relays

§ High speed permanent magnet generator familyfor wind markets to cover offshore powers up to7 MW

§ Motor series to meet IE3 and IE4 efficiency levels

§ The world’s most efficient motor series NXR fore.g. pump and compressor drives

§ Frequency converter series ACS580 for e.g.pump, blower and conveyor drives

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Innovations into competitive advantageStrong research collaboration


§ Strong research collaboration with business, education andresearch communities in Finland

§ Participating in CLEEN Ltd and its research programs, that boosttop talent in energy and environmental sectors

Top researchers in Finland in 2014

R&DMEUR

R&D %revenues

Change %2013-2014

1 Nokia 2 493 19.6 - 52 ABB 203 9.8 + 63 Wärtsilä 139 2.9 - 254 Orion 106 10.5 + 45 Kone 103 1.4 + 76 Stora Enso* 80 0.7 07 Amer Sports 76 3.4 08 Cargotec 67 2.0 + 69 Metso 59 1.6 - 2

10 Tieto 50 3.2 + 2511 Valmet 42 1.7 - 3012 Outotec 37 2.7 - 23

* Estimation (R&D costs not published in company’s financial statement)

Source: Tekniikka&Talous magazine 13.2.2015© ABB GroupJanuary 27, 2016 | Slide 12

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§ 5,187 employees, out of which 68% whitecollars and 32% blue collars

§ Men 80%, women 20%

§ Technical education background 2/3 from staff

§ About 1,000 summer trainees

§ About 220 apprentices and trainees

§ 110 thesis writers

§ 118 expatriates

§ ABB Finland has 11 expatriates from abroad

§ About 200 employees with foreign backgroundfrom over 40 countries

PersonnelKey figures

Education Structure

© ABB GroupJanuary 27, 2016 | Slide 14© ABB GroupJanuary 27, 2016 | Slide 14

Investments in development ofpersonnel

§ 10 million € in total§ about 1,875 euros /employee

Focus areas§ management and leadership training§ processes and procedures§ expert coaching§ further professional training

Recruitment§ 241 people in 2014§ 950 summer trainees in 2014§ Recruitments to be continued in 2015

ABB invests in development of personnel

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Cooperation with educational institutions

Development of relations with ABB’s keyinstitutions and partners§ Around 130 visits to ABB annually§ Around 20 visits to student events annually§ Around 20 trade fairs annually§ Sponsorship, projects in collaboration,

practical training, thesis writing

Physics laboratory in Helsinki andLappeenranta§ Target group: lower and upper secondary

schools§ Physics students of University of Helsinki

as teachers

Situation TodayIslands of AutomationSystem 800xA Extended Automation SystemThe Power of Integration

PLC

PLC, SCADADCS 1DCS 2

PLC, Panel

PLC, SCADA

PLC

DCS 3

PLC, SCADAPLC

PLC

System 800xA

One rich harmonized user interfaceincluding all control systems

One integration point for all relatedapplications

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System 800xA Extended AutomationPlant-wide consolidation, collaboration and optimization

Operator Effectiveness§ Full scope and features set includes control

room design based on human factor bestpractices

Integrated Safety§ Promotes collaboration by combining basic

process control with high-integrityapplications

Automation and Power Integration§ Promotes collaboration by combining

process automation and power automationin a common infrastructure

Enterprise Asset Management§ Full-scope asset monitoring and

manufacturing operations management

System 800xA removesbarriers and promotescollaborative process

automation!

© ABB / PA3BSE069722 en EJanuary 27, 2016 | Slide 17

Seamless Operation of Devices, Equipment & SystemsTopological view

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Improving Operator EffectivenessThrough embedded information

§ Monitor, control, optimize, andmaintain from one interface.

§ Embedded actionableinformation through AspectObject Technology

§ Relevant, filtered informationbased on user’s role andresponsibility

§ One click to all Information

Control

Faceplates

Trend

Graphics

Video

Asset Health

ReportsDocumentation

ERP/ CMMS

Integrated view of equipment and systemsPowerful workplaces with embedded functions

Alarm List

Trend Display Documentation

Video Group Display

Navigation Display Operator Note

ü The most feature rich operator interface availableü All information in one windowü Switch information context with just on mouse

click

Faceplate

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Agnico Eagle Finland Kittilä Mine Automation systemlayout


Agnico Eagle Finland Kittilä Mine Automation systemlayout


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Agnico Eagle Finland Kittilä Mine Automation systemweather report


Agnico Eagle Finland Kittilä Mine Automation systemGas detections


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Efficient engineeringOne common engineering workflow saves time

§ One engineering workflow inEngineering Workplace for:

§ Fieldbus topology

§ Device parameters

§ Control logic

§ Condition monitoring

§ Device parameters are stored in thesystem (devices not needed)

§ Built in device documentation

§ Bulk data tools for fieldbus configuration(topology and devices)


Device Management HART

§ IO interfaces for HART devices

§ S800 local and remote incl High Integrity I/O

§ S900 remote I/O

§ HART diagnostics routed through the control network

§ Fieldbus Builder engineering tool for topology anddevice configuration

§ DTM access possible for all types of users

§ OPC connection for asset management applications

§ Device Library with certified HART devices


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HART device usage in Agnico Eagle Finland – Kittilä

§ Visibility throughout the measurement to automation

§ One common tool to maintain, configure and fault detection.Same platform as in system engineering – One maintenancework environment!

§ Automatic follow up to all control loops, heat exchangers and allother supported HART devices.

§ Control and manage all field devices through one mouse click© ABB GroupJanuary 27, 2016 | Slide 27

Field device condition monitoring800xA Asset Optimization

§ Detect early warnings to maintain high plant availability

§ Apply predictive maintenance strategies

§ 800xA Asset Optimization enables

§ Automatic condition monitoring

§ Maintenance workplace for all maintenance actions

§ Share and access of maintenance data

§ One common workflow with CMMS


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Empowering the operators increasesavailability, safety, and quality and isa key enabler for consolidatedoperations

Alarm analysis acc to ISA 18.2and EEMUA 191 (5.1)

Support for hiding and shelvingof alarms (5.1)

Group alarms, a single alarminstead of several (FP1)

Alarm response, direct navigationfrom the alarm to objectinformation (FP1)

Operator effectivenessImproved alarm management


Agnico Eagle Finland Kittilä Mine – Intelligent AlarmMangement


§ System follows continuously alarms frequency of occurence,reason -> consequency and importance.

§ Alarm prioritization, packaging and relevance guides the workand process every day.

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Agnico Eagle Finland Kittilä Mine, Process dataManagement System - RTDB


§ RTDB system has daily log to manage the data

§ Data Collections::

§ MicroScada collects the energy usage information throughout themill and brings those to main database.

§ LIMS is laboratory data storage where all the process analysis arecollected.

§ SmartTag is used by geologists and it follows the ore content fedto the concentration plant.

§ Ulkoinen laboratorio (external laboratory) does the analysesrelated to environment and those will be fed to the data bank.

§ System will do the predictions day, week and monthly level based onreal production data.

§ In the future there are plans to implement the OEE calulations andcontinuous improvement models.

Agnico Eagle Finland Kittilä Mine Process dataManagement System – RTDB report example


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System 800xA Embedded Process & Power AutomationAll equipment controlled & operated in one environment

System Networks

AC 800MController

Fieldbuses

ProcessInstrumentation

ProcessElectrification

SubstationAutomation

PowerManagement

System Servers

IEC 61850

LV Switchgear, Drives, Motor Controller Protection & Control IEDs

Benefits:Common view of Process

and PowerSOE, Graphics,

Navigation …Full support of IEC 61850Better power protection

possibilitiesIncreased process

availability

Process Automation Power Automation

Safety easy to learn and operateEfficient working methods, Operations

Built-in safety functions

§ Same system for Safety andProcess Control

§ Embedded with high integrity forfast operator actions andinformation access

§ Prohibits unnecessary shutdownsor accidents

§ Marine approved hardware

Process Automation Process Automationand Safety

Safety

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Savings throughout the whole safety life cycleOne harmonized environment

Cost savings

§ One HMI

§ One alarm list

§ One engineering tool and one set ofengineering principles

§ One set of documentation foroperations, engineering andmaintenance

§ One set of spare parts

§ One team of process/safetyengineers

§ One support and service provider

§ Remote support capabilities

800xA Extended Security§ A modular approach

Fundamentalsecurity

Enhancedsecurity

Products Services

Advanced Access Control

800xA Whitelisting

Digital Signature

800xA Audit Trail

PC, Network and Software Monitoring

Automation Sentinel

Antivirus updates

Windows Securityupdates

Policies & GuidelinesConsultancy

Cyber SecurityFingerprint

My Control System(Field communication - e.g. security bulletins &

security reports)

Built insecurity

System Hardening & SystemConfiguration

(Robustness testing, roles based access control,IPSec, back-up & restore, host firewall for severs

& workstations, and storm protection forcontrollers & communication modules, etc.)

Training(e.g. E163)

Management& Monitoring

Industrial DefenderAutomation

Systems Manager™

Cyber SecurityMonitoring

Service(ServicePort)

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Data has no value until it is converted to a service

Data driven services

© ABB

What can we learn from data?

What services can we offer?

Customers Tasks& Needs

Value Proposition

KnowledgeAnalysisData

ServiceOffering

4.2

2.7 1.8

7.5

Future factoryInternet of things, people and service

People will control productionand make the decision based ondata from different sources• Data from factory production

devices• Data of raw material

availability, quality or price ofenergy

-> Better productivity, improvedcost savings and lowerenvironmental impact.

Future factory

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Advanced Services- The WorkflowMy Control System

auto

mat

icTr

ansm

issi

on

ServicePort

SPDC

BenchmarkFingerprint

ServiceLinkGPRS

Control SystemsJanuary 27, 2016 |Slide 39

Control SystemChannel

Rem

ote

Acce

ssP

latfo

rm

one-time datacollection

man

ual

Tran

smis

sion

scheduleddata collection

Customer

DataCollector

ServiceApplication

RAP

Health Check Event Monitoring

Watch Center


Documents

MMEA seminar 8.9.2015 ABB/A. Alalääkkölä Automation ...mmeafinalreport.fi/files/WP5 Automation Benefits from Measurement... · Automation Benefits from Measurement to Optimization