Issue 3 / 2005 The ABB India Magazine...ABB Ltd. in India. As part of the new organisational approach , eight regions have been defined to manage the business line and functional roles

Issue 3 / 2005The ABB India Magazine

Editorial Team

Harmeet S Bawa – Head, Corporate Communications

Anish Maria, Nandini Naik – Editorial ServicesAnuj Sharma – Automation TechnologiesNamita Asnani – Power TechnologiesKaushik Pandit – Building Systems

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

abb.co.in/contactemail: [email protected]

Design – Shilahar Associates

Dear Friends,

Indian industry is on the revival path after a quiet period during

which most sectors were in capacity correction mode. Few

would contend the fact that the metals industry is leading this

charge with significant brown-field and green-field projects

underway both in the ferrous and non-ferrous sectors and

many more initiatives on the anvil. In addition to new capacities

and expansions, there is also an increasing focus on

parameters like scale, productivity, efficiency and quality as the

Indian metals industry increases its international reach and

strives for competitive advantage. Indian industry is fast

realising that the business model is changing and to be a global

force, we have to think beyond traditional paradigms. State-of-

the-art automation technologies have a vital role to play in

enabling all of these and other critical success factors.

Seamlessly integrated process automation and systems are

the need of the hour to facilitate real-time control and

information, essential for effective decision making in an

increasingly complex and networked world where speed is

often the greatest competitive advantage.

Metals is the theme for this issue of CONTACT and you will get

a glimpse of ABB's domain expertise and technology offering

in this sector. Besides this there are of course the usual

features that bring you the latest on what is happening around

the world and recent developments in India.

Yours sincerely,

Ravi UppalVice Chairman and Managing Director, ABB India

CONTACTThe ABB India Magazine2

ABB realigns organisation 3

Global Roundup 4

India Roundup 6

New Technologies 9

Indian Industry must leverage automation technologies -Velli Matti Reinikkala, Head-Process Automation 10

Feature Story-Metals on the Move ! 11

Customer Interview -B L Raina, MD, Tin Plate Company of India Ltd. 14

Technology Digest 16

Living our commitment to Sustainability 20

Channel Line 21

Tech Bytes 22

Contents

CONTACTThe ABB India Magazine 3

ABB Group recently announced new mid-term targets from

2005 to 2009 and outlined a strategy that emphasizes

improved business execution and a broader approach to

value creation, including focus on growth, operating margin,

use of capital and cash generation. "We remain focused on

our core power and automation businesses. This is an

evolution of our strategy, not a revolution. ABB today is in a

strong position and we can look forward to sustainable and

profitable growth", said Fred Kindle, ABB's President and

CEO.

To support the execution of the strategy, the two core

divisions, i.e. power and automation technologies, are being

replaced by their five respective business areas. The new

divisions will therefore be Power Products, Power Systems,

Automation Products, Process Automation and Robotics.

A new position is being established at the Group Executive

Committee (EC) level to drive execution of the new strategy

across national and regional borders and facilitate the

integration of marketing and technology across the

organisation. Dinesh Paliwal will head this new position as

President, Global Markets and Technology. The regional

managers, Group Chief Technology Officer and Head of

Group Account Management for sales and marketing will

report to him. He retains his roles as ABB Group Executive

Committee member, CEO of ABB's U.S. operations and

regional manager North America and Chairman of

ABB Ltd. in India.

As part of the new organisational approach , eight regions

have been defined to manage the business line and functional

roles effectively across geographies and maximise synergies.

Ravi Uppal will be the Regional Head, responsible for the

South Asian region in addition to his current position as Vice

Chairman, Managing Director and country manager of ABB in

India. The major countries included in the South Asian region

are India, Pakistan, Singapore, Indonesia, Malaysia, Thailand,

Australia, New Zealand, Philippines and Vietnam. ABB

operations in these countries, shall continue to function as

independent entities.

ABB realigns organisation

Automation Products Process Automation RoboticsPower Products Power Systems

ABB

� High and medium-voltage switchgear,reactive powercompensators,power anddistributiontransformers.

� Mainly for utilities& industrial plants

� Transmission anddistribution systemsincluding HVDC andFACTS solutions,substations,integrated powerplants, networkautomation etc.

� Mostly for utilities& industrial plants

� Low-voltageproducts & systems,drives, motors,power electronics

� Mainly productbusiness “one millionproducts a day”

� Wide customerbase

� Automationsolutions forprocess industries

� Oil & gas, chemicals,pharma, pulp &paper, metals,minerals, marine etc.

� Robots, roboticsystems andservices

� Mainly for theautomotiveindustry, butalso othersectors

Effective 1st January 2006

ABB is helping New Caledonia’s boomingnickel mining industry by automating theworld’s largest nickel mine, Goro. NewCaledonia has 25 per cent of the world’sknown nickel reserves, and a thriving miningand smelting industry that is an importantsource of income for the island’s economyand its 213,000 population. The electricalequipment will be delivered in stages withmost of the work being done in the switchrooms of Brisbane, Australia before delivery.

ABB Australia’s composite offering for theproject includes 690V MNS motor controlcentres, variable speed drives, switchrooms and low voltage distribution boards.ABB will also supply the Profibus thatinterfaces with the intelligentM102 relays and the VSD’s.This not only saves ontraditionalcabling to theprocesscontrolsystems,but alsomakesinterfacing fareasier.

...the world’s largestnickel mine

ABB helps automate...

Global Roundup

...a steel plant in Columbus

ABB will supply a high-power rectifiersystem and two Static Var Compensator(SVC) systems for a steel mill to be built inColumbus, Mississippi for SeverCorr, LLC,which is owned by Severstal Group.

The steel mill will use an SMS Demag DCelectric arc furnace powered by ABB toproduce approximately 1.5 mt of rolledproducts annually. The high-power rectifier(ABB Thyribloc® ), rated at 2 x 80,000amp, 1,000 VDC, will convert AC utilitypower to DC as the primary power inputto the arc furnace. The project also includestwo SVC systems, one 160 Mvar EAFcompensation system Arc-Comp® andone 100 Mvar rolling mill SVC. The SVCsystems will provide the reactive powercompensation to meet utility powerquality requirements.

As part of its supply, ABB will provide itsnewly developed AC 800PEC equipmentcontrol platform incorporating Arc-Comp® ,the first application of this technology inNorth America. The AC 800PEC is ahigh-end controller belonging to ABB’sAC 800 automation family. It combines thehigh-speed control requirements of powerelectronics applications with low-speedprocess control tasks usually carried out

ABB powers......the world’s largest integrated aluminum plantCompanhia Brasileira de Alumínio (CBA) isincreasing production capacity by 35percent at what is already the largestintegrated aluminum complex in the world.Four ABB industrial substations, includingthe biggest substation ever to be installedin Brazil will help power this expansion. Theentire production process includes refiningthe bauxite into alumina, reducing andcasting the alumina into primary aluminiumand manufacturing the aluminum intoproducts like profiles and tubes, wires andcables, coils and tiles.

CBA increased production of primaryaluminum at the plant from 340,000 to385,000 tons earlier in 2005, and ABBsupplied the substation for the finishing line.With capacity set to rise to 460,000 tons in2007, ABB is once again the preferredchoice. The 750-megavolt ampere (MVA)substation will be expandable to 1gigavolt ampere (GVA) to facilitate futureincreases in production capacity. A 460/230kV step-down substation, two 230 kVswitching substations, and 230 kV and 460 kVtransmission lines are also part of the scope.

by separate PLC units. It is configured andprogrammed with Control Builder M andMATLAB® / Simulink® with Real-TimeWorkshop® .

A critical system enhancement offered byABB is its Arc-Comp® system. While aconventional SVC reacts to changes ofmeasured voltage and currents, the ABBArc-Comp® system, because of a fast-forward loop from rectifier control system toSVC control system, adjusts in advanceof actual system change which significantlyimproves performance of the compensationsystem with respect to network and furnaceoperation. With a stable network, DC voltagestability to furnace is improved which results inincreased arc stability. Improved systemstability results in higher production.



ABB motors will power the new high-speed trains between thebooming cities of Guangzhou, Shenzhen and Zhuhai in the PearlRiver Delta region of China.

Bombardier Transportation, the world’s largest train manufacturerhas selected ABB to supply 275 kilowatt high-powered trainmotors for 20 new high-speed trains that will run at 200 kms/hr.The 20 trains, each with eight cars, will link cities and manufacturingcenters on both sides of the Pearl River with a single, high-speedrailway from Hong Kong to Shenzhen in the east, throughGuangzhou and west to Zhongshan and Zhuhai.

The two companies have entered into a long-term agreementwhere ABB will supply motors, traction transformers, power semi-conductors and other power and automation products.

...high-speed trains in China

ABB in Rotterdam is working with "De minister van Verkeer enWaterstaat" to update the operator interface of the"Maeslantkering", the final storm barrier of the Dutch"Deltawerken" to help protect the main port of Rotterdamand its inhabitants. The "Maeslantkering" consists of two giantdoors - the structure of each door being as large as the Eiffeltower. In normal position they rest on the sides of the river. Incase of emergency these doors can be positioned right insidethe river to protect the land.

The barrier is in operation since 1997, being controlled byAdvant Controllers. To safeguard the functioning of thesystem, ABB was selected to replace the operator stationsand the information manager with a new operator interface.The new operator interface will be in the form of ABB's latestSystem 800xA with the well-proven AC400 connectivity.

800xA system helps protectDutch from rough seas

The Maeslantkering with its two giant doors.

ABB has recently signed a contract with Baosteel group tobuild a steel processing line with a speed of 1,040 meters perminute, making it the fastest production line in China, and thethird fastest in the world.

ABB has successfully executed many projects for Baosteelgroup, one of the major iron and steelmakers in China, including severalAnnealing and Pickling lines of theBaosteel Group Ninbo Baoxin StainlessSteel Company and an automationsystem modernization project on 2030Skin-pass Mill.

...the fastest steelproduction line in China

...Peru copper mineABB received an order from the Sociedad Minera Cerro Verde inPeru for 14 ACS 1000 variable speed drives for its copper minenear the Andean city of Arequipa. Six ACS 1000 (3 x 600 kW, 3 x1000 kW) will soft-start and control the speed of two conveyorsand eight ACS 1000 will control pumps (4 x 1120 kW, 2 x 410 kW,2 x 336 kW). Current copper production at Cerro Verde isapproximately 100,000 tons per year. After the expansion, outputis expected to triple to 300,000 tons per year and the life of themine is expected to increase to the year 2040. Earlier this year,ABB had received orders from Sociedad Minera Cerro Verde foreight ACS 1000 variable speed drives for High Pressure GrindingRolls (HPGR) and four gearless mill drives for ball mills.


Bharat Sanchar Nigam Limited, (BSNL) one of India’s leadingtelecommunication players has entrusted ABB to provideintegrated building solutions including access controlsystems, CCTV and Building Automation for their HeadQuarters building in New Delhi.

The Integrated Building Automation System includes control ofequipment like air-conditioning and ventilation systems in the entirecomplex, pumps, DG sets , lighting. etc. The 14-storeyed buildingwill have a climate -control system comprising of primary andsecondary pumps, air-handling units and treated fresh airunits, 3 chillers and 2 VAMs. The scope of work includesdesign, supply, installation, testing, commissioning andmaintenance of these units.

In terms of access control systems, the entrances to thebuilding on all 14 floors are provided with sensor-controlledautomatic locks. Status of all the doors will be displayed on acentral control station. Date and time will get recordedwhenever any door is opened or closed. As a part of theCCTV system, cameras are installed in areas that requirecontinuous monitoring.

Keeping BSNL connected

Max Healthcare, is setting up a multi-specialty hospital in Delhi.To be built in two phases, the 800-bed hospital will have tenoperation theatres and is spread over an area of 4,70,000 sq. ft.

ABB will provide ‘Clean room technology’ that ensuresminimal noise level, C02-free air circulation, prevents cross-contamination and ensures airflow conducive to quick andeffective dust removal ensuring adequate freshness.ABB’s scope of work includes air-conditioning and ventilationsystems for the entire complex including wards, laboratories,operation theatres, lobby and waiting rooms. Equipmentsupply will include 900 TR (3 x 300 TR) water-cooled screwchiller, condenser water pumps, primary chilled waterpumps, hot water pumps, air-handling units, fan coil units,ventilation fans and cooling towers.

Clean room technology for Max Hospital

ABB recently received an order from the EPC contractor CetharVessels (P) Ltd. to provide a turnkey Electrical Balance of Power(EBOP) solution for a 43MW thermal power plant coming up atSitapuram, Andhra Pradesh. The scope of supply includes the HVsubstation, generator unit and auxiliary transformers, MV and LTswitchgear, control & protection, plant communication systems,emergency DC power system and cabling. The customer willbenefit from ABB’s vast experience and domain expertise and byprocuring the total EBoP integrated solution from a single window.Power drawn from this plant will be supplied to the facilities of ZuariCement Ltd. and Sri Vishnu Cement Ltd.

Integrated EBoP solution

India Roundup

Robotics Service & TrainingCentre, set up in Pune

ABB successfully took up the challenge of meeting Jindal Power’srequirement to complete the turnkey construction of substationsand tramsmission lines for their upcoming 4 X 250 MW OP Jindalsuperthermal power plant near Raigarh in Chattisgarh within sixmonths.

The substation design is based on compact and modularstructures. Phase I of the project included design and constructionof 11 bays of 33 kV outdoor main switchyard, seven 33 kVremote-end bays and 15 kms of 33kV single/double circuittransmission lines, Phase II comprised 4 bays of 33 kV outdoorswitchyard and 40 kms of 33 kV double circuit transmission lines.

Completion ofJindal Power Projectin record time

In order to serve the growing customer-base in and around Western India, ABB inIndia recently inaugurated a RoboticsService & Training Centre in Pune,Maharashtra.

A presentation on ABB's Roboticsphilosophy highlighted the company'sapproach towards value-added servicessuch as productivity improvement &consulting and going beyond essential


services like spare-parts, logistics, training &field service.

The Robotics Service & Training Centre willimpart training on ABB robots, and servicethe demand for spare-parts and services tocustomers in the region. It has a trainingroom equipped with an IRB140 robot andthe latest version robot controller, IRC5.There is also a stock room for spare parts,and workstations for four service engineers.

The Power Electronics team of ABB India has recently beenentusted by The Thai Organic Chemicals Company Limited tosupply a rectifier system for their caustic soda plant in Thailand.Thai Organic Chemicals Company Limited (TOCCL) is a part of theAditya Birla Group in India. Recent successes in this domain includeIndian Aluminium Limited (INDAL) and Grasim, where ABB hassupplied complete rectifier systems and solutions.

ABB has designed, engineered and supplied a 16.5 kA, 490V DCRectifier System for TOCCL’s Caustic Soda Plant at Rayong,Thailand.

ABB India enhancesrectifier presence inSE Asia

In keeping with it's vision of facilitating global competitiveness ofIndian Industry, the Automation Industry Association of India (AIA)conducted Paper Tech 2005, a seminar on automation in the Pulpand Paper industry. Paper Tech 2005 provided a forum forinformation and knowledge-sharing on the development anddeployment of automation technologies across users, consultantsand technology providers. All major industry players and over 100delegates from large, medium and small paper companies attendedthe event.

In the inaugural address, Pradeep Dhobale, Chief Executive, ITC Ltd,Paperboards & Specialty Papers division stressed on the increasingrelevance of automation in the Indian Pulp & Paper Industry andshared ITC's experience in maximising gains through automation.Kasi Viswanathan, President IPPTA, Pres. (Operations), SeshasayeePaper & Boards Ltd delivered a keynote address.The speakersincluded both automation technology providers as well asrepresentatives from the industry, providing an overall perspective.

Many industry leaders presented in-depth case studies on the role ofautomation in their process. Among them were OP Goyal, DirectorJK Paper, CN Sudarshan from Seshasayee Paper & Boards, CSPanigrahi, CEO of Voith Ltd and Victor Anandaraj from TNPL. R RVederah, JMD, Ballarpur Industries Ltd. (BILT) presided over theplenary session.

AIA embarks on Industry Vertical Seminars

The founding members of AIA include the leading automationtechnology players in the country like ABB, Emerson,Siemens, L&T, Honeywell, Rockwell,Yokogawa and Invensys.

CIGRE Colloquium on HVDC, FACTS andemerging technologiesThe Committee for CIGRE India organized a week-long event inBangalore recently which included tutorials, study committee andworking group meetings as well as a colloquium on "Role of HVDC,FACTS and Emerging Technologies in evolving power systems".

Speaking at the occasion, Mr. Ravi Uppal, Country Manager, ABBIndia emphasized on the need to leverage innovative and moderntechnologies and stressed on 'quality systems and products' forcatering to the enormous power needs of the country.

The event also saw the release of the "Reliable fault-clearance andback-up protection of EHV and UHV transmission networks" amanual by Mr. Yues Filion, President of CIGRE. Published by theCBIP, (Central Board of Irrigation and Power) this manual is the resultof a working group formed in 2001 with members from major utilitiesrelay manufacturers and academic institutes chaired by Mr. BapujiPalki of ABB India.

ABB was one of the main sponsors of the event and experts fromthe company presented papers on various aspects of HVDC andFACTS technologies. The event also showcased a computer-demoon FACTS (Flexible AC Transmission Systems) as well as visualgraphics of the recent HVDC Vizag and TCSC Raipur projectsexecuted by ABB in India.

CIGRE (International Council on Large Electric Systems) is one of theleading global organizations on electric power systems. Founded in1921,it aims to develop and facilitate exchange ofengineering knowledge and information in the fieldsof power generation and high-voltage transmissionof electricity.


In line with its initiative to focus on industry verticals AIA isorganising,a similar event for the metals and mining sector tobe held in Kolkata on 25th November (www.aia-india.org)

ABB recently expanded its range ofelectrical relays with the addition of anew multi-function protection devicefor medium and large MVasynchronous motors.

ProtectionThe new range of REM600 relays aredesigned primarily for motorapplications ranging from 500kW to2MW. Part of this range, the REM610motor protection relay, features ahost of integrated functions forprotection against motor damage. Ithandles fault conditions during motorstart-up, normal operation, idling andcooling down at standstill, forexample, in pump, fan, mill or crusherapplications. The REM610 is suitablefor use in both circuit-breaker andcontactor controlled-drives. Withsingle, two and three-stageovercurrent and earth fault protectionfunctions as well as thermal overloadprotection, it is also ideal for feedercable and power transformerapplications.

High availabilityThe REM610 comes with a built-indisturbance recorder that recordsinstantaneous or RMS values ofmeasured signals via four analoguechannels and up to eight user-selectable digital channels. With itsnon-volatile memory, it records faultdata and reports it, even after

Introducing REM600 rangeof relays

auxiliary power failure. This, combinedwith a long mean time between failure(MTBF), enables the REM610 to offerhigh availability.

User-friendly configurationThree fixed and eight programmableLEDs enable fast fault-indication andlocation. A new interface on theREM610, featuring push buttons andan LCD display makes it easy to selectand view data in seven languages,ranging from details of recorded faultsto current and temperaturemeasurements and historical data. Auser-friendly graphic configuration toolenables users to set up application-specific configurations.

Remote monitoring andcommunicationUsers can program the relay by usingthe push buttons on the front of the unit,via serial communication with acomputer connected to thecommunication port, or remotelythrough a control or monitoring systemconnected through the unit’s serialcommunication bus. The REM610features a range of communicationoptions, including SPA-bus slave,MODBUS and IEC 60870-5-103 andalso wireless communication with alaptop computer if required.

Easy on installation andmaintenanceREM610’s compact size and smallmounting depth makes it ideal forretrofits and confined spaceinstallations. Its withdrawable ‘plug andplay’ cassette design makes it simpleto fit and remove, helping reducedowntime required for installation,testing and maintenance. Based ontwo separate units, this designautomatically closes off the currenttransformer when the unit is removed,enabling work to be carried out safely,without shutting off the supply.

The development and type testing of245kV transformer bushing has beensuccessfully completed as perIEC:60137 and IS:2099. The state-of-the-art range of transformerbushings available from ABBcomprises of 72.5, 145 and 245kVratings. The 245kV bushing isdesignated as GOM 1050 1600.Having passed stringent dry (900kVpeak) and wet (725kV peak)switching impulse tests as per ABB‘sglobal standards makes the productsuitable for high-end applications

Introducing 245 kVtransformer bushing


New Technologies

Indian Industry must leverage automation technologiesWe caught up with Veli-Matti Reinikkala Head-Process Automation, ABB Group, during his recent visit to India.Here are some of his thoughts on the future of Indian industry

Is this your first visit to India ?What are your initial impressions?

I have been to India once before. I see a lotof potential in India and the people are veryenthusiastic. There is ,of course, some wayto go with reference to developing theinfrastructure.Seeing the economicfundamentals, I believe the macro-growth issustainable. On the whole I get a verypositive feeling and a sense of optimism thatIndia will stake its claim in the emergingglobal economic order alongwith China.

How do you see the industriallandscape developing in India?

After a quiet period during which we sawover-capacity being balanced out withdemand pickup, industrial growth in India isonce again on an upswing and in fact indouble-digits now. In addition to efficiencyimprovements we are also seeing brown-field and green-field capacity additions inmany sectors like steel and non-ferrousmetals, pulp & paper, pharmaceuticals,cement etc. India has many naturalresources and a booming constructionsector so industrial investments are likely tocontinue. Moreover, besides the raising ofproductivity standards thanks to the entry ofglobal industry players in India, Indianentrepreneurs are also beginning to thinkbeyond the Indian market and are gearing upto play a bigger role in the world economy.Companies like ABB have a key role to playin facilitating this effort.

What is the role of processautomation in helping Indianindustry become globallycompetitive?

As India’s economic growth gainsmomentum it can be sustained only if themanufacturing sector grows at a steadypace and leveraging state-of-the-artautomation technologies can facilitate this.Industry will have to rise to the globalchallenge by addressing issues likeproductivity, efficiency, cost of operation,quality, functionality, consistency, methodsof production and aesthetics in order to gain‘competitive advantage’.

Historically, automation in India has beenseen more as a shop-floor tool than a‘business performance enabler’ but I can seethat this is changing now. Also there hasbeen a belief here that ‘cost advantage ‘ liesin lower labour costs but this attitude is alsofast changing. It must be mentioned herethat automation is not about replacinghumans as often perceived but aboutcomplementing human skills and efforts in abalanced manner. It’s about facilitatingprocesses, enabling measurement & control,ensuring optimum efficiency, increasingproductivity, maintaining consistency andquality etc. While the Indian industry hasaccepted and is adopting enterprisesolutions for business processes, it is yet torecognize the full potential of manufacturingautomation and ‘collaborative systems’.

Business decisions can be greatly facilitatedthrough automation , by allowingmeasurement, control and reporting of keyperformance indicators (KPI’s) required as a‘dashboard’ to monitor, manage and controlproduction and enterprise operations. Ithelps provide real-time information to decisionmakers about the health, efficiency, andeffectiveness of shop floor operations, wheretrue value creation takes place. Automationcan also help manufacturers track andimprove plant and enterprise productivity andperformance through Real-time PerformanceManagement (RPM) - integration of real-timemanufacturing data with real-time cost datafor achieving operational excellence (OpX).

“If you can’t measure it, you can’t control it “.The world’s leading Automation Technologyproviders are well established in India, soaccess is certainly not an issue. Now it’s up toIndian entrepreneurs to take full advantage ofthe latest technologies on offer and leveragethem to gain competitive advantage.

Tell us something about therecently introduced System 800xAtechnology from ABB and otherfuture developments

By removing the barriers of traditionalDistributed Control Systems (DCS),the 800xA system supports the platform,application, and professional service needsof total plant management and control.It dramatically improves plant-wideproductivity through the followingpowerful, integrated core functions.

With System 800xA, customers havethe ability to extend the automation reachof their present system to enjoy new levelsof productivity. It provides the flexibility toimplement the functions these customersrequire today and the agility to add othersas needs evolve.

The system dramatically improvesplant-wide productivity by providingintegrated core functions such asOperations, Engineering, InformationManagement, Batch Management, AssetOptimisation, Control & I/O and Fieldbus(Field Device Integration).

Around 800 engineers from around theworld worked on its developmentincluding 50 research engineers fromABB’s global Corporate ResearchCentre in Bangalore.

I think that with the 800xA, we havereally ‘cracked it’. In the near future,we will address new applications of 800xArather than develop alternatives. In otherwords, we will use the customising featuresavailable in the 800xA to make itadaptable to more and more applications.Going forward, the DCS platform,which incidentally is also the base for the800xA, is the one we will continue to use.


Metals on the Move !As India integrates with the world economy, Indian industry is staking its rightful claim in the emerging global order. Indian entrepreneursare fast coming to terms with the fact that ‘factor advantages’ are no longer enough to sustain competitive advantage. The ‘completevalue proposition’ today, encompasses several key parameters including price, quality, productivity, efficiency, aesthetics, deliverysystems etc. and state-of-the-art automation technologies have a vital role to play in enabling these.

Metals & Minerals are among the fastest growing sectors in India today, with significant brown-field and green-field projects underwayboth in the ferrous and non-ferrous segments and many more initiatives on the anvil. In addition to new capacities and expansions, there isan increasing focus on productivity and efficiency as the Indian metals industry increases its international reach and strives for competitiveadvantage. This theme feature focuses on the metals sector and provides some useful insights on the market, capacity build up, somesuccess stories and ABB’s technology offering to the sector.

Feature Story

Apparent Consumption of Finished Steel (2003)

Consumption and Production of Finished Steel in India

Apparent Per Capita consumption of finished steel - (2003)

China Vs India Metal Consumption

India China China & India as% world

Steel (mt) 35 320 35

Aluminium (mt) 0.9 6.3 24

Nickel (000t) 30 143 13

Copper (mt) 0.3 3.3 22

Iron Ore (mt) 59 406 37

Bauxite (mt) 5 29 21Source: World Bank, Statistical outline of India, China Statistical Year Book, CLSA AsiaPacific Markets


Source -Steel Statistical Yearbook 2004, International Iron and Steel Institute Source -Steel Statistical Yearbook 2004, International Iron and Steel Institute

Source: www.steel.nic.in


ABB serves the metals industry across the value chain Markets and processes serv

� Open pit and underground mining

� Cement manufacturing industry

� Bauxite beneficiation, alumina refin

� Minerals processing for production cathodes, and ingots

� Open pit and underground mining

� Meltshops and casters of steel bloo

� Melting and casting - upto finished p

� Hot rolled coil -upto finished produc

� Hot rolled coil to cold rolled coil, inpickling, annealing, and tempering

� Cold rolled to coated steel, i.e., all galvanizing, painting, coating, tinnin

� Profile rolling mills

� Road and railway tunnels


ved:

ning & primary aluminum smelting

of ore concentrates, pellets, DRI/HBI,

oms, billets and slabs

roducts - for non-ferrous metals & alloys

cts - stainless steel

cluding all types of rolling mills,g linestypes of processing lines forng, cutting, slitting, etc.

A complete range of offering for Plant andProcess Requirements

On the Tin trail...

BL RainaManaging Director, Tinplate Companyof India Ltd.

• Born: 1944

• Wife : Lata (involved in socialresponsibility initiatives) ;Son:Computer Engr. ; Daughter :Electronics Engr. (USA)

• Education : Mechanical Engineer ;PGDM Business Mgt. XLRI ;General Management ProgrammeCEDEP (INSEAD), France

• Experience 35 yrs - Production,Maintenance, Marketing with TataSteel /Associate Companies. Priorto taking over as MD TCIL, helooked after International Trade atTata Steel

• Hobbies : Golf

• Management Mantra : Actionsspeak louder than words

What are some of the commonapplications of this metal ? Tell ussomething of the market.

Tin is mainly used for packaging of processededibles (eg. oils, beverages, fruits, dairyproducts, baby foods etc.) and also forchemicals, paints, aerosols, talcum powder,battery jackets, crown caps, closures etc.

Globally, tinplate production is around 12 to14 mtpa. The world per capita consumptionis 9 -10 kg. , in China it is 1.5 kg and in Indiaas low as 0.4 kg. India’s total consumption oftin is about 350,000 tpa of which, nearly halfof it is imported. Some of the key advantagesoffered by tin as a packaging medium includesultra-violet ray and bacterial protection, aromaand flavour retention, eco-friendliness, longershelf-life, pilfer and tamper proof, excellentprintability for branding etc.

The only indigenous producers of tinplate inIndia are TCIL (original capacity 90,000 MTnow 110,000 MT) and SAIL’s Rourkelaplant (capacity 150,000 MT). TCIL hasimproved its domestic market share from18 per cent in the late 1990s to 35 per centpresently, by focusing on qualityimprovements and shifting to a thinnerproduct mix with increased value addition.

Could you share with us the originsof your company and the early years

Prior to the First World War, India’s supplyof tinplate came primarily from South Walesin Great Britain. Maritime trade between thetwo countries was disrupted by the warand in order to address the shortfall TataSteel and Burmah Oil formed a joint venturenamed the Tinplate Company of India Ltd(TCIL), incorporated in 1920 at a site calledGolmuri in Jamshedpur. The first steel plateof Tinplate gauge was rolled on 18th Dec1922 from the Hot Dip Plant (HDP)producing Hot Dip Tinplate from tin barssupplied by Tata Steel.

Notwithstanding some capacityenhancements, the business model of thecompany remained the same and over aperiod of time, it started to lose out in amarket where tin-substitutes like PET, paper,Tetra Pak etc. started to gain ground.Instead of struggling alone to increase itsshare of an uncertain pie, TCIL joined hands

with the other members of the value chain toform the Tinplate Promotion Council (TPC)comprising TCIL, its promoter Tata Steel,the only domestic competitor, SAIL and 12major can fabricators.

Could you tell us something aboutTCIL’s business profile , productsand processes

Headquartered in Kolkata, TinplateCompany of India Ltd. (TCIL) has itsmanufacturing facilities at Jamshedpur inthe newly constituted state of Jharkhand .TCIL is primarily in the business of providingcost-effective metal packaging solutionsfor edible and non-edible products. Wemanufacture various grades of electrolytictinplates, tin-free steel sheets and Full HardCold Rolled Sheets (FHCR) used for metalpackaging. One unit produces electrolytictinplate (ETP) and tin-free steel (TFS),and the other is the cold rolling mill (CRM).The company’s ETP line operates at ashigh as 126 per cent of its nameplatecapacity (90,000 MT) while the capacityutilization of CRM is over 115 per cent of itsrated capacity (1,20,000 MT). TCIL gets itsbasic raw material in the form of hot rolled(HR) coils from Tata Steel which it convertsto tin mill black plate coils and the ETP/TFSmakes tinplate from these. To keep pacewith technological developments, TCIL wasthe first to set up a combination linecapable of producing both ElectrolyticTinplate (ETP) and Tin Free Steel (TFS)in1979. Before being tin-plated, coil has tobe trimmed to the required width as per thecustomer’s order and then passed throughthe CPL (Coil Preparation Line) with edgetrimming facility. The unique propertiesof tin provide a coating on the steel thatprotects the contents, while providing thesteel with an attractive appearance,corrosion-resistance and ease in bonding,welding and painting. Tin is applied to both

It goes without saying that metals is a sector very much in focus today and hence chosen as the theme for this issue of CONTACT. Whilewe all get to see, read and hear a lot about the so called ‘stalwart’ metals like steel, aluminium, copper etc. we rarely see much on thehumble ‘tin’ and yet this is a metal that touches all of us in our everyday lives. So we decided to bring you an exclusive customer interviewwith the Kingpin of Tin himself and caught up with Mr. BL Raina, Managing Director , Tinplate Company of India Ltd. (TCIL), India’s leadingplayer in the sector. In 1997, Tata Steel under the stewardship of Dr.JJ Irani appointed BL Raina as Managing Director of the company witha mission to ‘fix it’ or ‘axe it’ . The rest , as they say is history – a turnaround story that is even taught as a case-study at IIM-Ahmedabad,recognised among the leading management institutes in the world.


Customer Interview

sides of the black plate coil through anelectrolytic process. Typical applications forelectrolytic tinplate include food and beveragecontainers, paint trays, battery tops andpaint, varnish and aerosol cans. The ETPLine takes care of this process. We producemainly four types of tinplate – Oil Can (OC),General Line (NOC), Open Top Sanitary Can(OTSC) and Tin Free Steel (TFS).

Could you elaborate on the groundcovered since you came on boardand your future vision

Over a period of time, productionprocesses and technologies deployed atTCIL became outdated and obsolete. Theoperations were highly labour-intensive andproductivity was abysmally low. Thecompany was bleeding financially and for allintents and purposes, its promoters wereon the verge of writing its epitaph in 1997.

In the first year after my taking over thehelm at TPIL, the company incurred a loss of620 MINR with 5000 employees on the rolls.Today, the workforce is about1500 peopleand the company had a real turnover (aftertaking into account the fact that thecompany has captive inputs from its parentcompany) of 7.5 BINR in 2004 with a targetto reach 9 BINR in the current fiscal andmargins in the range of around 15 per centand a positive EVA (Economic Value Added).The Company is also exporting to specific-end users in niche markets in SE Asia, WestAsia and Europe and exports, earlierinconspicuous now account for around 25-30 per cent of volumes.

Tin as a packaging medium hastremendous potential for growth, especiallyas we grow our agri-based and processedfood industry in the country. The market isexpected to grow in excess of 15 per centCAGR over the next few years and tinplatedemand is expected to be between420,000 MT and 530,000 MT per annumby 2010. TCIL today , is the largestindigenous producer of tin-coated and tin-free steel sheets in India, enjoying 35 percent market share. We plan to double ourcapacity by 2007-2008 and foresee settingup another green-field plant in Jamshedpur.

Tell us about some of your recentinitiatives to improve plant operations

Over the years, TCIL has been drivingexcellence in operations through a series ofstrategic interventions. This has resulted inbreakthrough improvements in productivityparameters, many of which are now closeto international benchmarks. The Companyis now working with Japan Institute of PlantMaintenance (JIPM) for implementation ofTotal Plant Maintenance (TPM) programand the Company has been cleared for theTPM Award in October 2005 by JIPM.During FY 04-05, both the Cold Rolling Mill(CRM) and Electrolytic Tinplate plant (ETP)achieved record performances, with aproduction increase of over 10 per cent.The ETP production was 140,665 MT(2003-04 : 127,984 MT) and CRM productionwas 167,217 MT (2003-04 : 54,211 MT)

Product / market development efforts havealso been intensified. Thinner products arebeing introduced and innovative solutionsdeveloped. Earlier this year, an innovative‘three-tier tea caddy’ we fabricated, receivedthe Best CAN Award in the ‘Food’ categoryduring an International Steel PackagingCongress organized by the association ofmajor European steel producers, in Germany.

TCIL has also been focusing on technologyand capacity expansion for the past fewyears in collaboration with Tata Steel andNippon Steel , Japan. During 2003-05, thecompany invested significantly and is now ina position to consistently operate at a scaleof 145,000 MT per annum.

Based on your experience, what areABB’s main strengths and areasyou would like more focus

One of my early memories of working withABB dates back to 2002, when they werethe only ones willing to take up thechallenge of replacing a PLC system within4 days, on a line we were refurbishing andcould not afford to shutdown any longer.They accomplished the mission in recordtime and we were impressed with thetechnical competence and excellentsupport. This led us to work with ABB onseveral subsequent projects.

On a corporate level I must compliment themanagement and leadership for beingextremely customer-focused and establishingdurable relationships. We at TCIL have anambitious growth vision and I feel we have abigger date with ABB in the years ahead.

In terms of key strengths, the technologyand user-friendly design features e.g.operating panels are exemplary and we feelthat ABB delivers value in terms of itsproducts, solutions and specializedsupport. As quality awareness increasesand our product gets thinner, we would liketo see more exacting technologies forthickness controls. We would also like tosee more intelligence being added toproducts and advanced diagnosticstechnologies with reference to electronic-fault detection. Facility managementsolutions is another area where we couldwork together in the future.


ABB and TCIL

• 2002 : Revamp of DC Drives & Automation in ETP (Electrolytic Tin Plate) linecompleted in record time (shutdown of 4 days)

• 2004 : Revamp of DC Drives and Automation – Coil Preparation Line (CPL)

••••• 2005 : Electrics & Automation to increase the speed of the existing ETP Line (scopeincludes Reflow Electrics, Plating Converter, RMC, DC Motors & ACS800 Inverters)

of productivityAspects

Nils Leffler, Peter Terwiesch

A manufacturer’s goals are clear: to delivermore of a better product, faster and at alower cost than its competitors. Shorter time-cycles and increased production uptime aretherefore at the top of the agenda. In most ofthe industries that ABB serves, energy, rawmaterials, logistics and labour are majorcontributors to the final product cost.

To remain competitive in a global market,companies therefore have to reduce theirenergy consumption, material usage anddistribution costs while at the same timeincreasing their productivity. But that is not all.

Ever-more-stringent environmentallegislation and safety stipulations have to becomplied with in order to operate at all. Inan increasing number of countries andindustries, customers and governmentalbodies expect products to beaccompanied by a complete audit trail. Withthis increase in complexity, it is hardlysurprising that manufacturers look toadvanced optimisation techniques toenhance productivity and ensure that theirbusiness targets are reached.

The recent troubled state of the worldeconomy has even helped here. Lofty

Manufacturing is all abouttransforming capital, raw materials,energy and labour into productsand services for customers. Forsocietal as well as political reasonsthis has to be accomplished withincertain environmental, safety andregulatory constraints. And thereare cost-drivers to consider, like theproduction plant itself and marketprices for materials, personnel andenergy.

Manufacturing companies that wantto improve their bottom-lineperformance can no longer rely onthe ‘easy pickings’ of the past. Newstrategies are called for. The totalrefurbishment of a plant or moving itto a lower-cost country are two,albeit capital-intensive options. Butthere is another way for plantowners to achieve the competitiveedge they are seeking: by improvingthe productivity of existingmanufacturing equipment. Since theopportunities to do this are mostlikely to be found in complexprocess areas, more sophisticatedoptimization tools are needed.These tools are on the way.

discussions about advanced software forcollaborative co-operation across the entirevalue chain have given way to a morepragmatic search for productivityimprovements. Industry and the utilitycompanies have come to realise that therewill be no more ‘easy-pickings’.

As a result, more complex tasks are nowbeing tackled across all industries and in allareas, from engineering through operation todistribution. While all of these ‘aspects ofproductivity’ contribute to better results,they do so in different ways. Aggregated,they improve the bottom-line, whateverthe industry.

BenchmarkingBenchmarking within an industry points outsome significant differences in the overallperformance. Pharmaceutical companiesare a case in point, and a good example ofa sector where there are opportunities forimprovement (see table). The data indicatesthat there is a considerable upside toadopting more advanced strategies forboth scheduling and operation optimisation.It is interesting to also see that the figuresfor the different industrial sectors are very

similar. This is because ‘best-in-class’means just that, and applies to all sectors,all of which are now approaching the sameperformance level.

The importance of automation

The over-capacity that exists in manyindustries today is forcing companies tofocus on utilising existing assets rather thanon investing in new capacity. Here,automation can be a key factor. When capitalis scarce, automation solutions often offerthe best return-on-investment.

Recent decades have seen broad consolidationin all industries, motivated in most cases bycompanies’ need for global market reach. ABBhas been more than a by-stander. In fact, wecan justifiably claim to have been a driver in theconsolidation of the automation industry, wherewe are today a global leader. We activelydevelop new strategies made possible byadvances in a whole host of areas:communications, computer capabilities, opensoftware and pricing trends, sensortechnologies and applications.

Automation suppliers need to be able todeliver products, systems and services to


Technology Digest

consistent standards, and do it globally.This is because many customers operateworldwide and prefer to rely on just a fewsuppliers. This also means that expertisemust be available around the clock andsupported by remote connectivity tools fordiagnostics and troubleshooting.

The goal of achieving enterprise-widedecision support in real time continues tofeed the trend toward deeper integration ofthird-party systems, such as ERP8, CMMS9and GIS10, with the automation systems.Productivity-enhancing tasks that are part ofthis strategy include optimal operationdespite constraints, with the scopeextended across departments and plants.Optimal scheduling of production orders andmaintenance are becoming essential featuresin the asset management software that isnow an integral part of the automationsupply. The virtual factory, as a concept, hasto be supported by algorithms that enablethe optimised distribution of orders tofactories around the world.

Automation suppliers must sit up and takenotice of another customer requirement –improved asset productivity. The buzzwordhere is ‘overall equipment effectiveness(OEE)’, and new asset management toolsare being developed to improve it. Ratherthan just increase the tonnage incrementally,the control system has to support speed,quality and flexibility.

Removing the need for intermediate buffersreduces inventory, resulting in better energyefficiency with faster cash and product cycles.The automation system must ensureconsistent quality, high yield within theproduction constraints, and fast gradechanges in a more dynamic environment. Allbusinesses have to be able to deal today withhard constraints, like safety and healthregulations, environmental legislation, as wellas soft constraints such as product quality,

control toward control of the completeprocess line, from single plants to multipleplants, and from a single optimisationobjective to multiple goals .

The value of real-time informationCommunication is the key to optimisingoperations across departmental boundaries.This is true whether the information is used tosupport decision-making or for closed-loopcontrol, as in either case real-time informationhas to be delivered to the right place at theright time. Many new technologies areavailable for this today, and the benefits areconsiderable: personnel are empowered bybeing given access to information acrossdisciplines; wireless communication encouragesmobility and web-based services provideaccess to expertise. All of this is offered in thespirit of productivity improvement.

Intelligent field devices communicating overfield buses provide accurate measurementdata and have self-diagnostics capability.The trend towards more complexmeasurements with equipment capable ofself-calibration is also driving product qualityand at the same time reducing raw materialusage. A good example of this is thedemand for direct measurement of qualityvariables in paper production or the analyticalmeasurement of chemical components.

Every item of installed equipment has aconsiderable amount of documentation

a) Inventory reduction (eg: buffer removed) b) Optimization of constraints c) Optimization scope extended

1 Aspects of productivity 1 c

7) Enterprise Resource Planning8) Computer Maintenance Management System9) Geographical Information System

with different grades demanding differentmarket prices. The control system mustensure smooth, optimum running of anoperation within the limits imposed by theseconstraints . It has become clear that toaccess further potential productivityimprovements, the optimization scope has tobe broadened to include larger process areas.However, this makes the tasks even morecomplex. The trend is away from single-unit


Traditional static accounting uses averagedata and indicates that order revenue andvariable costs are linear. The contributionmargin increases with production volume.

2 The value of real-time information

In reality, revenue and cost per ton vary overtime and according to supply source, customerand operating rate. Max. profit is oftenachieved below max. operating rate, whererevenues no longer exceed costs.

attached to it – manuals, drawings, spare-parts lists, operating history, and so on. Eachdocument has to be continuously updated,and must be accessible when needed. ABBhas introduced a technology that describeseach device as a software object containingthe properties of the real object, like a motor,as so-called Aspects. These Aspects mightbe located in several different systems, suchas CAD, CMMS, ERP or a control system,but the Aspect integrator ensures that all theinformation is both timely and consistent. Anobject does not necessarily have to be anactual piece of equipment, like a motor, butcould be more abstract, for example an order,with information such as the original purchasespecification, quantities, location in thewarehouse, etc, as its Aspects.

Data-consistency is essential for moreadvanced optimisation and modelling. Weneed to ensure measurement accuracy,consistency between production plan andmaintenance plan data, use of real-timecosts and prices rather than historicalaverages. Use of real-time data cansignificantly impact the computing of theoptimal production level, which mightsometimes deviate from full production. Infact, the variable cost might rise steeply andnon-linearly as full production is approached,while the fixed-cost contribution continues todecline linearly, resulting in maximum profitbeing achieved below the maximumoperating rate.

Tools for advanced optimisationOptimising an operation within the businessconstraints outlined above, and doing itacross several departments or a whole

plant or network, possibly across multipleplants or multiple networks, requirespowerful computers and new algorithms.Process models are needed that combineon-line estimation with the laws of physics.Such a toolkit for optimal control will havemany different interactive components . Themodels themselves will change over theprocess lifecycle, being continuouslyupdated with the help of real-time data.

Economic optimisationEvery business, whether it manufacturesproducts, provides services or distributeselectricity over a network, must ultimatelybe interested in being able to control itsoperations from an economical standpoint.Normally, this translates into minimisation ofthe ‘cost minus revenue’ function. The moreelements that are taken into account, themore realistic the control strategy will be.However, this comes at the cost of anexponential increase in complexity.

The minimisation of this so-called economicobjective functional over time is subject tothe hard and soft constraints describedbefore as well as to the dynamic behavior ofthe different components, since several of

5

Asset life-cycle: Implementation of anouter economic optimisation loopenables operating setpoints to beprovided to the inner control loop.

4 The economic objective functional

them change over time. What the industryultimately wants is to be able to calculatethese control strategies on-line, based onreal-time data. A closer look at the individualcomponents shows how:

� Asset costs depend on two differentphases – the design and the lifecycle.The latter depends on the residual lifeexpectancy and on maintenance andinspection costs, which might be afunction of operating strategies.

� Energy costs have a thermal and anelectrical component. In each case,companies can either purchase theenergy or generate it themselves. Costsvary with market prices and fuel type.The export of excess generation can beincluded in the formula by inserting anegative cost factor.

� Material costs are dependent on marketprices, the quantity and discountstrategies. Inventory costs can add to thedynamics by bringing factors into play likethe storage of intermediate products inbuffers or final storage of the end product.

� Finally, the labour costs depend onseveral factors – manned-shifts,inspection and maintenance frequencyand the plant’s location, among others.In practice, this cost element has asignificant impact on the outcome ofany optimisation attempt.

All of the above costs are balanced againstthe product revenues, which vary withchanging market prices.

(5(5(5(5(5))))) shows how, by implementing an outereconomic optimisation loop, operating setpoints are provided to the inner-control loop.


Source: ABB Review>

Frontiers of advanced controlAs demand for more sophisticatedmathematical modelling of industrialprocesses grows, we can expect to seeintensive R&D efforts in several areas. Atthe top of the list are improved ease of useand robustness of algorithms in an on-linesetting. Since plants can be seen ashomogeneous entities, we can expect tohave to deal with more complex problems.Going beyond a single site, we will tacklethe virtual plant with multiple productionlines, located around the world. Researchin the application area will look at ways todecompose these larger tasks and applydistributed problem-solving techniques,such as agent approaches, withoutintroducing sub-optimisation.

Non-linearity, transitions between steadystates, dynamically changing constraints,and abnormal event handling, are allproblems that industry is familiar with andwould like to have on-line, real-time solutionsfor. Prediction and advanced schedulingmust be able to cope with longer timehorizons with variable time intervals.

Data consistency and data quality isanother area in which further research workhas to be carried out. Mass balance

techniques can compensate formeasurement errors caused by sensors‘drifting’ or failing. This ensures a degree ofconsistency, but further improvement ispossible. Using predictive maintenance toimprove asset management of sensors,rotating machines and actuators, is aproven means of eliminating unplannedproduction stops.

Ease of use has two facets. On the onehand, the models must be designed foreasy interaction and be comprehensible tothe operators. On the other, it must bepossible to generate them from the planttopology as it is described in the P&I(Process and Instrumentation) diagrams. Itis important for the data to be entered justonce. Economic data should originate fromERP systems. Life-cycle dimensions shouldbe built into the overall models.

We can say, in summary, that asset andenergy aspects of productivity deservemore emphasis in modeling, control andoptimisation. Recent advances in automationhave simplified the industrial application ofcontrol and optimisation, but there is aconstant need to improve the modeling andengineering as well as the usability of themodels. To reach these desirable featureswe still have a way to go, but even small

3Control models change over the process life-cycle, being continuously updated withthe help of real-time data (SS) Steady State

steps in this direction promise to have asignificant impact, as further articles in thisissue of ABB Review will show.

Such models are used to determinepredictive behavior over long time intervalsin order to optimize production orderscheduling and to calculate the bestpossible operating level from real-timeinformation. Time horizons of 24 to 48hours are very common, but even longerintervals than these are desirable. A wayforward here might be clever algorithmsdesigned around structural decomposition.

Today’s control systems are equipped withtool kits that contain P, PI and PIDcontrollers – the ‘workhorses’ of theautomation industry. While conditionmonitoring of rotating machines is commonenough, condition monitoring of controlloops is anything but common. In fact, atypical plant could well have 30 to 40percent of its loops running on manualbecause of poor tuning. That such a plantwould be performing well below par hardlyneeds saying. Fortunately, automatic tuningpackages that solve this problem are available.

In the area of more advanced control, thecurrent trend is toward model predictivecontrollers (MPCs), but controllers basedon quadratic cost functions or linearcontrols with state constraints are alsowidely used. The MPCs being adoptedtoday are mostly Single Input Single Output(SISO) types. Multiple Input Multiple Output(MIMO) controllers with linear constraintsare also gaining in popularity. Thealgorithms most commonly used wherenon-linear constraints exist are gain-scheduling algorithms. Optimizationalgorithms normally focus on steady-stateconditions with transient behavior (gradechanges) handled in small ramps. Object-oriented modeling is becoming morepopular as the relevant tools andprogramming languages are developed.

In the near future, real-time dynamicoptimization of transient conditions, hybridmodeling of process dynamics and mixed-integer programming will all be included in thetoolbox of the process engineer. Ultimately,economic optimization of processoperations, including life-cycle aspects, will bethe solution of choice for industrial customers.


Living our commitment to Sustainability

Greentechnologies

The Troll A gas platform in the North Sea isthe first off-shore platform in the world to bepowered by a direct current (DC) electricitylink originating on land - an achievement withconsiderable cost and environmentalbenefits made possible by ABBtechnologies. The platform, located some70 kilometers off the coast of Norway, is runby Norwegian oil giant Statoil and startedcommercial operation in 1996. On October1st, 2005, two 40 MW compressorscommenced operation at Troll A to maintainthe gas delivery pressure, compensating forfalling reservoir pressure. ABB deployedtwo key technologies - HVDC Light (HighVoltage Direct Current) and the VHV Motor(Very High Voltage) - as well as othersolutions to help power the two 40-MWcompressor units on the Troll A platformwithout any local power generation.

The benefits of transmitting power from theshore to the platform includes zero-pollution(all electricity used on Troll A is generated byhydro-power on the mainland), increasedtransmission efficiency, longer life-cycles forequipment, fewer maintenance stops and aperfect health and safety record on theplatform. It all adds up to major savings andlower costs.

Transmission of power from shore toplatform eliminates carbon-dioxide andnitrogen oxide emissions from the platformand its gas treatment plant at Kollsnes.

Avoiding tax on CO2-emissions also cutscosts. High among the list of other benefitsis health and safety. Use of the technologiesand avoidance of on-board powergeneration - has meant no injuries and noloss of time through incidents, a key elementin Statoil's business strategy.

Months have lapsed since the Tsunamistruck off the coast of Sumatra, causingwidespread damage and loss to life andproperty. In India, Tamil Nadu, parts ofAndhra Pradesh, Kerala and the entireAndaman and Nicobar islands wereaffected. The victims of this disaster arestill trying to pull their lives together. Atthe time, ABB responded withimmediate aid in the form of clothes,stoves, blankets etc. With the reliefphase over, a long-term rehabilitationprogramme is in place.

After dialogues with affected people,NGOs and local administration and aneed-gap analysis to understand currentrehab efforts, ABB has decided to workwith marginal groups in 17 villages ofNagapatnam and Karaikal districts torestore their livelihood.

The fisherwomen are an integral part ofthe fishing community, responsible formarketing, processing and distributionof fish. Most of their equipment like ice-boxes, baskets etc, were lost in thetsunami and many have debt burdenswith no means of repayment. Alongwith Sneha, a local NGO, ABB isworking with 50 self-help groups of 15women each, to reinstate their lostlivelihood. Means of augmenting theirincome have been created such asgroup ownership and running of autos,grinding machines, creation of fish-dryingplatforms for processing excess catch,

Rebuilding lives!and helping them form a federation tonegotiate better prices.

A boom in construction followed thetsunami, creating potential in constructionrelated trades like electricians, plumbersetc. The government and NGOs wantsthese jobs to remain with the affectedgroups hence strengthening the localeconomy. Skill training in some of theseidentified trades to enhance alternative/non-fishing based livelihoods is thesecond area where ABB is involved. TheConstruction Workers BuildingConstruction (CWBC) is conducting atwo-month skill-training programme andthey would absorb the trainees inconstruction contracts negotiated withthe government. Apart from training, thesuccessful trainees would also beprovided with tool kits.

Persons with disability form anothersection of the community that needsfocused assistance. Marginally disabledpersons who were earlier running smallbusinesses like petty shops, etc. lost alltheir inventory and equipment. Workingwith the District Disability Network, ABBis focusing on identifying such personswith moderate disability, and reinstatingthem in entrepreneurial activities, as wellas construction related trades.

ABB has also partnered with Action Aid -an international NGO with extensiveexperience in disaster relief for theTsunami rehabilitation effort.

ABB employees had contributed a day’ssalary which was matched by thecompany and this fund is now being usedfor the rehabilitation programme.


Channel Line

At a glittering event held in Bangalorerecently, ABB India honoured its topperforming channel partners from acrossthe country. Mr. Uppal, VC and MDaddressing the audience, said," I amheartened and encouraged to note not justyour achievements but also the spirit ofambition and determination for the future.""We truly value you as a 'partner' in ourprogress and look forward to yourcontinued dedication, loyalty and support

as we continue to reach for even greaterheights " he continued.

"Our channel partners are truly our'partners' and we are indeed encouragedby their enthusiasm and support in helpingus grow our product business aggressively.We on our part will continue to supportthem in every way in order to maximize ourmarket presence." said Mr. BiplabMajumdar, Head - AT Division, speaking atthe occasion.

Winners

RK ManchandaClassic Engineering, Delhi

D KanthilalCauvery Electricals, Bangalore

Ashok GuptaGupta Engineers, Faridabad

K SridharTrend Electric Co.Pvt.Ltd. Chennai

Avinash WighmalShrirang Sales Corp. Surat

Devang MunimPooja Industrial Agencies - Surat

Vinod AgarwallaIntegrated Data Systems, Kolkata

Munish SharmaVenture Control Systems, NOIDA

U C RatadiaSuman Electric Udyogs,Bangalore

Krishna & Javed BaigJK Automation, Kolkata

ABB India recently launched a mobile display van at New Delhi toreach out to industrial customers and channel partners in theNorthern region. This will help to increase awareness and give afirst-hand experience of the comprehensive portfolio and vastproduct range. The van is equipped with product display stands,with a hydraulic lift, facilitating easy entry and exit of the stands.Pull-up banners and product catalogues give the customer anoverall feel of the Company and its offering. A sales engineer willaccompany the van to various cities, towns and industrial areas,where along with the Channel Partners, they will organisemeetings, road shows and demonstrations. This is the first ‘pilot’;based on the experience, more such display vehicles will be rolledout in other regions.

A road show with a difference!

President’s club honours topperforming channel partners


Launching of the first standard products mobile display van

Tech Bytes

All for one, and one for allABB's universal motor controller (UMC22-FBP) utilises the new FieldBusPlug, so OEMs don't need to makecostly product adaptations to meet multiple fieldbus protocols. It helps improve reliability of electric motors incomparison to conventional methods, like thermal overload relays. That's important because the productivityof a paper mill, for example, depends heavily on the reliability of its electric motors - and downtime would betremendously costly. UMC22-FBP can save OEMs money at every stage in the design and manufacture ofany kind of motor-driven machinery. The FieldBus Plug adds simplicity and flexibility - from the drawing boardto installation on site because the entire motor control centre comes as a complete unit, the manual labourrequired to install the system on site is also reduced significantly - cutting installation costs while increasingoperational uptime.

Pioneering videographic recordersABB’s SM series of videographic data recorders packs in more innovations and features than any other datarecorder, which is why the SM3000 - won the prestigious “Control Engineering Editor’s Choice Award” for“service to industry, technological advancement, and market impact”. Since its launch, the SM series hasbecome an increasingly popular replacement for paper chart recorders and older generation recorders in abroad range of processes where emissions, quality and product integrity have to be monitored and recorded

continually or at frequent intervals.

It features Microsoft Windows compatibility for ease in use, solid state compact flash memory cards for high data storage capacity,large choice of display like strip and circular charts, digital indicator, process and bar graph displays, remote process monitoring, real-time information, advanced data access and e-mail facilities via Ethernet communications systems. SM videographic recorders are usedall over the world in industries like food and beverage, aero and automotive, water and wastewater and electric power.

Award-winning MotorformerABB’s unique invention – the Motorformer is a very high voltage motor and generator that is suitable in anyapplication where conventional synchronous machines are used, both onshore and offshore. The motor operates atvery high voltages of up to 70 kV (compared to 15 kV typically for a conventional motor) that is connected directlyto the grid, with no need for a transformer or related secondary-side switchgear.

The stator windings operating at various voltage levels consist of standard XLPE insulated power cables, circular in shape as opposed tothe conventional rectangular one – allowing for a smooth field distribution around the conductor. By eliminating the need for a transformerand switchgear, the Motorformer also omits the additional civil work associated with system installation and commissioning. In addition,the total footprint is much smaller, reducing the amount of space required. Fewer system parts means less maintenance, as well asimproved reliability and availability. Apart from the stator windings, the Motorformer has been designed with conventional ABBcomponents.

Monitoring via SMSABB’s new GSM-enabled FieldIT AquaMaster water flow meter allows water utilities to perform flowmeasurement, configuration and diagnostics remotely using standard SMS messaging.

Water flow meters control and monitor water flow and pressure in pipes that carry potable water into factories &households. ABB’s modern electronic meter FieldIT AquaMaster with an integrated data-logger, offers superior

data accuracy as compared to the traditional mechanical meters. Like any metering equipment, water flow metersrequire regular reading, testing and occasional configuration changes. Given the vast number of meters and distance between them,checking and servicing these meters manually on-site is an extremely costly scheme. Using ABB’s new generation of GSM-enabled FieldITAquaMaster, most of these operations can be carried out remotely using only a standard GSM mobile telephone or a GSM-linked PC.


ABB young scientists rated top innovators in MIT reviewKatrine Hilmen, a scientist at ABB’s corporate research center in Norway has been namedone of the world’s top 35 young innovators by the Massachusetts Institute ofTechnology’s (MIT) Technology Review. In 2004, ABB research scientist CharlotteSkorup was named to the Young Innovators list for research involving software to simplifyand improve the way human beings interact with machines.


www.abb.co.in/contact

Recent Media Coverage

The last word

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

Thank you for your feedback, encouragement and useful suggestions which help us continue to strengthen CONTACT. It isour endeavor to ensure that CONTACT not only brings you the latest from the world of ABB but also helps build a commonknowledge and technology platform in the power and automation space. We shall continue to bring you these ‘themebased’ issues, which you have appreciated. Do feel free to suggest any specific topics you would like us to cover.


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In perfect tune with metal

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Hitting the right note at the right time is the secret behind all harmony. Fine-tuning the processes in the iron, steel or non-ferrous metal industries can help your business to become more productive, efficient and competitive. By providing theright information at the right time in the right place, ABB's wide range of solutions make sure that all the instruments inyour production facility will always know what key you're playing.

Whether it's hot or cold rolling mills, casters or melt shops, ABB can help you with the design, planning, engineering,supply and commissioning of your complete electrical and automation systems. ABB provides process automation,advanced drive technology, smart measuring instruments, technological control, modelling and a full range of service - allfrom one single source. So lets make music together!

Documents

Issue 3 / 2005 The ABB India Magazine...ABB Ltd. in India. As part of the new organisational approach , eight regions have been defined to manage the business line and functional roles