Issue 1 / 2003 The ABB India Magazine · Issue 1 / 2003 The ABB India Magazine ABB wins overall ......

Issue 1 / 2003

The ABB India Magazine

ABB wins overallWall Street JournalTechnology award

ABB India wins singlelargest export order

ProductivityEnhancement throughAutomation –The Industrial IT way

CONTACT – The ABB India Magazine2

CO

NTE

NTS

CONTACTEditorial Team: Harmeet S Bawa, Vikram V Kanth, Antaash Sheikh.Correspondents: Manish Bhargava, Namita Asnani.

ABB India, GF-Corporate Communications2nd Floor, East Wing, Khanija Bhavan,49, Race Course Road, Bangalore - 560 001.

All trademarks acknowledged.Design: Shilahar Associates, Bangalore.

www.abb.com/in

A new simpler ABB 4

ABB to implement Industrial IT solution for 5the world’s longest oil pipeline

ABB’s first Industrial IT factory goes online 6

Building knowledge capital through training 9and empowerment

Welcome to the world of IndustrialIT 10

Channel Line 20– ABB India’s B2B portal crosses Rs. 120 million mark

during first 6 months of operation

ABB and Sustainability 21– Rain water harvesting– A ray of hope

Q&A 22

More options with ABB’s Industrial IT fieldbus solution 14

Exploring the value of Industrial IT enabled products 18from ABB

Productivity Enhancement through Automation, 19The Industrial IT way

Putting Industrial IT to the test 4

Issue 1 / 2003

CONTACT – The ABB India Magazine 3

Dear Friends,

Thanks to the continued support of our customers and the effortsof our employees, ABB India registered a strong performance forthe year ending 2002 despite a challenging and competitivemarket environment. Order intake for the year was up 20% andRevenues grew by 14%. In addition to the continued confidenceof our domestic utility and automation customers, we also brokenew ground in international markets with the companywinning several turnkey export projects and we also increasedour global product exports and services.

We re-entered the market for HVDC and reactive power compensation, winning significant orders in theseareas, after a long gap. We made excellent progress with our strategic focus on standard products anddeveloping our channel partner business. This included the addition of over 120 channel partners, acrossthe country, several brand initiatives, the successful launch of our e-portal, which got off to a flying start,resulting in significant e-channel business. Several new products and applications were introduced, bothin the power and automation technologies arena, including 400 kV power transformers, new range of LVproducts and drives, flame proof and higher frame size motors, to name a few.

Our continued focus on improving productivity and efficiency helped us deliver greater value to ourcustomers and other stakeholders. We implemented several new IS and HR initiatives including thecompletion of SAP implementation. We stepped up our communications’ activities and enhancedcompany visibility considerably thereby strengthening our brand equity. Besides the ongoingconfidence of our customers, these efforts were also widely acknowledged by the media, investors andthe communities we operate in.

ABB, as you know has been recognised as a technology leader for over a century, with many pioneeringbreakthroughs to its credit. We invest around 7% of our Group turnover in research and order relateddevelopment, which is weaved into the fabric of our business strategy and product portfolio. We have avery high ‘intensity of innovation’, with around 75% of our present business being based on productsdeveloped in the past five years.

In today’s highly competitive business environment, all businesses are seeking radical productivity andefficiency improvements. ABB is spearheading this effort through its open architecture basedIndustrial IT platform aimed at real-time, seamless integration of plant operations and business processesacross the entire value chain. In keeping with this vision, ABB is also ‘Industrial IT enabling its ownproducts to facilitate a scalable ‘plug and produce’ architecture based on ‘product suites’ to suit specificprocesses and requirements. Over 35,000 ABB products have already been Industrial IT enabled to date.Our global R&D centre in Bangalore is also facilitating the development of Industrial IT . In this issue ofCONTACT you will read more about Industrial IT, which we have termed ‘the next way of thinking’.

In the year ahead we will continue to focus on our strategic initiatives aimed at creating value for ourcustomers and other stakeholders by leveraging our domain competence and vast manufacturing andmarketing presence in the country and applying our business philosophy of “thinking global-acting local”.I look forward to the continued confidence and support of all of you in this endeavour.

Ravi UppalVice Chairman & Managing Director, ABB India



Business Area

High voltageproducts

Medium voltageproducts

PowerTransformers

DistributionTransformers

Utility AutomationSystems

Power Systems

ABB’s new simplified structure

will help focus on core

businesses and make response

times faster, making it easier for

customers to transact with ABB.

A new simpler ABB

Power Technologies Automation Technologies

Business Area

Control PlatformProducts

Drives & Motors

Low Voltage Products& Instruments

Robots, Automotive &Manufacturing

Paper, Metals, Marine& Turbocharger

Petroleum, Chemical& Consumer

7 Divisions

AutomationTechnologies13 Business

Areas

3 Divisions

6 BusinessAreas

Powertechnologies7 Business

Areas

6 BusinessAreas

Novartis, one of the world’s leading pharmaceutical

players has chosen ABB to upgrade the first of its

pharmaceutical and biotech plants to 21 CFR Part

11 regulations and other U.S. Food and Drug

Administration (FDA) requirements. The plant,

located at Torre Annunziata near Naples in Italy,

is a key facility in Novartis’ global network of

production centres for finished pharmaceuticals

and active ingredients.

The upgrade has four main aims – facilitating 21

CFR Part 11 compliance, renewing an outdated

control system, increasing the number of products

from one to three and raising production capacity.

ABB has tailored a solution based on its Industrial

IT platform to meet these objectives. The solution

consists of Operate IT operator stations, Control IT

AC800F controllers and Produce IT Batch software.

ABB is also responsible for engineering,

configuring and validating the entire system to 21

CFR Part 11 and other FDA standards, and this

state-of-the-art solution will enable the plant to

Putting Industrial IT to the test

operate as a paperless environment, in which the

vast amount of paperwork required by law to

record and verify each operation in the production

process is replaced by a more efficient,

computerised system of electronic batch records

and electronic signatures.

Based on its success, the Industrial IT solution

being implemented, could become the preferred

platform for other Novartis’ plant upgrades

worldwide.



ABB is to supply control and safety systems for the

world’s longest oil pipeline, running from Azerbaijan

to Turkey. The new system is based on ABB’s

Industrial IT technology, which links products and

services with the information needed to run, service

and maintain them. The construction consortium,

BTC, will be able to control operations at both ends

of the pipeline, which are 1,760 kilometres apart and

in different countries. Construction of the US$ 2.9

billion underground pipeline will start next year and

is due to be completed in 2005. When commissioned,

it is expected to carry one million barrels of oil a day

from Sangachel on Azerbaijan’s Caspian coast,

through Georgia, to a new marine terminal at Ceyhan

on Turkey’s southern Mediterranean coast. ABB will

supply, install and commission integrated control and

safety systems to provide operational control,

emergency shutdown options, and fire and gas

monitoring of the pipeline, a marine terminal and two

offshore production platforms.

The work includes remote-controlled subsystems to

isolate sections of the pipeline for regular

“A cross-border technology solution is

needed to make sure this extremely complex

pipeline runs efficiently. Our Industrial IT

platform is unique in that it handles both

process and safety control in one system,

rather than with separate systems as is done

traditionally. This is important to ensure

pipeline efficiency, as well as environmental

and personal safety.”Dinesh Paliwal

Head – Automation Technologies

inspection and maintenance. The pipeline will be

linked over its entire length by a fibre optic

telecommunications backbone. Associated field

instrumentation includes transmitters and ultrasonic

flow metering for the terminal, valve and pumping

stations.

ABB to implement Industrial IT solutionfor the world’s longest oil pipelineABB to implement Industrial IT solutionfor the world’s longest oil pipeline

ABB Industrial IT keepsthe beer flowingABB is set to help Warsteiner breweryflow into the future by implementingstate-of-the-art Industrial IT technologyat two of its production plants inGermany.

At the Warstein site, more than 42,000I/O points will be coupled with 37 Control ITcomponents via Profibus, operated from 17operate process stations. And at the Paderbornbrewery, the system will be expanded to morethan 12,000 I/O’s and 13 controllers. The twoinstallations will not only replace nine existingsystems, but the entire revamp, includingInform IT Production Manager, will integrateall operations at the breweries – from batchlogging to filtration, from central power supplyto refrigeration.

“ABB’s Industrial IT solutions are thetechnology of the future,” said Ulrich Brendel,technical director at Warsteiner. “WithIndustrial IT, we have access to the wholeproduction process and, thanks to objectorientation, all production parameters aretransparent,” he added.



ABB’s first Industrial IT factorygoes onlineNew technology at the Lodz distribution transformerfactory in Lodz will increase speed and efficiency

ABB’s focused factory, in the city of Lodz,

Poland, which manufactures distribution

transformers between 250 and 2000 kVA is the

first ABB factory to go online using Industrial IT.

Industrial IT will now drive the entire production

process leading to significant increase in speed

and efficiency, shorter delivery times and

accurate delivery schedules.

With Industrial IT in place, customers will be

able to get quotes, confirm product delivery

dates, configure the technical data for a

transformer and automatically enter the order

into the Enterprise Resource Planning (ERP)

system of the factory. Very soon, the new system

will also provide information about plant

capacities, and which ABB factory can carry out

an order in the shortest possible time; work can

then be done in a single factory, or spread across

multiple factories within a region or globally.

ABB’s unique Aspect-Object technology provides

a simple and intuitive way for Lodz management

and supervisors to monitor and control factory

operations. Every user desktop can be

customised to meet individual job needs and

requirements, while retaining a common ‘look

and feel’. In addition to the planning and control

functions, the Aspect Integrator provides instant

access to a wide range of user-defined reports.

Management can view current job status, quality

and test results, as well as historical performance

information, with a simple click of a mouse.

This ‘virtual‘ global factory concept will be an

important breakthrough for ABB in the drive for

improved speed and full utilisation of capital

resources. For the first time in ABB and the

industry as a whole, control and business

information will be accessible on one screen -

drawings, bills and machine maintenance

information. Apart from improving cycle times

and machine use, such electronic information

transfer will ensure accuracy and consistency in

manufacturing leading to quality improvements.

The Industrial IT set-up in Lodz can be deployed

in discrete manufacturing elsewhere in the

world.

Industrial IT technology and solutions have been

introduced at every stage of the business in Lodz

– from online ordering and planning, through

the manufacturing process to final product

shipment. “Industrial IT is highly beneficial and

profitable for customers. It radically increases

speed, cuts total cycle time by more than 50%

and consistently ensures a high-quality product,”

said Peter Smits, head of Power Technologies

division. “The usual delivery time for a

distribution transformer is five weeks. However,

the actual production time is only five days.

Time is lost through many interfaces causing

waiting time and double-checking of

information. Real-time applications and the

integration of all systems within the factory cut

that time drastically,” he added.



New alliance to enable ‘shop floor to top floor’ connectivity

ABB, Accenture, Intel and Microsoft have formed analliance to help manufacturers bridge the gapbetween plant floor operations and enterprise ITsystems. The alliance aims to help manufacturers bysimplifying integration, gaining greater visibility intotheir businesses, making informed, real-time businessdecisions and enhancing their financial performance.

The four companies will provide a full range ofcomputing diagnostics, solution design,development and integration services formanufacturers. The team’s joint development workwill help customers gain access to manufacturing

Stop press!

Markus Bayegan receivingthe award at the EuropeanInnovation Award ceremony

ABB wins overall Wall StreetJournal Technology award

ABB won the gold award for technology in theEuropean Innovation Awards held by The WallStreet Journal, Europe. ABB received the accolade,ahead of 190 individuals, organisations andcompanies in 20 countries, for its development ofwireless sensor technology.

ABB unveiled its award winner “Robbie” at thetechnology fair in Hanover, Germany, earlier thisyear. Robbie is an assembly line robot fitted withwireless sensors that allow performance data to besent to a central computer. The data is sent usingradio waves rather than being transmitted via aheavy cable. Robbie also has a wireless powersupply rather than a conventional cable withenergy from a magnetic field being converted intoelectrical power.

ABB’s award winner ‘Robbie’

automation technology that will work seamlessly ina plant environment and integrate with a widecollection of enterprise IT systems.

The collective resources of the alliance membersbring automation and power products,manufacturing solution expertise, robust computingand networking, and programme management andintegration skills together to support a powerfulopen architecture for enterprise solutions.

“It shows that the quality of our research anddevelopment and technology-based innovation ishigh, contributing to significant value creation inour business areas. It is also very well received byour customers,” said Markus Bayegan ABB’s ChiefTechnology Officer.

Reporting on the technological advance representedby “Robbie”, The Wall Street Journal said that itpromises to make cabling, including power cables,on electronic equipment a thing of the past.

Optimize IT receives Editor’s Choice Awardfrom Control Engineering Magazine

The magazine chose Optimize IT Real TPI for multiplereasons – the product helps manufacturers determineand improve the performance of their factories. It helpsplants run smarter and better with substantial costsavings; it automates data collection and analysis andprovides customised reports tailored to address theneeds of plant management. The product has been

successfully adopted by customersacross industrial segments includingseveral Fortune 100 companies who areusing it to improve their competitive advantage on adaily basis. The product has enabled manufacturers toimprove productivity, reduce costs and improve returnon assets through capital cost avoidance.


ABB India wins single largest export order

ABB India has been awarded its single largestexport order to date by Public Establishment ofElectricity for Generation & Transmission (PEEGT),the Power Generation and Transmission Utility ofSyria. The turnkey order includes six new 230/66/20kV substations for Dera, Al-Fayha, Bebila,Telhamis, North Aleppo and Sarakeb and will helpin substantially improving power supply to thesetowns. The project is scheduled for completion inabout 24 months. This is a fitting example of ABB’sglobal optimisation philosophy and reinforces ABBIndia’s growing reputation in the internationalmarket.

“We are already working on projects with

PEEGT Syria and this order reflects the

customer’s trust in our capabilities. It is an

endorsement of ABB’s leadership in power

and automation technologies and recognition

of its unparalleled domain expertise”.

– Ravi UppalVice-Chairman and Managing Director, ABB India.

The scope of the project includes design,procurement, manufacture & supply of equipmentfor all the substations. ABB’s multi-productequipment supply will include Power & InstrumentTransformers, Outdoor Circuit Breakers, MVSwitchgear and Control & Relay Panels from itsstate-of-the-art manufacturing facilities at Vadodara,Nashik and Bangalore.

“ABB’s cutting-edge power technologies and

local manufacturing capabilities combined

with our proven engineering and project

execution competencies have been decisive

factors in this success”.– Inder Sadhu

Head-Power Technology Systems

Expanding horizonsAs part of its focuson exports, ABBIndia has beenrapidly expandingits geographicalfrontiers andrecently broke newgrounds by winningsignificant orders inBhutan and Iceland.

ABB India secured a turnkey substation order fromthe Bhutan Power Corporation Development &Construction Department for supply andconstruction of 220kV and 66kV substations atRurichhu & 220kV bay extension at Semtokha.

Rurichhu, a greenfield substation, at an altitude of900m will evacuate power from Basochhu lowerstage Hydro Electric Project. It is proposed to be an

unmanned substation and will be controlled fromthe main control centre through OPGW/ PLCC linkand fibre optic terminal equipment. Semtokhaextension substation, located near Thimpu, is at analtitude of 2,300m. The project is scheduled forcompletion in 15 months.

The breakthrough Iceland order is for 6 nos.indoor 66kV SF6 EDI circuit breakers from NationalPower Company, Iceland. This is the first time thatcomplete EDI breakers will be sourced from India.The EDI circuit breaker is part of the ED series ofcircuit breakers for which ABB India is the globalsourcing base within the Group.

These orders bear testimony to the high quality andadaptability of ABB products, which can beinstalled in countries with diverse climatic andtopographical conditions. It is also proof of theability of the ABB India team to tap new businessopportunities anywhere in the world!



Building knowledge capital throughtraining and empowerment

ABB India has recently set up a new customer

training centre at Vadodara. This is in addition to

similar centres at Bangalore and Nashik. The main

objective of this centre is to enhance technical skills

and develop competencies of personnel across

functions and levels. The training modules, designed

by ABB’s expert team of trainers with unparalleled

domain knowledge and experience, are structured

to provide in-depth information on ABB’s wide

range of products, systems and solutions for power

transmission and distribution including the latest

technological developments. The programme

curriculum addresses the needs of all levels of

management, engineers, supervisors, technicians

and operating personnel and creates opportunities

to learn, grow and reach higher performance levels

through knowledge empowerment.

Trainees will have access to world-class

infrastructure like sophisticated learning aids,

multimedia presentations, simulations and product

cut-outs, practice benches for hands-on training

and well-equipped class rooms with instant access

to ABB university e-learning modules.

Some of the chief benefits of the ABB training

programme are:

! Better return on training investment by

maximising productivity and performance

! Reduced life cycle costs thereby increasing

return on investment and return on assets

! Maintaining products and systems at a high level

of readiness, so as to minimise downtime and

mitigate the need for equipment repair

The training initiative is a major step in building on

the company’s long-term relationships with its

customers to provide them with effective and

customised solutions that address their specific

business needs. ABB’s training programme aims at

giving customers the knowledge advantage to

enable them to ‘power’ ahead and maintain their

leadership edge in their respective market space!

Maneja, Vadodara

Peenya, Bangalore

Nashik



=

IndustrialIT

Technology Digest

Welcome to the world of

Compatible enterprisebuilding blocks

Through the broadest technology initiative in its

history, ABB is “information enabling” every

product – bundling documentation, configuration

and connectivity tools, life-cycle support, and more

in consistent electronic format.

Using patented ABB Aspect Object™ technology,

these electronic characteristics are built into a

powerful software shell which represents the

physical object in every sense. Simply copy and

paste the Aspect Object into your automation

platform, then point and click for faster installation,

operation and asset management!

! Consistent, electronic asset information in every

box

! Plug-and-Produce installation and integration of

enterprise objects

! Compatible ABB products for every

link in the enterprise value

chain

An open, enterprise-widearchitecture

Meet the ABB Aspect Integrator Platform™ – a

revolutionary, open architecture for managing and

optimising every link in the enterprise value chain.

This powerful Microsoft® Windows-based architecture

sets the standard for every Industrial IT product from

ABB and its partners. The Aspect Integrator allows

grouping of devices and their associated Aspect

Objects in easy-to-navigate structures tailored to the

needs of operations, maintenance or management

personnel. Real-time interaction between these

Industrial IT Enabled products means configuration,

operation and evaluation of each takes place within

the context of its larger system. The result: Fast

installation, logical navigation and more intuitive

enterprise management!

! Monitor, control, optimise and maintain from

one powerful, open platform

! Evaluate and deploy plant components - just

like browsing the files on your PC

! Attach data just once, for automatic installation

across multiple system structures

Imagine a business where your systems for power, automation, and information are

seamlessly integrated. Every component in the enterprise value chain has the built-in tools

necessary to install, operate, optimise and maintain across its total lifecycle. A compatible, open architecture

reaches from plant floor to top floor. Faster system design, deployment, asset management, optimisation and

collaboration are just a mouse click away.



A personalised enterprise workspaceto fit each user’s responsibility!

Control LogicHierarchy

Physical LocationHierarchy

MaintenanceHierarchy

YourHierarchy

Asset information thatfollows the asset

Physical installation of system devices has long

been the easy part. The difficult part is collecting

the information to install, operate and maintain

each component – then keeping it up to date.

Industrial IT from ABB changes all this. No matter

where each real object – or its asset information –

is deployed, one “click” on the Aspect Object

opens the links necessary to configure, optimise,

analyse and influence the real object.

The list of dynamic device characteristics (Aspects)

begins with complete electronic documentation,

drawings and instructions. Depending on the

product and its level of Industrial IT Certification

additional Aspects may include integral

configuration and maintenance tools, control

faceplates and graphic symbols, communication

protocols, on-line service, and more. The result:

“Plug-and-Produce” installation, operation and

asset management – just a mouse click away from

each device!

Customising your view ofthe business

To help every user find and act on the right

information, ABB Aspect Objects may be organised

in a variety of logical structures. Depending on

your interest, these might relate to process flow,

control logic, physical location, maintenance status

or others. Regardless of the arrangement, each

Aspect Object maintains its dynamic links to the

real device and its associated information.

This capability allows creation of secure

“workspaces” for each type of user, accessing the

same portfolio of Aspect Objects through various

navigational options, shortcuts and favourites.

Imagine performing the following sequence for

any device with just a few clicks of a mouse...

! Search the object library for devices of desired

capacity

! Select the asset that meets your needs, then

copy and paste its Aspect Object into the

process flow

! Call up the device faceplate to configure

setpoints and communications

! Open a live video link or diagnostic tool and

admire your work!

Zoom in to any enterpriselevel for fast answers, action,or asset management!



ProfileIT

DriveIT

MeasureIT

OptimizeIT

OptimizeIT

SustainIT

SupportIT

PlanIT

ProduceIT

AdviseIT

DriveIT

FieldIT

ControlIT

ProduceIT

ProcessIT

FulfillIT

RoboticsIT

ProcessIT

SimulateIT

MeasureIT

ProcessIT

ProduceIT

PowerIT

ProtectIT

InformIT

PowerIT

ProtectIT

CollaborateIT

EngineerIT

OperateIT

OptimizeIT

ControlIT

Compatibility across theenterprise value chain

The “Plug-and-Produce” ABB Industrial IT

architecture sets the stage for real-time interaction

across the enterprise value chain – from eBusiness

order input, to just-in-time procurement and

production, to logistics and distribution of highly-

customised end-products. Drawing from a vast library

of dynamic enterprise objects, the Industrial IT

architect deploys repeatable power and automation

scenarios to fit a wide variety of business objectives.

Just as one would browse the files in a PC directory,

the user navigates among multiple structures of

enterprise assets – assigning each to the most

productive and profitable task at hand!

! Faster systems engineering with compatible

Industrial IT building blocks

! Improved maintenance and asset management

within a logical systems hierarchy

! Intuitive access to just-in-time business analysis

and planning functions

! Reduced time-to-market through “copy and

paste” configuration of new systems

! Improved real-time plant information, for pass-

through to business IT systems

! Compatible information across the enterprise –

tailored to each job responsibility

ABB software tools forevaluation of processparameters, productquality, equipmentcondition monitoring, plusdiagnostics andrecommended actions.

AdviseIT

Systems and software formeasurement and analysisof product composition,including gas and liquidanalysis, spectrometry,chromatography andmore.

Software solutions toimprove interactionamong suppliers,manufacturers and endcustomers for maximumvalue in the eCommerceage.

CommunicateIT

Connectivity andnetworking tools to ensuregreater capacity, reliabilityand securityfor enterprisecommunications.

Monitoring and reportingsolutions to speedcompliance withqualitative regulatoryagencies such asenvironmental health andsafety.

ComplyITCollaborateITAnalyzeIT

FieldIT

Intelligent field devicesand software formeasurement oractuation, includingfieldbus-compliantcommunicationssolutions.

Financial services tosupport the procurementand lifecycle managementof Industrial IT systems orother business assets.

FinanceIT



PlanIT

InformIT

ConsultIT

SupportIT

RoboticsIT

ProduceIT

FulfillIT

CollaborateIT

ConsultIT

FulfillIT

A diverse portfolio of ABBconsulting services to helpmake the most of humanresources, physicalassets and groupprocesses.

ConsultIT

ABB hardware, software,and systems for real-timecontrol, supervision andmanagement ofoperational variables.

Software and services tooptimise the designprocess for end products,primary equipment,process trains orcomplete manufacturingplants.

DriveIT

ABB motors, drives, andsoftware solutions toprovide and improve theefficiency of motion,torque, speed andposition.

Powerful ABB softwaretools for faster configura-tion of automationsystems and processequipment, includinggraphics, physical layoutand documentation.

EngineerITControlIT DesignIT

ABB sensors, scannersand imaging products tomonitor variables includingweb and sheetcharacteristics, force,torque, stress, proximity,voltage, and more.

MeasureIT

A compatible range ofmetering and remotereading solutions formeasurement ofelectricity, gas and waterconsumption.

ABB solutions andservices to optimiseproduct fulfillment, fromorder entry andproduction planningthrough logistics anddistribution.

InformIT

Data recording, tracking,integration, and historiansolutions for improvedenterprise information anddecision support.

Technologies to supportintegration or connectivityof multiple products orsystems, featuring theABB Aspect IntegratorPlatform.

IntegrateITMeterIT FulfillIT

ABB products andsolutions to supply,regulate, convert anddistribute electrical poweracross the full range ofvoltages and applications.

PowerIT

Value-added ABB tools forancillary processing of end-products or sub-productsthrough material handling,assembly, mixing, metal-working, finishing andmore.

Console, handheld, panel,and wireless solutions fordynamic, real-timeinteraction between plantsystems and humanoperators.

OptimizeIT

ABB software tools fortuning, tracking, andoptimising of automationand power systems, plantassets or end-productquality.

Software and services toimprove plant andbusiness efficiencythrough forecasting,capacity planning,scheduling and logistics.

PlanITProcessIT OperateIT

Source: ABB Review



More options with ABB’s Industrial IT fABB embraced fieldbus technology from the

beginning and has made it an integral part of its

Industrial IT architecture. A complete fieldbus

automation solution is now available that fully

exploits the benefits of synergy between the fieldbus

and other key Industrial IT features. This solution

includes innovative products that offer customers

complete freedom when choosing communication

protocols, plus standardised engineering, high

system availability and asset optimisation. What is

more, it can be installed without risk in hazardous

areas.

Historically, communication between field

devices and a control system has been over

analog, 4–20 mA current loop interfaces. This

widely used technology works well and allows

accurate transmission of process variable

measurements as well as effective closed-loop

control.

Fieldbus technology, however, is digital. This

brings remarkable simplification to system

architectures, with a corresponding saving in field

cabling, equipment room layout, marshalling racks

and safety barriers. Further, when digital field

instruments are used, significantly more data

becomes available; ‘smart’ transmitters with

powerful microprocessors and memory chips,

manage valuable device configuration and status

information. Significant gains come from making

the data available to the automation system for

remote engineering and maintenance.

Technically Fieldbus is a digital, bi-directional,

multidrop communication system for instruments

and other plant automation equipment, put more

simply, a single-cable network that can replace

conventional means (eg, a 4–20 mA current loop)

of transporting data between field devices and a

control system. Devices which can be connected

to fieldbuses include flow, pressure, temperature

and level instruments, analysers, switchgear,

programmable logic controllers, process

controllers, remote I/O stations, drives, motors

and human-to-machine interfaces.

Fieldbus architectures consist of field instruments

connected to local, low-speed segments linked

together by a high-speed communication backbone.

Fieldbus communication is bi-directional over a

single cable, and a high-speed Ethernet-based

broadband network can easily accommodate

hundreds of devices at fast scan rates. The simpler

wiring and consequent saving in material and

installation costs, is obvious, at least in theory. So, in

practice, the number of low-speed segments needed

could be high, with each one requiring a linking

device, power supply, connectors, terminators, etc.

With traditional technology, each signal sent to the

hazardous area requires an IS barrier to filter out

dangerous current and voltage peaks. IS barriers are

usually located on the I/O marshalling racks in the

equipment room. The additional equipment

footprint required can be expensive.

Fieldbus I/O connections are made in software,

which eliminates marshalling panels altogether.

Additionally, only one IS barrier is required per

low-speed segment, so the number of IS barriers is

greatly reduced. A smaller footprint and less

material translate into a significant saving, and this

is confirmed by experience [1].

[1] Typical traditional automation architecture

Field devices connect to the marshalling racks and safety barriersover 4–20 mA current loop interfaces. Controllers then transferinputs/outputs to the Distributed Control System (DCS).



IT fieldbus solution

Remote engineeringThe greatest benefit of fieldbuses lies in theadditional data communication they makepossible – Reduced commissioning effort. Theadvantage of using fieldbuses is especiallynoticeable during commissioning. Instead of thetwo men (one in the control room and one in thefield) often needed to configure a loop intraditional systems, one engineer can single-handedly commission each loop. The saving intime and cost is dramatic, 10–15% having beenachieved in one application [2].

Single-loop integrityIn the early days of process automation, one fielddevice was connected to one controller and manysuch independent loops operated in parallel. Amajor advantage of this architecture was that afailure in one loop did not degrade others (‘single-loop integrity’). Distributed control systems laterconcentrated the I/Os and control functions intoever more powerful controllers and I/O modules.But this came at the expense of single-loopintegrity; failure of one component could nowimpact several loops and have a catastrophic effect

on operations, so expensive redundancy schemeshad to be incorporated into the architecture. Thefieldbus restores single-loop integrity.

The Foundation fieldbus protocol, for example,enables control functions to be distributed amongthe field devices. Peer-to-peer communicationbetween the devices ensures autonomy of thisfunction from the rest of the architecture.

Now, a control loop can be assigned to one low-speed segment, ensuring that it will keep runningeven if there is a failure somewhere in the rest of thenetwork. Additionally, the fieldbus checks the statusof the network elements. Failure of a component isimmediately detected and reported. Field devices canbe substituted on-line, without having to cut off thepower or interrupt normal network operation. TheHigh-Speed Ethernet components used in the fieldbusare mass produced and typically redundant andrugged; this drives down the cost of, and need for,redundant architectures.

The predicted saving is diminished by thelimitations in low-speed segment capacity, addedengineering complexity and extra demands madeon the hardware.

‘Smart’ devices contain valuable status andperformance information that cannot be accessed viaan analog link. When a fieldbus is used, thesevariables can be retrieved and a whole new world ofpossibilities opens up for predictive maintenance,advanced diagnostics and asset optimisation. Thefollowing two examples serve to illustrate this.

Fieldbus status signals allow operators to immediatelyidentify the malfunctioning device, obtain anindication of the cause and significantly acceleraterepair operations with on-line substitution.

When a fieldbus is installed, maintenance engineershave access to internal valve parameters, such as stemtotal travel length, number of strokes, total operatingtime, etc. These parameters are indicative of valveperformance and they can reveal degradation.Maintenance need now only be carried out whenrequired. This all adds up to less plant disruption andshorter downtime. Besides the lower maintenancecosts, there are big gains in plant availability, higherproduction and higher productivity.

[2] Fieldbus architecture

The controller (A) interfaces between the DCS and the fieldbus. Thefieldbus servicing the high-power devices (PLC, drives, analysers,MCC, safety, condition monitoring) is connected to the fieldbushandling the devices with lower power requirements (instruments,valves) via a linking device (B).



ABB’s fieldbus solution has significantdifferentiating features

ABB saw the potential of the fieldbus for processautomation early on and soon began to participatein various fieldbus organisations, making significantcontributions to the technology specifications (HighSpeed Ethernet and Profibus) as well as playing aprominent role in the pilot tests.

ABB has made fieldbus technology a requirementfor its control products and offers a completefieldbus solution that fully leverages the innovativeaspects of Industrial IT, such as Object Aspects.

Indeed, fieldbus has been made an integral part ofthe ABB Industrial IT architecture. The ABBfieldbus solution has several key differentiatingfeatures, including the following.

ABB’s Control IT AC800 controllers acceptsimultaneous inputs from all these different protocols.The unique ABB Fieldbus Plug allows a product tobe simply and quickly connected to any bus.Selection of automation solutions is no longer subjectto protocol constraints; they are all accepted in theIndustrial IT architecture. The end-user is free tochoose the technology that best fits his requirements,regardless of the communication protocol.

Standardised engineering using AspectObjectsIn a typical process industries automation project, itis not unusual to find field devices from as many asfive or even ten different suppliers – each with aproprietary engineering tool. These have to be allmastered by the configuration engineer, a tedious,cumbersome and expensive process.

Here again, ABB leads the market with aninnovative solution: the Field Device Tool (FDT).The FDT is a software application, based onMicrosoft technology, that resides in the systemengineering tool and provides a standardisedengineering interface. Each device comes with asoftware ‘driver’ (Device Type Manager, DTM) thatwill be accepted by all FDT compliant engineeringtools. The device is then configured (eg, setting ofthe transmitter parameters) via a standard interface,irrespective of the device engineering environment.This makes engineering as simple as loading theprinter driver on a PC. ABB further exploits this

feature by making the DTM an Aspect of thedevice. ABB’s Industrial IT architecture then letsusers access the device configuration anywhere inthe system – a single mouse click is all that isneeded.

Secure communication

ABB also has some unique products that ensurecontinued communication should a networkcomponent fail:

The Redundancy Link Module (RLM01) duplicatesthe communication path over two redundant high-speed PROFIBUS DP segments, thereby ensuringcontinued communication in the case of failure inone line.

The Linking Device LD 800 connects the high andlow-speed segments. It offers I/O interfaceredundancy, whereby failure of one linkingmodule is automatically backed up and access tothe low-speed segments continues uninterrupted.

Increased capacity in hazardous areas

One of the unique devices offered by ABB is theMultibarrier MB204, a low-speed multiport junctionbox that provides spurs to four devices. It increasesthe capacity of a low-speed segment by up to afactor of four, while preventing short circuits in asingle spur from affecting the rest of the segment.

[3] ABB’s Industrial IT fieldbus solution lets end users selectautomation solutions without regard to the communication protocol,simplifies engineering, secures communication and supportsinstallation, operation and repair.



Asset optimisation

The maintenance trigger is a system-residentsoftware that collects selected status inputs fromequipment and processes them in a predefinedmaintenance logic. All inputs are accessible,irrespective of their communication protocol. Uponreaching one of the predefined maintenanceconditions (for instance, a maximum number ofstrokes in a control valve), the trigger is activatedbefore the valve performance degrades. A faultreport is presented at the operator station and theoperator can send a maintenance work orderrequest to the Computer Managed MaintenanceSystem (CMMS). Root cause analysis is greatlyfacilitated by a detailed audit trail giving thecomplete device event history while repair,installation and operation are supported byextensive electronic documentation.

Mysore Paper Mills Ltd

Industrial IT Quality Control System (QCS), Measure IT ScanningPlatform SP700 with basis weight, moisture and caliper measurements, aswell as a Profile IT Calender Profiler to be installed on the third papermachine (PM3) of the mill. ABB will also provide engineering,commissioning and training.

ONGC’s WIN – Northern offshore fields fire and gas systemto be upgraded to SafeGuard Industrial IT platform

ABB will upgrade the existing fire and gas safety

system for Oil & Natural Gas Corporation Limited

(ONGC) to the SafeGuard Industrial IT platform

for their WIN-Northern offshore fields at Mumbai.

This follows a similar fire and gas safety system

revamp by ABB for ONGC BHN Platform.

“The BHN Platform revamping job was the first

of this nature and magnitude executed by an

Indian Company,” said Vijoy Kumar, DGM

(E&T) at ONGC. “We appreciate the effort put

in by the ABB team to complete this project

well in time.”

ABB’s offering for the

WIN Project includes

fire, gas, smoke and

heat detectors in

addition to a TUV AK-6 (SIL-3) certified dual

modular redundant SafeGuard PLC-based fire

and gas system with Operate IT operator

stations. ABB’s scope of supply also includes

surveying of the existing facilities at the

platform along with the design engineering of

the entire fire and gas system.

Some recent Industrial IT applications in India

All these features are Industrial IT Object Aspects,accessible by a mouse click. Further, a CMMSresident Maintenance Order Manager helps track theWork Order through scheduling, resource allocation,execution and closure. Spare parts inventorymanagement and automatic web-based partspurchasing can also be incorporated, depending onthe sophistication of the CMMS package. Provisionsare also made for interfacing to established CMMSpackages, such as PSDI Maximo, IFS and SAP.

ABB has fully embraced this technology, embeddingit in the ABB Industrial IT architecture and making ita prime feature of its control products. Fieldbustechnology will continue to evolve and ABB willcontinue to exploit the synergy between it andIndustrial IT to bring exciting products that make lifeeasier for everyone.

Source: ABB Review



Exploring the value of

products from ABBImagine a situation where the main circuit breaker

in your company’s distribution station has tripped

and there is no power for your machines.

Production has ground to a standstill. Neither

automatic nor remote manual reset works. You’ve

got just 15 minutes before your financial baseline is

affected. The technician you dispatch to the station

regrets, but he hasn’t trained on this type of circuit

breaker. The only person who really knows this

particular breaker is off-duty, and the manuals are

locked in his office.

Enter Industrial IT

Fortunately, there’s a

better way to run a

business – and avoid

the nightmare

described above.

Look again. You’re in

luck. Your circuit

breaker is Industrial

IT Enabled and

certified, like all other

enabled products, to

carry electronic documentation as an integral part

of it. No need to look in a separate system, or for a

locked-up binder. And there’s no more reliance on

that key information that your chief engineer – and

only he – carries around in his head.

Thanks to Industrial IT, all the documentation and

drawings you need are at your fingertips. And not

only now. Any time, from purchasing to the breaker’s

ultimate de-installation, the essential information you

require is made immediately available.

This is what the ABB certification programme

called Industrial IT enabling is all about – ensuring

that every Industrial IT Enabled product supports

and adds value to its key lifecycle processes.

Enabled breaker – Empowered technician.

Returning to the industrial crisis described at the

beginning, what would our technician have done

with an Industrial IT Enabled circuit breaker?

First, he would have clicked on the breaker icon on

his plant overview – opening up all the

documentation and drawings, plus a technical

reference manual. Looking at these, he would see

that the rod that moves the auxiliary switches was

deformed, probably concluding that it had

happened during a violent storm the day before. As

a temporary measure, he might quickly fabricate a

makeshift rod from some spare metal lying around

his office, getting the plant back on line in five

minutes. And just another five minutes is all he

would need to order a replacement part from the

supplier via the eCommerce web link built into the

documentation. A plant back on line and a problem

solved ... thanks to an Industrial IT Enabled product.

And some ingenuity on the part of the technician.

PS1 modular substation. ABB has developed a comprehensiveproduct information environment for this substation, comprisinga complete Industrial IT based model with all the documentationembedded in a collection of Aspect Objects.



ABB India Automation Division hosted a three day

conference from 20th - 22nd Feb, 2003 in

Bangalore, for large and medium size end user

customers titled Productivity Enhancement

through Automation, The Industrial IT way. The

aim of the conference was to increase awareness

of ABB’s Industrial IT initiative alongwith the

product and solution offering with emphasis on

how Industrial IT can help enhance productivity

and efficiency, thereby making customers more

competitive.

The conference was attended by over 90

customers across India representing companies

from a wide range of sectors, including Cement,

Metals and Mining Oil, Gas & Petrochemicals,

Refining, Pharmaceuticals, Pulp, Paper, among

others. It provided an ideal platform for

showcasing ABB’s Industrial IT portfolio through

presentations, customised breakout sessions,

videos, posters and kiosks. The main focus of the

conference was on explaining the concept, uses &

benefits of Industrial IT for the industry at large.

More than 10 experts representing the ABB Group

from various centres of excellence made

presentations on technological developments and

were extremely well received by customers across

the spectrum.

One senior customer from Tata Iron & Steel

Company (TISCO) commented: “Nowadays we

don’t get many opportunities to see new

technologies all under one roof in a forum such

as this. We are extremely delighted to see ABB’s

vast product and solution offering for its

customers in India, especially, the technical

advances made possible using the IndustrialIT

platform.”

These sentiments were reaffirmed by another

customer who remarked, “I am delighted to see

the technological capabilities of ABB. I never

imagined that the portfolio was so vast. I am sure

that by using ABB’s Industrial IT platform, we canovercome the biggest paradox we face as

customers - The push for standardisation coupled

with the ever growing need for technological

upgradation.”

On the final day of the conference, customers

were invited to see live product and solution

demonstrations at ABB’s Peenya manufacturing

facility at Bangalore. Customers evinced keen

interest in the products & solutions on display,

such as Operate IT, Knowledge Manager, Pocket

Portal, Process Portal, AC450 RMCs, 800 M,

Control Valves, Instrumentation products and

Robotics. They showed keen interest in energy

saving possibilities with AC Drives.

Johan Bjorklund from ABB Singapore, one of thepresenters, observed, “Customers liked the variousproducts range and demos that they could have afirst-hand look. The interactive sessions enthusedcustomers and they look forward to exploring thepossibility of implementing Industrial IT solutionsin their plants. The end-users’ perspective of theirneeds and expectations from automation vendorsgave us an insight into how customers perceiveautomation today and how they would like tohave it in the future.”



Channel LineABB India’s B2B portal crosses Rs. 120 millionmark during first 6 months of operation

Channel partners who deal with ABB’s wide range

of automation technology standard products (like

LV products, electric motors and machines, drives

and control automation products) all have one

answer about ABB’s B2B portal – “Fantastic!”

Over 300 trained Channel partners have been

accessing the site since June 2002, placing and

tracking orders, looking at inventory levels,

viewing receivables status and lots more - all in

real time, thanks to the full integration of the portal

with the ERP system. With total transparency,

privacy and security built into this B2B portal,

orders over Rs. 120 million have already been

logged in - opening a whole new way of doing

business.

Before the launch of the portal, business was

conducted in a highly conventional manner –

Channel partners created their offer along with

sales engineers, who would further clear them with

their managers. After getting the consent, channel

partners would place their orders, often through

the sales engineer responsible, who would then

feed the order into the ERP system. All enquiries

related to the availability of stock, delivery period,

receivables and other transaction details were

earlier routed through sales engineers, losing

valuable time and hampering speed of response.

“This initiative is aimed at reducing the

order to delivery time for automation

product lines. In addition, apart from

keeping channel partners abreast with

latest developments in the company, it

allows them to directly create offers, place

and track their order & payment status as

well as view inventories and swap or sell

inventories between themselves.”

Subir PalHead – Channel Management,

Automation Technologies

“This is an incredible tool, we can now

directly see the availability of stocks, create

our own enquiries and place as well as

track our orders through the Net. This

system has helped us cut through put time

between placing of an order to the delivery

of products. When stocks are not available

in the company, we now have an option to

pick the required stocks from one of the

other channel partners who have opted to

display their inventory on the site. We are

excited by the various prospects available to

us through this site.”

Mr. Agarwal – ABB channel partner



ABB and SustainabilityRain water harvesting

ABB’s Peenya facility has taken a

major step forward in water

conservation through the

process of rain water harvesting.

Simply put, this involves

collecting and utilising rain

water, water flowing out of

drains, overhead pipes and other

such sources, which are

generally ignored leading to

tremendous wastage of this

precious resource.

Being a company with a strong sense of social

responsibility, ABB has always been very active in

fulfilling its commitment to the communities in

which it operates. As part of its sustainability

initiatives, ABB’s Peenya unit in conjunction with

the HOPE foundation runs a weekly health

programme in the village of Nelagadaranahalli,

located at the outskirts of the factory. This

programme provides free weekly medical

consultation to the inhabitants of the village. Apart

from dispensing medicines, qualified doctors also

address other health issues like immunisation,

cataract operations and tuberculosis awareness.

The popularity of this health camp has spread far

and wide with villagers travelling miles to avail of

its services. The doctors and nurses treat about 150

patients on each weekly visit. It is heartening to

see so many people of all ages gathering there to

seek medical attention. This is only the beginning.

A ray of hope

Villagers attending the health camp

To ensure that the project runs

smoothly, the team responsible

for implementing the scheme

first conducted a feasibility

survey which involved

identifying collection points

from where water could be

easily collected during rains. The

other collection points included

tapping rain water from roofs

and roads, spots marked around

wells and bore wells. In total,

5 main collection pits were

made with 3 subsidiary pits.

The whole exercise proved to be

a big success as during periods

of heavy rainfall a minimum of

1.5 lakh ltr of water is collected,

which is used for watering the

gardens at the Peenya facility for

at least 10 days. These efforts

have therefore resulted inconserving water and preserving

nature at large.

Novel methods of water conservation at ABB’s Peenya facility



You Ask – We AnswerQ

&A

Q. We would like to know

when the entire range of

MCBs and RCDs along

with distribution boards

will be launched

– Nikhil Oza, Santosh Agencies, Hubli

We will be launching these

in the 2nd quarter of 2003

nationwide in a phased

manner. A brochure for the

same is available with our

channel partners.

Q. Can you share with

us the basics and

fundamentals of HVDC

transmission and

distribution?

– PK Jain, VP, Aarti Steels Ltd., Ludhiana

to-Point, back-to-back and

multi-terminal systems.

The development of HVDC

technology dates back to the

late 1920s with the first

commercial line operational

in 1954. Significant

improvements in HVDC

technology came around

1970 – one of the more

recent being HVDC

convertor and DC cable

technology called HVDC

light - from ABB! In India

ABB has already

implemented three HVDC

projects – Vindhyachal back-

to-back – Interconnecting the

Northern and Western

regions, Rihand-Dadri and

Chandrapur-Padghe bipole

long-distance transmission

links located in the north and

west respectively.

Q. What is a residual

current operated device?

Where are they used?

– LJ Joseph, Exec. Engineer, TNEB, Chennai

In electrical

installations

where neutral

connections

are commonly

used, there are

occasions

when the current flows from

the line conductor to earth

and hence back to the current

source. Such currents are

usually caused by some kind

of defects and are termed as

earth fault current. There is

nothing to prevent an earth

fault from occurring. However,

such faults can be quickly

isolated if Residual Current-

operated Devices like RCCBs

& RCBOs are installed. The

ABB range of RCCBs makes

use of the well proven

principle of utilising core

balance transformers with

permanent magnet trip

devices. They are able to

detect earth fault current and

disconnect at the shortest time.

RCCBs are commonly used for

protection against electric

shock on account of direct

contact with live parts and

current flows through the

body that has to be

disconnected at the shortest

time or in the event of touch

voltage being too high for the

body in contact with exposed

metal parts, protection against

fire hazards and against the

occurrence of electrically

ignited fire due to earth fault

current.

Q. Is there any test for

assessing the life of

clophen (askaryl) filled

transformers? Can ABB

retrofit clophen Trafo with

oil-filled Trafo?

Mohan Jha, DGM (Elec) Hindustan Paper

Corpn. Ltd., Assam.

– We have no test for

assessing the life of clophen

(askaryl) filled transformers

and ABB has not started to

retrofit clophen Trafo with

oil-filled Trafo.

HVDC stands for High

Voltage Direct Current and is

today a well proven

technology used to transmit

electricity over long distances

by overhead transmission

lines or submarine cables. It

is also used to interconnect

separate power systems,

where traditional AC

connections can not be used.

There are different types of

HVDC transmission – Point-



Communicating...

As always we have endeavoured to bring you the latest in technology development at ABB. Thisissue is dedicated to Industrial IT, which is ABB’s common technology platform aimed at makingcustomers more efficient and competitive by empowering them with real-time seamlesslyintegrated information. We hope you found this issue interesting and look forward to yourfeedback in ensuring that we remain in CONTACT.

Harmeet S. BawaHead GF-Corporate Communications, India

Power Technology Products Brochures Industrial IT Brochure Power Technologies Training Programme Folder

Corporate posters Wind power poster STATCON poster


www.abb.com/in

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