One ABB Seminar Surabaya Ganesh Kamath, Surabaya, 30 rd October Advanced Services Powered by ServicePort TM

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1 One ABB Seminar Surabaya 2014 Ganesh Kamath, Surabaya, 30 rd October 2014 Advanced Services Powered by ServicePort TM

2 Process Automation Serving a full range of processes... Cement Food and Beverage Life Sciences Marine and Cranes Metals Minerals Oil, Gas and Petrochemical Printing Pulp and Paper Specialty Chemicals Turbocharging Additional industries via channel partners and other ABB businesses Developing Markets November 3, 2014 Slide 2

3 Promoting Collaboration Integrated Process and Power Automation Control Room Control System Control Same operations interface and engineering for shared information and knowledge Process Control Server Centralized Historian and Data Archiving Controller Process & Power Workplaces Profibus/Profinet Plant Network Standardized procedures, settings, control logic and libraries LV Switchgear Drives Motor starters Controller Electrical integration based on Open Standards such as IEC 61850, Profinet/Profibus IEC Plant-wide Sequence of Events for better root cause analysis Common system therefore reduced spare parts, training etc Protection & Control IEDs Process Instruments Process Instrumentation Process Electrification Common, Centralized integrated asset Historian management and Data strategy Archiving Substation Automation

4 ABB Life Cycle Service Comprehensive Service Portfolio Automation Preventive kits Repair Refurbish HV & MV Switchgear Relay protection Testing Calibration Coordination Upgrades Control Optimization Fingerprint Implement Scan Track Transformer Oil Testing Assessment Periodic maintenance Repair Refurbish LV and MV drives Preventive kits Periodic Maintenance Repair Refurbish Industrial Energy Efficiency Reliability and integrity Motors & Generators Preventive kits Periodic Maintenance LEAP Repair Refurbish November 3, 2014 Slide 4 Full Service

5 ABB Service Services Portfolio Over 22,000 service people in 100 countries Integrated solutions for reliability, productivity and energy efficiency November 3, 2014 Ver. 1.1 Slide 5

6 ABB Process Automation Services We address your entire asset lifecycle Design & Construction ABB Service Portfolio Installation & Commissioning Warranty & Post-warranty Front-end engineering Detail Engineering Equipment selection & procurement Construction Commissioning Start-up Operation Lifetime extensions Decommissioning Spare Parts Installation & Commissioning Training Remote Services Repairs & Interventions Condition Monitoring Preventive Maintenance Upgrades & Retrofits Evolution Services Optimization Services Consulting (Energy Efficiency, Productivity, Reliability, Safety) Full Service (Maintenance Outsourcing) November 3, 2014 Slide 6

7 ABB Service Activity Process Deliver Operational Excellence Solution Identify Service Need Maximize Systems Service Products ServicePoint LCS Leverage Service Knowledge Increase Delivery Efficiency Keep Production Running Certification Skill Requirements Optimize Processes November 3, 2014 Slide 7

8 Early days of automation Few units Data collection difficult Range of control limited Troubleshooting very hands on Space defines number of controllers ABB 03 November 2014 Slide 8

9 Modern Day Automation We can not use yesterday s service methods to solve today s problems Data is easily accessible Range of controllers extensive Hard drive defines number of controllers Troubleshooting is digital ABB 03 November 2014 Slide 9

10 Goal: Continuous Improvement Action plan Tuning ABB 03 November 2014 Slide 10 Stand Alone Tools Signal Analyzer Loop Tuning Loop Analyzer Continuous Tools Service Portal CMMS System Certification and Training Actuator Signal Logic Implement

11 Automation System Performance Goal Production Production and Quality Operators don t turn off features that work! System Utilization 0 Manual ABB 03 November 2014 Slide 11 System Utilization Problem 100 A well tuned control loop will improve performance and production when utilized Case Study: High system utilization is cutting production! Auto Control is only used during upsets A few shifts tried to use control There is an inverse correlation between production and control utilization No service done in over 5 years!!!

12 Industrial Trends in Control Performance Half life of process controllers Given: Then: Loop performance degradation PID loops tuned at once Within 6 months, performance of 50 of these loops will degrade 6 Simple PID utilization 30% 15% 30% 25% Manual Operation Output out of range Increasing variability Improving process PID Controllers are designed to: Regulate the process Reduce product instability Improve operations However, customer data shows: PID loops are not being maintained PID loops have degraded PID loops are standing in the way of production and performance ABB 03 November 2014 Slide 12

13 Advanced Services: Performance Migration Maximum Off Specification Goal Optimal: Mechanical Constraints Sustain: Improvement Projects Implementation: Corrective Action Diagnose: Current Reduction in Variability = Less Raw Material Usage Improved energy consumption Wider Operating Window Increases in production, quality, and product purity Faster troubleshooting time November 3, 2014 Slide 13 Advanced Automation Solutions

14 Optimization Services - Methodology Diagnose Measure Process Pro-Active Solutions, not Re-Active Detailed Scope with defined objectives Forecast Performance Implement Service 3 Sustain Improve Performance Apply corrective actions Sustain 2 Implement Maintain Performance Preventative Maintenance 1 Diagnose Increased Performance November 3, 2014 Slide 14 6-Sigma similarities

15 Make more of a better product for less Higher production efficiency Reduced downtime Improved system stability Maximized asset lifecycle Better process performance Performance Channels Faster, more flexible service Work smarter, not harder November 3, 2014 Slide 15

16 What are ABB Advanced Services? Traditional system approach Equipment Performance Control System Time Performance peaks, then degrades 100 Overall Performance 50 0 Advanced Services powered by ServicePort Consistent performance improvement Time 100 Traditional service approach 80 Service Performance Time Performance depends on availability November 3, 2014 Slide 16

17 Secure, remote Advanced Services delivery ServicePort is a service delivery platform through which customers receive Advanced Services for Process Equipment Industry Services are delivered through channel subscriptions ServicePort is a on-site tool November 3, 2014 Slide 17

18 Proven process Diagnose Measure performance gap Forecast benefits (ROI) Deliver action plan Service 3 Sustain Manage performance gap Schedule maintenance Define condition triggers Maintain to conditions Implement Fix performance gap Define monitor plan 2 Implement Fix performance gap Define and monitor plan Sustain Manage performance gap Schedule maintenance Define condition triggers Maintain to conditions 1 Diagnose Measure performance gap Forecast ROI Deliver action plan Increased Performance

19 Advanced Services value areas Fingerprint ServicePort Diagnose Assess Assess Implement Action Action Sustain Repeat View Scan Track November 3, 2014 Slide 19

20 Monitoring Service based on channels Channel line-up November 3, 2014 Slide 20

21 Types of channels Channel Lineup Cyber Security Channel Harmony Performance Channel Hoist Performance Channel Loop Performance Channel QCS Control Utilization Channel QCS Sensor Stability Channel QCS VPA Channel Equipment Channels Process Channels Industry Channels System 800xA Channel November 3, 2014 Slide 21

22 Equipment Performance Services Help improve equipment availability, prevent equipment deterioration and extend asset life. 800xA Performance Services help customers manage 800xA control systems, improve system performance and extend asset life. Harmony Performance Services help customers manage Harmony control systems, improve system performance and extend asset life. November 3, 2014 Slide 22

23 Process Performance Services Help improve process performance, prevent process disruptions and protect assets. Loop Performance Services identify and correct control loop performance issues. Cyber Security Performance Services identify strengths and weaknesses for defending against cyber attacks within a plant s control systems. November 3, 2014 Slide 23

24 Industry Performance Services Applying industry-specific knowledge to help improve equipment performance and extend asset life. Quality Control System Performance Services evaluate current QCS performance levels and provide a basis to evaluate and identify opportunities to improve measurement and control utilization. Mine Hoist Performance Services evaluate performance levels of ABB or other mine hoists and provide a basis to evaluate and identify opportunities to improve mine hoist utilization. November 3, 2014 Slide 24

25 Secure, remote-enabled access to service experts November 3, 2014 Slide 25

26 How to find needles in a haystack? Few units Not difficult to find issues. Many units Much harder to find issues. Time to find with simple tools is not practical. Avoiding false positives is essential Few Represents one unit 300 units are shown here. This represents a small area of an industrial process. November 3, 2014 Slide 26 Many

27 View, Scan and Track View Raw Data raw data associated with each channel Trends for Experts Scan Math Severity presents KPIs generated from raw data through periodic diagnostic monitoring KPI(s) Track Rules Gap>rule = Alarm generates notifications based on predefined KPIs Goal Present November 3, 2014 Slide 27

28 View the raw data Time Events Data View Aligned to visibly show issues November 3, 2014 Slide 28

29 Scan the status Identifies, classifies and prioritizes issues November 3, 2014 Slide 29

30 Track changes November 3, 2014 Slide 30

31 Channels produce reports that guide improvements November 3, 2014 Slide 31

32 Expected financial results Production Reduced off-spec Product change Raw materials Energy Quality Target shift Typical Savings for process areas with 250 control loops Energy Quality Raw Materials $225,000 per year $ 50,000 per year $ 75,000 per year

33 Example of how services are deployed over one year Month 1 Month 12 Initialization, Baseline Setting, Training View (performance) Calculations / evaluations / daily usage Scan (scheduled): Scan analysis / report / implementation planning / notification validation Track (event-triggered): remote troubleshooting assistance Customer (on demand) November 3, 2014 Slide 33

34 November 3, 2014 Slide 34