ABB Ability Process Power Manager for Energy Industry Facilities
ABB Ability Process Power Manager offers a comprehensive solution for power management in energy industry facilities. It addresses challenges such as managing multiple power sources, minimizing downtime, enhancing safety, optimizing aging assets, and coping with margin pressures. This intelligent and integrated software solution helps balance power, prevent disturbances and blackouts, improve asset performance visibility, and ensure a stable power supply throughout the plant.
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INDUSTRIAL AUTOMATION ENERGY INDUSTRIES ABB Ability Process Power Manager Ensuring a reliable and stable energy supply
ABB Ability Process Power Manager Agenda 1 Energy management portfolio 2 2 Challenges facing energy industry facilities 3 3 ABB Ability Process Power Manager 4 4 Why choose ABB 5 Sales playbook 6 6 Call to action, conclusion & questions 6 Slide 2 September 20, 2024
Challenges Facing energy facilities Managing multiple power sources: New energy assets within the plant or enterprise present increased management complexities and risks. Better process power management helps mitigate these risks. Minimizing unplanned downtime and blackouts: Plants needs a reliable energy supply and the ability to quickly act and restore power to minimize performance losses. Enhancing safety: Blackouts and unreliable electricity increase safety risks. With improved power supply reliability, plants can limit exposure to unsafe situations and help keep their people and plant safe. Aging assets: Plants need to optimize the life of equipment with better asset utilization. This includes identifying which assets are more likely to interrupt stable energy supply. Margin Pressures: Increasing operational costs coupled with profitability challenges are forcing producers to become more energy efficient. Reliable energy supply is key to efficiency. Slide 4 September 20, 2024
What is the ABB Ability Process Power Manager? A comprehensive solution for power management and control of electrical infrastructure Intelligent: power balancing and predictive planning help prevent disturbances and blackouts Integrated: Software runs on System 800xA to help prevent production disrupts by adequate reaction to disturbance Inclusive: improves asset performance visibility while reducing risk and inefficiencies associated with managing multiple systems Enabling a stable power supply throughout your plant Slide 6 September 20, 2024
ABB Ability Process Power Manager How it works Platform Automated Functions User: Operator Power Control User: Operators Assets User: Process/Plant Supervisor 800xA and 800M Compact Controllers 800M-PM861->PM891 S800 IO Load shedding Load shedding prediction Load reduction Power controlled Synchronization Restart and re-acceleration Load-dependent start and stop Blackstart recovery Asymmetric load Control of main electrical equipment and power distribution Generator Transformer Circuit breaker Load shedding reports Restart and re-acceleration report Condition-based asset monitoring Intelligent communication IEC61850 Modbus Profinet Hardwired communication Provides comprehensive visibility for enhanced energy resource management Slide 7 September 20, 2024
ABB Ability Process Power Manager Quick glance dashboard for better and faster decision making Active plant networks Quick drill down Essential information to operate Main capabilities Warning and Alarm message Active topology Slide 8 September 20, 2024
Features ABB Ability Process Power Manager Load shedding Integration Remote access Power balancing and recovery with ABB System 800xA process and electrical control systems of plant equipment for operation, collaboration and diagnostics and predictive planning to avoid disturbances or blackouts Scalability Dynamic tripping Flexibility Simulation training to support large, complex electrical systems of loads, which can be preconfigured or manually configured to a set of priorities to provide automated functions and/or process- dependent functions provide realistic operator training for daily operations and crisis situations Slide 9 September 20, 2024
Benefits ABB Ability Process Power Manager Lowers capex costs Improves efficiency Increases uptime Enables better decisions with single installation and commissioning, leading to less cabling and a smaller footprint and expedites decision making through an overview of the electrical system by automating reactions based on priority or criticality with comprehensive and deep visibility Optimizes network Drives ROI Minimizes downtime Improves health & safety and minimizes footprint by increasing energy efficiency by ensuring faster recovery of power and production after a failure and mitigates environmental impacts Slide 10 September 20, 2024
3 unique competitive differentiators ABB Ability Process Power Manager 1. Dynamic network determination 2. 200 load-shed priorities 3. Scalable & robust power control modules Delivers fast-acting blackout prevention, especially valuable for complex electrical networks with multiple substations and power sources Save critical loads while minimum load is shed, minimizing unnecessary over-sheds Manage of synchronization, active and reactive power control and distribution of multiple power generation sources automatically Slide 11 September 20, 2024
Case study 1: ADNOC Gas Processing (formerly GASCO) site in Abu Dhabi ABB Ability Process Power Manager reduces energy costs by 39 MUSD Customer needs ABB s solutions Customer benefits Power Management with IEC61850 GOOSE and MMS Designing the load shedding and balancing of the gas plant Results 3X ROI in less than 1 year Avoid blackouts Through efficient and fast load shedding avoid blackouts and prevent process interruptions or shutdowns. Fewer plant disruptions and reduced downtime Expected GTG trips due to warm climate and high load 42 GTG trips and 4 load shedding events Active and reactive power control Large plant with more than 20 substations Reduced cost of signal cabling with network infrastructure Overload shedding More than 1900 Protection devices Prepared for digital Energy Industries, U.A.E. Scope of delivery Benefits ABB Ability Process Power Manager Availability CapEx OpEx +5% 10% 39 MUSD Slide 13 September 20, 2024
Case study 2: Tangguh LNG Train 3 in Indonesia ABB Ability Process Power Simulator increases availability by 30% while reducing cost Customer needs ABB s solutions Customer benefits Simulate 6 generators, 25 transformers and 80 loads Real-time plant scenarios and operator training Pre-engineering time reduced Ability to simulate and track the consequence(s) of each operation performed 7-10 man days reduced onsite [Month? Year?] Prepare environment for Factory Acceptance Test (FAT) Reduced cost for generator load test Minimize unexpected equipment behavior and unplanned scenarios FAT Application was improved and corrected Tuning of control application generator interfaces to shorten commissioning time and expenses for load tests Payback: < 1 year Ensure the PMS functionality implementation is ready and tuned for commissioning Require operator training before and after go-live. Benefits Scope of delivery Time-to-Market CapEx Availability Quality Energy Industries, Indonesia ABB Ability Process Power Simulator ABB Ability System 800xA Simulator 30% 60% 2% 10% Slide 14 September 20, 2024
Case study 3: Barents sea platform in Norway ABB Ability Process Power Simulator provided a trusted solution for the site s vFAT Customer needs ABB s solutions Customer benefits Plant model to be implemented by ABB Need to test a new vFAT (Virtual Factory Acceptance Test) under operating conditions 100 hours of engineering reduced to achieve the same level of functionality Fixing the application before commissioning enabled correct load shedding Update of the application going from version 5.1 to 6.0.3 Final solution provided in 1 week Provide testable solution for each plant scenario or events Testing via the simulator reduced preparation time and provided more reliable vFAT Update needs to be FAT-compliant before starting installation on-site Without ABB Ability Process Power Simulator, the solution could not have been tested ABB Ability Process Power Simulator is also compatible for testing additional applications by the customer Use of dynamic real-time simulation Several trip limits fixed, would have caused blackout if situation did occur Energy Industries, Norway Payback: < 1 year Scope of delivery Benefits ABB Ability Process Power Simulator ABB Ability System 800xA Simulator Time-to-Market Productivity Availability Quality 25% 5% 2% 25% Slide 15 September 20, 2024
Case study 4: North Sea Offshore platform ABB Ability Process Power Simulator reduces testing time by 25% while increasing safety and quality Customer needs ABB s solutions Customer benefits Creating and integrating the model More detailed insights from testing scenarios Need to upgrade and document the IAT (Internal Acceptance Test) and the FAT (Factory Acceptance Test) of the application Consider electrical parameters and specifications Simulator available for next phase integration Review and synthesize datasheets and collect physical variables for setting up the simulators environment Better scenario forecasting reduced offshore costs Update of the application from version 5.1 to 6.0.3 Improved knowledge transfer. ABB Ability Process Power Simulator can be used by the operator to train internal staff Update needed to be FAT-compliant before starting installation on-site Model the Single Line Diagram and make the application ready for testing Reduced ability to have non-physical simulation possibilities Load shedding and shutdown testing as well as logic testing Payback: < 1 year Scope of delivery Benefits Energy Industries, North Sea Quality OpEx Time-to-Market ABB Ability Process Power Simulator ABB Ability System 800xA Simulator 10% 25% 25% Safety CapEx Availability 100% 50% 5% Slide 16 September 20, 2024
Case study 5: JG Summit Petrochemical OSBL Stage 1 Expansion in Philippines ABB Ability Process Power Management increases reliability and efficiency Customer needs ABB s solutions Customer benefits Project management, engineering & supply of Increasing reliability and efficiency of JG Summit s Petrochemical facilities that s located in a 250-hectare fully integrated, world class manufacturing complex through electrical solution, and control and monitoring of complete electrical network with process power management system using ABB s Ability 800xA The project is to increase the production in the existing Naphtha Cracker Plant and add on a new bimodal high-density polyethylene (HDPE) plant. 69kV air-insulated switchgears 13.8kV MV AIS Switchgear, with double bus bar 6.6 kV MV AIS Switchgear LV Switchgear Power and distribution transformers Capacitor bank Soft starter IS-limiters Process power management system Slide 17 September 20, 2024
Case study 6: Petrobras refineries in Brazil ABB Ability Process Power Manager key component in increasing output by as much as 40 percent Customer needs ABB s solutions Customer benefits Dramatic improvement in operational efficiency brought by integrated electrical and safety systems. Smart integration gives technicians the ability to monitor and control the whole facility from a single interface and also to incorporate power management applications and intelligent IEC 61850 substations in the process automation systems. ABB solutions were a key part of Petrobras modernization program which was intended to increase output by as much as 40 percent and produce new high-quality, low sulfur fuels and biofuels to meet growing global and domestic demand for cleaner energy Petrobras wanted to increase the productivity of their plants and to produce new low-emission fuels from renewable sources of energy. Scope of delivery - 10 of 12 of Petrobras refineries are equipped with ABB s power management system. ABB is upgrading and expanding the systems at all ten refineries. Slide 18 September 20, 2024
Case study 7: Duqm Refinery and Petrochemicals Complex in Oman, Hub IMEA ABB Ability Process Power Manager enables better performance with centralized control and operations Customer ABB s solutions Customer benefits Coordinated teamwork with support from Petrofac strategic account manager and hub manager - For End User: Unified systems (for both IPCS & PMS) on a 800xA platform to give centralized control and operations - End-User: The Duqm refinery and Petrochemicals Industries Company - EPC Package 1: Tecnicas Reunidas Team members were coordinated for technical, sales, customer relationships with both the end user and the EPC - For EPC: Well conversant with ABB solutions in past projects, execution from ABB local unit being very close to the customer - EPC package 2: Petrofac & Samsung (JV) Scope of delivery - Design, engineering, documentation, assembly, testing of 800xA based IPCS and Power Management System with Process Power simulator. Project value (package 1 & 2) 10M USD - Installation supervision and commissioning assistance. - Training Approx 63,000 Hardware IOs Slide 19 September 20, 2024
The leader in energy management Superior technologies Complete portfolio ABB listens to our customers and is constantly investing in advanced technology solutions such as the Energy Management PPM. We offer the most comprehensive range of process and electrical control solutions. Comprehensive support and accountability Deep energy expertise Continuity of care with one service agreement to interact with for the entire plant: process, electrical and power management Proven expertise with more than 30 years of experience in process and electrical control Slide 21 September 20, 2024
