Innovation in Process Control & Instrumentation Mr Prasoon Bisen ...
Innovation in Process Control & Instrumentation Mr Prasoon Bisen ...
Innovation in Process Control & Instrumentation Mr Prasoon Bisen ...
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July 2009<br />
<strong>Innovation</strong> <strong>in</strong> <strong>Process</strong> control & <strong>Instrumentation</strong>,ABB India Presentation<br />
© ABB India<br />
July 6, 2009 | Slide 1<br />
<strong>Prasoon</strong> S<strong>in</strong>gh <strong>Bisen</strong>,<br />
Market<strong>in</strong>g Manager,North Region & sBU 4143<br />
<strong>Process</strong> Industries Products<br />
ABB, India
Contents<br />
© ABB India<br />
July 6, 2009 | Slide 2<br />
ABB India,<strong>Process</strong> Automation<br />
ABB <strong>Process</strong> Automation <strong>in</strong> Food<br />
Industry
ABB India Organisation<br />
© ABB India<br />
July 6, 2009 | Slide 3
Market<strong>in</strong>g Organisation<br />
© ABB India<br />
July 6, 2009 | Slide 4
Turbocharg<strong>in</strong>g<br />
S Pandiyan<br />
© ABB India<br />
July 6, 2009 | Slide 5<br />
Region North<br />
Ashish Kaul<br />
PA Division – Organization Chart<br />
Analytics<br />
Shuvro C<br />
Region South<br />
Sethumadhava<br />
Region Chennai<br />
Karthikeyan<br />
Customers<br />
Region West<br />
Arv<strong>in</strong>d Mangal<br />
Region East<br />
OP Choudhary<br />
Regional Sales organisation & Key Account Management<br />
PCB Mfg<br />
Uday M<br />
F<strong>in</strong>ancial <strong>Control</strong>l<strong>in</strong>g<br />
N Gopalakrishna<br />
PA Division Management Team<br />
M<strong>in</strong>erals<br />
S Gandhi<br />
Cement<br />
E V<strong>in</strong>od<br />
Bus<strong>in</strong>ess Comunication<br />
Amit Sharma<br />
Bus<strong>in</strong>ess <strong>Process</strong>es<br />
M C Thomas<br />
OG,Chem,P&P,Analytical<br />
Atul Shah<br />
Oil & Gas<br />
KK Mallick<br />
<strong>Process</strong> Automation<br />
GNV Subba Rao<br />
Mar<strong>in</strong>e,P&P<br />
KVS Rao<br />
Metals,M<strong>in</strong>erals<br />
<strong>Control</strong> Syatems<br />
Chem, Pharma<br />
Ravishankar TR<br />
Bus<strong>in</strong>ess HR<br />
Indrajit Bose<br />
Bus<strong>in</strong>ess Integration-Peenya<br />
M S Natesha<br />
Metals<br />
D Maheshwari<br />
Force Meas<br />
Viswanath<br />
Human Resources<br />
Raja Radhakrishnan<br />
Service<br />
Manoj M<br />
Country Management
Revenues 2001-2008 : Trend<br />
350<br />
300<br />
250<br />
200<br />
150<br />
100<br />
50<br />
0<br />
© ABB India<br />
July 6, 2009 | Slide 6<br />
53<br />
CAGR 2001 to<br />
2007 30 %<br />
5*%<br />
56<br />
22%<br />
68<br />
22%<br />
83<br />
20%<br />
100<br />
( MUSD <strong>in</strong> budget ’08 rates)<br />
30%<br />
330<br />
2001A 2002A 2003A 2004A 2005A 2006A 2007 A 2008 RF<br />
*Growth over previous period<br />
62%<br />
162<br />
57%<br />
254
On the Horizon<br />
© ABB India<br />
July 6, 2009 | Slide 7
<strong>Instrumentation</strong> Factory : Faridabad<br />
© ABB India<br />
July 6, 2009 | Slide 8
Power Electronics, Drives, LV Systems - Bangalore<br />
© ABB India<br />
July 6, 2009 | Slide 9<br />
PES Factory<br />
LVS Factory<br />
Adm<strong>in</strong>.block<br />
Ma<strong>in</strong> security<br />
Drives Factory
Medium Voltage Switchgear Factory, Nasik<br />
© ABB India<br />
July 6, 2009 | Slide 10
<strong>Process</strong> Automation Factory : Bangalore<br />
© ABB India<br />
July 6, 2009 | Slide 11
Challenges <strong>in</strong> Food Industry<br />
© ABB India<br />
July 6, 2009 | Slide 12<br />
Ma<strong>in</strong>ta<strong>in</strong> Hygiene<br />
Ma<strong>in</strong>ta<strong>in</strong> Fresh Quality<br />
Speed & flexibility to meet Market Demand to ensure<br />
product Safety & Quality<br />
Integration of various islands of processes <strong>in</strong>to one s<strong>in</strong>gle<br />
environment for management to monitor
Products & Systems<br />
© ABB India<br />
July 6, 2009 | Slide 13<br />
<strong>Process</strong> Automation Systems<br />
System800xA>Medium & Large plants<br />
Freelance >Small & Medium plants<br />
Manufactur<strong>in</strong>g Execution systems<br />
Smart Clients<br />
Integration to ERP
AIS<br />
Electrical<br />
Integration<br />
Integration Components:<br />
Faceplates<br />
Eng<strong>in</strong>eer<strong>in</strong>g /<br />
Commission<strong>in</strong>g<br />
Asset Monitors<br />
Historical Data Collection<br />
Diagnostics<br />
Applications<br />
DCS Configuration Support<br />
IEC 61850<br />
GIS<br />
High<br />
Voltage<br />
© ABB India<br />
July 6, 2009 | Slide 14<br />
Web HMI<br />
Power<br />
Trafo<br />
MV<br />
Switchgear<br />
ABB’s Unified Integration Approach<br />
MV<br />
Drives<br />
Distribution<br />
Trafo<br />
LV<br />
Switchgear<br />
Servers<br />
PROFIBUS<br />
Drives<br />
800xA<br />
<strong>Control</strong>lers<br />
LV<br />
Products<br />
Remote I/O<br />
Workplaces<br />
Fieldbus Network<br />
Proxies<br />
to other<br />
fieldbuses<br />
<strong>Control</strong> Network<br />
Prior Generation<br />
<strong>Control</strong>lers<br />
Valves<br />
FF<br />
<strong>Instrumentation</strong>
Functional CPM Product Model as foundation<br />
© ABB India<br />
July 6, 2009 | Slide 15<br />
BUSINESS SYSTEMS<br />
Cement/<br />
M<strong>in</strong>erals<br />
User Experience – Smart Client<br />
Enterprise Connectivity<br />
Industry Specific Solutions<br />
Life<br />
Sciences<br />
Pulp &<br />
Paper<br />
Common Industry Functions<br />
Oil & Gas Chemicals<br />
Execution Management, Energy<br />
Management, Advanced <strong>Process</strong> <strong>Control</strong><br />
CONTROL SYSTEMS<br />
ABB & third party<br />
Information Layer<br />
PIMS, ISA-95, Persistent Layer<br />
Manufactur<strong>in</strong>g Service Bus<br />
SHOP FLOOR DEVICES<br />
& SÝSTEMS<br />
OTHER<br />
APPLICATIONS
Probase Library with 800xA>Eng<strong>in</strong>eer<strong>in</strong>g<br />
© ABB India<br />
July 6, 2009 | Slide 16<br />
Ready made <strong>in</strong>dustry objects like<br />
Tanks, production l<strong>in</strong>es, valves, motors, pumps<br />
Use ”out of the box” or with project specific modifications<br />
Standardized communication<br />
Advanced product rout<strong>in</strong>g<br />
Proven solutions with ABB know how<br />
Eng<strong>in</strong>eer<strong>in</strong>g Guidel<strong>in</strong>es – best practice of 800xA eng<strong>in</strong>eer<strong>in</strong>g<br />
Bulkdata tools
Probase Library with 800xA<br />
An object oriented library based on system 800xA<br />
A complete <strong>in</strong>dustry library :<br />
© ABB India<br />
July 6, 2009 | Slide 17<br />
- Proven & readymade software modules & process objects, specifically for liquid food Industries.<br />
Level of function & quality has been structured at a high level :<br />
Decades of <strong>Process</strong> <strong>Control</strong> experience with<strong>in</strong> the Application area collected & organised <strong>in</strong>to<br />
creat<strong>in</strong>g FOOCOS library.<br />
Scalable & Modular <strong>in</strong>dustrial library:<br />
- High degree of reuse of control logics possible<br />
RSL Concept : Rout<strong>in</strong>g, Storage & L<strong>in</strong>e <strong>Control</strong> :<br />
- <strong>Control</strong>lable & supervised flow paths (Routes)<br />
- Rout<strong>in</strong>g also <strong>in</strong>cludes Queue handl<strong>in</strong>g : Used for Superior Product schedul<strong>in</strong>g<br />
- Rout<strong>in</strong>g has built <strong>in</strong> process tune parameters: Used for different sett<strong>in</strong>gs like dra<strong>in</strong> time, delay<br />
time, etc.
Advantages<br />
Consistent Product Quality & rapid production throughput :<br />
© ABB India<br />
July 6, 2009 | Slide 18<br />
Provides operators, eng<strong>in</strong>eers & ma<strong>in</strong>tenances staff real time access to process data & asset <strong>in</strong>formation for secur<strong>in</strong>g product safety & quality.<br />
Speedy & Efficient Eng<strong>in</strong>eer<strong>in</strong>g:<br />
Advanced product rout<strong>in</strong>g modules simplify eng<strong>in</strong>eer<strong>in</strong>g & help control each stage of the product flow - from <strong>in</strong>take to f<strong>in</strong>ished product<br />
User friendly operator workplace: Fast & easy access to multiple product transfers.<br />
- Interlock <strong>in</strong>dications and onl<strong>in</strong>e help texts for rapid response & corrective action
Operations<br />
The ProBase operation tools extends the functionality of the 800xA operations<br />
Interlock <strong>in</strong>dications and onl<strong>in</strong>e help guides the operator <strong>in</strong> any situation<br />
Easy access to operation of the entire plant with valve matrix and product<br />
transfer graphic symbols<br />
© ABB India<br />
July 6, 2009 | Slide 19
CIP (Clean<strong>in</strong>g In Place)<br />
© ABB India<br />
July 6, 2009 | Slide 20<br />
A Recipe based CIP editor for optimal use of clean<strong>in</strong>g agents & excellent dra<strong>in</strong><strong>in</strong>g<br />
accuracy<br />
A generic CIP recipe can be used on different types of process equipment<br />
The CIP L<strong>in</strong>e controls Clean<strong>in</strong>g on several CIP objects via different CIP Circuits
CIP - Clean<strong>in</strong>g <strong>in</strong> Place<br />
Ready made solutions for<br />
© ABB India<br />
July 6, 2009 | Slide 21<br />
CIP Station, CIP l<strong>in</strong>e, CIP circuits and CIP objects<br />
Recipe based execution of CIP sequence<br />
Designed for optimal use of detergents and optimal clean<strong>in</strong>g accuracy<br />
Onl<strong>in</strong>e tools for circuit tun<strong>in</strong>g and optimization
Plant ma<strong>in</strong>tenance, optimization and quality<br />
Ma<strong>in</strong>tanance<br />
© ABB India<br />
July 6, 2009 | Slide 22<br />
Built <strong>in</strong> supervision and report<strong>in</strong>g of motor runtime and valve strokes<br />
Record<strong>in</strong>g tool for application and/or production test report<strong>in</strong>g<br />
Optimization>Designed for optimal <strong>in</strong>tegration with 800xA extended<br />
functionality like<br />
Production/Batch Management<br />
Device Management<br />
Asset Optimization<br />
Quality>Documentation and test accord<strong>in</strong>g GAMP4 (ISO 9000-3)
References<br />
© ABB India<br />
July 6, 2009 | Slide 23<br />
Examples<br />
Amul,Gandh<strong>in</strong>agar<br />
Tetra Pak – Tetra Plant Master<br />
Warste<strong>in</strong>er Brauerei<br />
Forcit OY<br />
Valio YO<br />
Arla Foods<br />
VK-Mühlen<br />
Iparlat<br />
Nestle<br />
Alcro Beckers
ProBase-Summary<br />
Proven process solutions<br />
© ABB India<br />
July 6, 2009 | Slide 24<br />
<strong>Process</strong> know how from several <strong>in</strong>dustries<br />
Standardized eng<strong>in</strong>eer<strong>in</strong>g solutions<br />
Common eng<strong>in</strong>eer<strong>in</strong>g methodology for optimal efficiency and ma<strong>in</strong>tenance<br />
Operations<br />
CIP<br />
Operators have always access to all product transfers and current<br />
<strong>in</strong>terlocks <strong>in</strong> the plant<br />
More flexible, accurate and economical clean<strong>in</strong>g<br />
800xA functionality<br />
Extend the automation solution with the power of the 800xA system
Real life example – rout<strong>in</strong>g <strong>in</strong> brewery <strong>in</strong>dustry<br />
© ABB India<br />
July 6, 2009 | Slide 25<br />
The rout<strong>in</strong>g maps the PI-diagram to control<br />
logic i.e. the control logic is configured <strong>in</strong> a<br />
functional way accord<strong>in</strong>g to the PI-diagram<br />
The built <strong>in</strong> rout<strong>in</strong>g logic controls and<br />
<strong>in</strong>terlocks the complex valve matrix for<br />
production, flush<strong>in</strong>g, clean<strong>in</strong>g<br />
The rout<strong>in</strong>g <strong>in</strong>cludes built <strong>in</strong> ABB process<br />
know how for fill, dra<strong>in</strong> and flush values,<br />
handles product codes, batch id:s etc.<br />
The rout<strong>in</strong>g queue handl<strong>in</strong>g improves<br />
productivity with onl<strong>in</strong>e product changes
What is Smart Client?<br />
A th<strong>in</strong> client user <strong>in</strong>terface for System 800xA<br />
Graphics<br />
Trends and SPC<br />
Alarm and Events<br />
Excel Interface<br />
© ABB India<br />
July 6, 2009 | Slide 26<br />
®<br />
Includ<strong>in</strong>g
Extend<strong>in</strong>g to other sources<br />
© ABB India<br />
July 6, 2009 | Slide 27<br />
CPM<br />
Solutions<br />
DCS SCADA DCS Robotics PLC Other OPC<br />
cpmPlus Enterprise Connectivity<br />
ERP Integration<br />
Databases<br />
Information Feeds<br />
XML<br />
Web Services<br />
Manufactur<strong>in</strong>g<br />
OPC devices
Customer Overview<br />
© ABB India<br />
July 6, 2009 | Slide 28<br />
Owner & Market Position<br />
Amul is the largest food brand <strong>in</strong><br />
India and world's Largest Pouched<br />
Milk Brand with an annual turnover<br />
of US $1050 million .<br />
Managed by an apex cooperative<br />
organization GCMMF. Its milk<br />
process<strong>in</strong>g capacity 10-12 millions<br />
liters per day.<br />
Products<br />
Includes milk powders, milk, butter,<br />
ghee, cheese, curd, chocolate, ice<br />
cream, cream, shrikhand, paneer,<br />
gulab jamuns, basundi, Nutramul<br />
brand and others.<br />
ABB delivery<br />
System800xA with Dairy Library
Royal Friesland Foods<br />
End Customer: Royal Friesland Foods<br />
System Integrator: Tetra Pak <strong>Process</strong><strong>in</strong>g Systems<br />
Site: Leeuwarden, the Netherlands<br />
Application: New Milk Plant<br />
© ABB India<br />
July 6, 2009 | Slide 29<br />
Phase1 of 3 : Milk Reception<br />
Automation from ABB<br />
System 800xA SV3.1<br />
4* AC800M, PM864<br />
System 800xA Operations: 5 clients<br />
S800 I/O (about 1500)<br />
Profibus DP/PA communication<br />
Integrated with PlantMaster from TetraPak<br />
Startup: February 2005<br />
Why ABB: Probase Library & TetraPak as Global<br />
Solution Provider<br />
For <strong>in</strong>formation:<br />
Aad Fokker, ABB NL<br />
www.fcdf.nl<br />
August 2004 _Europe,_TheNetherlands,_Food&Beverage,_Dairy,_RoyalFrieslandFoods,_2004,_Medium,_AC800M,_Profibus
Arla Foods, Denmark<br />
SI: Tetra Pak, Lund, Sweden<br />
Client: Arla Foods, Denmark<br />
Site: Roedkaersbro, Denmark<br />
Application: Due to <strong>in</strong>creas<strong>in</strong>g focus on healthy food and peoples<br />
overweight, Arla has developed a new butter oil product called Pure<br />
Ghee primarily to be sold <strong>in</strong> Middle East area. Need of new<br />
production system <strong>in</strong>clud<strong>in</strong>g new automation (Tetra PlantMaster<br />
system based on Industrial IT)<br />
Automation from ABB: 800xA system with 2 operator workplaces,<br />
one operator panel <strong>in</strong> process area, 3 AC 800M type PM 861, 600<br />
S800 I/O channels<br />
In operation: Augusti 2004<br />
For <strong>in</strong>formation:<br />
© ABB India<br />
July 6, 2009 | Slide 30<br />
Mikael Samuelsson, Tetra Pak, Lund, Sweden<br />
www.tetrapak.com<br />
www.arla.com<br />
Nov/Dec 2004_Europe,_Denmark,_Food&Beverage,_Dairy,_ArlaFoods,_2004,_Small,_AC800M,_Panel
Valio Oy, F<strong>in</strong>land<br />
Client: Valio Oy<br />
Site: Äänekosken tehdas, Äänekoski, F<strong>in</strong>land<br />
Application: Blue cheese mill.<br />
Automation from ABB: System 800xA 4.0 (partly upgrade from 2.0<br />
delivery) with 7 AC 800M controller, 7 <strong>Process</strong> Portal Operator<br />
Workplaces and 1 Eng<strong>in</strong>eer<strong>in</strong>g Station, Some 3000 I/O channels –<br />
S800 I/O. Fieldbusses: IO/Profibus DP , Field devices / Profibus PA,<br />
Valves / Profibus DP/ Asi<br />
In operation: First delivery end 2005 and second delivery end of<br />
February 2006<br />
ABB´s advantage: Valio is an old ABB client on SattL<strong>in</strong>e systems<br />
For <strong>in</strong>formation:<br />
© ABB India<br />
July 6, 2009 | Slide 31<br />
June/July 2005<br />
Osmo Va<strong>in</strong>io, ABB F<strong>in</strong>land<br />
www.valio.com<br />
_Europe,_F<strong>in</strong>land,_Food&Beverage,_Dairy,_ValioOy,_2005,_Large,_AC800M,_Profibus
Newmarket Co-Op, Ireland<br />
Client: Newmarket Co-Op, Ireland<br />
SI: Tetrapak<br />
Site: Newmarket County, Ireland<br />
Application: Modernisation of creamery produc<strong>in</strong>g cheddar cheese<br />
Automation from ABB: System 800xA with six <strong>Process</strong> Portal operator<br />
workplaces and one redundant AC 800M controller<br />
Delivered: February, 2006.<br />
For <strong>in</strong>formation:<br />
© ABB India<br />
July 6, 2009 | Slide 32<br />
Bertil K. Andersson, ABB Sweden<br />
_Europe,_Ireland,_Food&Beverage,_Dairy,_NewmarketCo-Op,_2006,_Medium,_AC800M
Dairy Farmers of Brita<strong>in</strong> (DFB), UK<br />
Client: Dairy Farmers of Brita<strong>in</strong> (DFB)<br />
SI: TetraPak<br />
Site: Llandyrnog creamery, North Wales, UK<br />
© ABB India<br />
July 6, 2009 | Slide 33<br />
The fourth largest cheese factory <strong>in</strong> the UK focused on cheddar<br />
cheese production<br />
Application: Evolution project of an ABB Alert 2000 <strong>in</strong>stallation of 2000<br />
I/O<br />
Automation from ABB: System 800xA with two <strong>Process</strong> Portal operator<br />
stations both with dual screens, one AC 800M with redundant CPU, a<br />
small amount of S800 I/O, plus the reuse of a lot of exist<strong>in</strong>g ABB Alert I/O<br />
and an ABB Altop Valve control system. Profibus will be used to <strong>in</strong>terface<br />
to all I/O channels - new and old<br />
In operation: February 2006<br />
For <strong>in</strong>formation:<br />
Bertil K Andersson, ABB Sweden<br />
_Europe,_UK,_Food&Beverage,_Dairy,_DFB,_2006,_Medium,_AC800M,_Satt,_Profibus
Camp<strong>in</strong>a, The Netherlands<br />
Client: Camp<strong>in</strong>a, The Netherlands<br />
SI: TetraPak, Houten, The Netherlands<br />
Site: Camp<strong>in</strong>a Dairy, Rotterdam<br />
Application: Upgrad<strong>in</strong>g Alert 500 solutions to System 800xA<br />
Automation from ABB: System 800xA operations with 3 AC 800M controllers<br />
(PM864AK01) and five <strong>Process</strong> Portal operator workplaces (rich clients).<br />
Exist<strong>in</strong>g 1.200 ALTOP-valves plus the 1.500 ALERT-I/O will rema<strong>in</strong> and<br />
communications will be done via Profibus<br />
In operation: August<br />
For <strong>in</strong>formation:<br />
© ABB India<br />
July 6, 2009 | Slide 34<br />
Ad Albers, ABB The Netherlands<br />
www.camp<strong>in</strong>a.nl<br />
_Europe,_TheNetherlands,_Food&Beverage,_Dairy,_Camp<strong>in</strong>a,_2006,_Medium,_AC800M,_Satt,_Profibus
Dairy Crest, UK<br />
Client: Dairy Crest, UK<br />
SI: Tetrapak <strong>Process</strong><strong>in</strong>g, Ireland<br />
Site: Aspatria diary, Lake District, UK<br />
Production of up to 80 tons of cheese per day, <strong>in</strong>clud<strong>in</strong>g mild, medium and<br />
mature cheddar, as well as Double Gloucester<br />
Application: Upgrade of Alert 500 control system<br />
Automation from ABB: System 800xA which will replace the Alert 500 system<br />
orig<strong>in</strong>ally delivered by Alfa Laval Automation: 3 <strong>Process</strong> Portal operator<br />
workplaces and one redundant AC 800M controller. The exist<strong>in</strong>g Alert I/O system<br />
will rema<strong>in</strong> and will communicate with the controllers via Profibus<br />
In operation: Successfully s<strong>in</strong>ce fall 2006<br />
For <strong>in</strong>formation:<br />
Bertil K Andersson, ABB Sweden<br />
http://www.dairycrest.co.uk/<br />
© ABB India<br />
July 6, 2009 | Slide 35<br />
_Europe,_UK,_Food&Beverage,_Dairy,_DairyCrest,_2006,_Small,_AC800M,_Profibus
Woollaston Estates, New Zealand<br />
Client: Woollaston Estates w<strong>in</strong>ery, New Zealand<br />
© ABB India<br />
July 6, 2009 | Slide 36<br />
Production of Sauvignon Blanc, Riesl<strong>in</strong>g, Chardonnay, Rosé and<br />
P<strong>in</strong>ot Noir for specialist outlets <strong>in</strong> New Zealand, the United States,<br />
Ireland and the United K<strong>in</strong>gdom<br />
Site: Upper Moutere, South Island of New Zealand<br />
Application: <strong>Control</strong> system for 17 w<strong>in</strong>e tanks, govern<strong>in</strong>g and monitor<strong>in</strong>g<br />
tank temperatures as well as controll<strong>in</strong>g heaters, chillers and pumps<br />
Automation from ABB: One AC800M controller and two clusters of S800<br />
I/O, plus a s<strong>in</strong>gle PGP workplace<br />
For <strong>in</strong>formation:<br />
Shane Archer, ABB New Zealand<br />
www.woollaston.co.nz<br />
_Oceana,_NewZealand,_Food&Beverage,_Brewery,_WoollastonEstates,_2006,_Small,_AC800M
Delegats, New Zealand<br />
Client: Delegats Company, New Zealand<br />
Site: Blenheim, South Island of New Zealand<br />
Application: <strong>Control</strong> system for w<strong>in</strong>ery<br />
Automation from ABB: 8 AC800M controllers with approximately 3,600<br />
remote I/O, two PGP workstations and two PP865 <strong>Process</strong> Panels.<br />
Stage 2 will add another 1,000 I/Os<br />
For <strong>in</strong>formation:<br />
© ABB India<br />
July 6, 2009 | Slide 37<br />
Shane Archer, ABB New Zealand<br />
www.delegats.co.nz<br />
_Oceana,_NewZealand,_Food&Beverage,_Brewery,_Delegats,_2006,_Large,_AC800M,_Panel
© ABB India<br />
July 6, 2009 | Slide 38
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