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One ABB Seminar Surabaya 2014Ganesh Kamath, Surabaya, 30rd October 2014
Advanced Services – Powered byServicePortTM
© ABB GroupNovember 3, 2014 | Slide 2
Process AutomationServing 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 channelpartners and other ABB businesses
§ Developing Markets
Control Room
Control System
Control
Process
Protection &Control IEDs
Promoting CollaborationIntegrated Process and Power Automation
Controller
Plant Network
Controller
Profibus/Profinet
SubstationAutomation
Process ControlServer
IEC 61850
Process & Power Workplaces
Instruments
LV SwitchgearDrivesMotor starters
ProcessElectrification
ProcessInstrumentation
Plant-wideSequence of
Events for betterroot cause analysis
Same operationsinterface and
engineering for sharedinformation and
knowledge
CentralizedHistorian and
Data Archiving
CentralizedHistorian and
Data Archiving
Common, integratedasset management
strategy
Electricalintegration based
on Open Standardssuch as IEC 61850,Profinet/Profibus…
Electricalintegration based
on Open Standardssuch as IEC 61850,Profinet/Profibus…
Common systemtherefore reduced
spare parts, trainingetc…
Standardized procedures,settings, control logic and
libraries
Standardized procedures,settings, control logic and
libraries
© ABB GroupNovember 3, 2014 | Slide 4
ABB Life Cycle ServiceComprehensive Service Portfolio
HV & MV SwitchgearRelay protection
• Testing• Calibration• Coordination• Upgrades
Transformer• Oil Testing• Assessment• Periodic maintenance• Repair• Refurbish
Motors & Generators• Preventive kits• Periodic Maintenance• LEAP• Repair• Refurbish
LV and MV drives• Preventive kits• Periodic Maintenance• Repair• Refurbish
Automation• Preventive kits• Repair• Refurbish
Control Optimization• Fingerprint• Implement• Scan• Track
Industrial Energy Efficiency Reliability and integrity
Full Service ®
© ABB GroupNovember 3, 2014 | Ver. 1.1 Slide 5
ABB ServiceServices Portfolio
§ Over 22,000 service people in100 countries
§ Integrated solutions forreliability, productivity andenergy efficiency
§Optimization Services
§Full Service (Maintenance Outsourcing)
Training
Installation & Commissioning
Remote Services
Spare Parts
Condition Monitoring
Preventive Maintenance
Evolution Services
Repairs & Interventions
Upgrades & Retrofits
ABB Process Automation ServicesWe address your entire asset lifecycle
§ABB Service Portfolio
§Front-endengineering
DetailEngineering
Equipmentselection &
procurement
Construction Commissioning Start-up Operation
Design & Construction Warranty & Post-warranty
Lifetimeextensions
Installation & Commissioning
Decommissioning
§Consulting (Energy Efficiency, Productivity, Reliability, Safety)
§© ABB Group§November 3, 2014 | Slide 6
§© ABB Group
§November 3, 2014 | Slide 7
Certification
LeverageServiceKnowledge
Skill Requirements
IncreaseDeliveryEfficiency
Service Products
Solution
IdentifyServiceNeed
ABB Service Activity Process
ServicePoint
LCS
KeepProductionRunning
DeliverOperationalExcellence
OptimizeProcesses
MaximizeSystems
© ABB
Early days of automation
§03 November 2014 §| Slide 8
Few units§ Data collection difficult§ Range of control limited§ Troubleshooting very hands on§ Space defines number of controllers
© ABB
Modern Day Automation
§03 November 2014 §| Slide 9
We can not use yesterday’sservice methods to solvetoday’s problems§ Data is easily accessible§ Range of controllers extensive§ Hard drive defines number of controllers§ Troubleshooting is digital
© ABB
Goal: Continuous Improvement
§03 November 2014 §| Slide 10
1234
1234
1234
1234
Stand Alone Tools§ Signal Analyzer§ Loop Tuning§ Loop Analyzer
Continuous Tools§ Service Portal§ CMMS System§ Certification and Training
Action plan
Tuning
Actuator
Signal
Logic
Impl
emen
t
© ABB
Automation System Performance
§03 November 2014 §| Slide 11
Prod
uctio
nan
dQ
ualit
y
Goal
Problem
Operatorsdon’t turn offfeatures that
work!
System Utilization0
Manual
100
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!!!
Production
SystemUtilization
Case Study: High systemutilization is cutting production!
A well tuned control loop will improveperformance and production when utilized
© ABB
Industrial Trends in Control Performance
§03 November 2014 §| Slide 12
Manual OperationOutput out of rangeIncreasing variabilityImproving process
30%
15% 30%
25%
Half life of process controllersGiven: 100 PID loops tuned at onceThen: Within 6 months, performance
of 50 of these loops will degrade
100
Loop
perfo
rman
ce
degr
adat
ion
50
06
Simple PID utilization
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 GroupNovember 3, 2014 | Slide 13
Advanced Services: Performance MigrationMaximum Off Specification
Diagnose: Current
Implementation: Corrective Action
Sustain: Improvement Projects
Optimal: Mechanical Constraints
Reduction in Variability=
• Less Raw Material Usage
• Improved energy consumption
• Wider Operating Window
• Increases in production, quality, and product purity
• Faster troubleshooting time
• Advanced Automation Solutions
Goal
© ABB GroupNovember 3, 2014 | Slide 14
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
© ABB GroupNovember 3, 2014 | Slide 15
Advanced Services powered by ServicePort™Make more of a better product for less
Performance Channels
§Higher productionefficiency
§Reduced downtime
§ Improved system stability
§Maximized asset lifecycle
§Better processperformance
§Faster, more flexibleservice
Work smarter, not harder
© ABB GroupNovember 3, 2014 | Slide 16
Advanced Services powered by ServicePort™What are ABB Advanced Services?
0102030405060708090
100Control System
Equ
ipm
entP
erfo
rman
ce
Time
Traditional system approach
Performance peaks,then degrades
0
20
40
60
80
100
Ser
vice
Per
form
ance
Time
Traditional service approach
Performance depends onavailability
Advanced Servicespowered byServicePort
0
50
100
Ove
rall
Per
form
ance
Time
Consistentperformanceimprovement
© ABB GroupNovember 3, 2014 | Slide 17
Advanced Services powered by ServicePort™Secure, remote Advanced Services delivery
§ ServicePort is a servicedelivery platform throughwhich customers receiveAdvanced Services for§ Process§ Equipment§ Industry
§ Services are deliveredthrough channelsubscriptions
§ ServicePort is a on-site tool
Advanced Services powered by ServicePort™Proven process
Diagnose§ Measure performance gap§ Forecast benefits (ROI)§ Deliver action plan
Implement§ Fix performance gap§ Define monitor plan
Sustain§ Manage performance gap§ Schedule maintenance§ Define condition triggers§ Maintain to conditions
Service
IncreasedPerformance
Diagnose§Measure performance gap§ Forecast ROI§Deliver action plan
§1
Implement§ Fix performance gap§Define and monitor plan
§2
Sustain§Manage performance gap§Schedule maintenance§Define condition triggers§Maintain to conditions
§3
© ABB GroupNovember 3, 2014 | Slide 19
Advanced Services powered by ServicePort™Advanced Services value areas
Sustain
Implement
Diagnose Assess
Action
Repeat
Assess
Action
View Scan Track
Fingerprint ServicePort
© ABB GroupNovember 3, 2014 | Slide 20
Advanced Services powered by ServicePort™Monitoring Service based on channels
Channelline-up
© ABB GroupNovember 3, 2014 | Slide 21
Advanced Services powered by ServicePort™Types of channels
Cyber Security Channel
Harmony Performance Channel
Hoist Performance Channel
Loop Performance Channel
QCS Control Utilization Channel
QCS Sensor Stability Channel
QCS VPA Channel
System 800xA Channel
Channel Lineup
EquipmentChannels
ProcessChannels
IndustryChannels
© ABB GroupNovember 3, 2014 | Slide 22
Advanced Services powered by ServicePort™Equipment Performance Services
Help improve equipment availability, prevent equipmentdeterioration and extend asset life.
800xA Performance Services help customersmanage 800xA control systems, improve systemperformance and extend asset life.
Harmony Performance Services help customersmanage Harmony control systems, improve systemperformance and extend asset life.
© ABB GroupNovember 3, 2014 | Slide 23
Advanced Services powered by ServicePort™Process Performance Services
Help improve process performance, prevent processdisruptions and protect assets.
Loop Performance Services identify and correctcontrol loop performance issues.
Cyber Security Performance Services identifystrengths and weaknesses for defending againstcyber attacks within a plant’s control systems.
© ABB GroupNovember 3, 2014 | Slide 24
Advanced Services powered by ServicePort™Industry Performance Services
Applying industry-specific knowledge to help improveequipment performance and extend asset life.
Quality Control System Performance Servicesevaluate current QCS performance levels andprovide a basis to evaluate and identify opportunitiesto improve measurement and control utilization.
Mine Hoist Performance Services evaluateperformance levels of ABB or other mine hoists andprovide a basis to evaluate and identify opportunitiesto improve mine hoist utilization.
© ABB GroupNovember 3, 2014 | Slide 25
Advanced Services powered by ServicePort™Secure, remote-enabled access to service experts
© ABB GroupNovember 3, 2014 | Slide 26
Advanced Services powered by ServicePort™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
Many
Represents one unit
300 units are shown here.This represents a small areaof an industrial process.
© ABB GroupNovember 3, 2014 | Slide 27
Advanced Services powered by ServicePort™View, Scan and Track
Math
Rules
raw data associated witheach channel
presents KPIs generated from raw datathrough periodic diagnostic monitoring
generates notifications based onpredefined KPIs
View
Scan
Track
Goal Present
Gap>rule = Alarm
KPI(s)
Sev
erity
Raw Data
Trends for Experts
© ABB GroupNovember 3, 2014 | Slide 28
Advanced Services powered by ServicePort™View the raw data
Time Events
Data View – Aligned to visibly show issues
© ABB GroupNovember 3, 2014 | Slide 29
Advanced Services powered by ServicePort™Scan the status
Identifies, classifies and prioritizes issues
© ABB GroupNovember 3, 2014 | Slide 31
Advanced Services powered by ServicePort™Channels produce reports that guide improvements
Advanced Services powered by ServicePort™Expected financial results
Typical Savings for process areas with 250 control loops
Energy
Raw materials
Product change
Reduced off-spec
Production
100 200 300 400 500
Quality
Target shift
Energy
$225,000 per year
Raw Materials
$ 75,000 per year
Quality
$ 50,000 per year
© ABB GroupNovember 3, 2014 | Slide 33
Advanced Services powered by ServicePort™Example of how services are deployed over one year
Initialization, Baseline Setting, Training
View (performance) Calculations / evaluations /daily usage
Scan (scheduled): Scan analysis / report /implementation planning / notification validation
Track (event-triggered): remote troubleshootingassistance
Customer (on demand)
Mon
th1
Mon
th12
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