—

Accelerating sustainable growth

in Hyderabad
ABB Technology Day

—
27TH AUGUST 2018

Digitalization in Generating Plants

Automation, optimization and digitalization
—
Power Generation Solution
Comprehensive & integrated portfolio
Power evacuation and grid
connectivity
• HV substation equipment
• Tele-protection system
• Control and protection
• Substation automation system
• Metering
• Station transformer
August 30, 2018
Plant common facilities
• Plant lighting
• Communication and CCTV
• Cabling system
• Earthing and lightning
protection system
Generated power evacuation
• Unit auxiliary transformer
• Generator circuit breaker
• IPB
• Generator step-up transformer
• Transformer monitoring
• Protection equipment
Slide 2
Power Generation control, monitoring & optimization
Total plant automation & digitalization
• Boiler control
• Boiler protection / burner management
• Turbine control
• Condition / vibration monitoring
• Plant auxiliaries control
• Operator workplace
• Engineering
• Alarm management
• Electrical and device integration
• Information management
• Performance monitoring
• Plant optimization
• Asset management
Field instrumentation • Enterprise management
Primary • Cyber security
• Pressure, temperature, flow and
level transmitter
• Positioner and position
Electrical switch room
transmitter • MV / LV switchgear
• Combustion instrument • Motor control center / distribution protection
• Non-segregated phase bus-duct
Analyzer • Distribution transformer
• Flue gas • Diesel gen-set and UPS
• Continuous emission monitoring • Variable frequency drive and soft starter
system (CEMS) • Control and safety systems cabinets
• Steam and water analysis (SWAS) • Emergency diesel generator
—
Power Generation, ABB India
What we are and what we do

Our team Significant presence

– Experts in delivering fossil and green power
automation solutions; water automation;
energy efficiency solutions
– Experts in power plant optimization and
advanced control solutions
– Leading DCS supplier for Power plants in India
– Leading Excitation systems supplier in India
– Leading Flame Scanner supplier in India
– Leading Digital solution provider in India

What we do Track record

– Automation and optimization for power plants – – World’s largest solar plant automation
Coal, Gas, Hydel, Solar PV and water industries
– Restoration of 1000+ MW hydro plant in 6
incl. desalination, pump storage and water
months
distribution
– 130MW DCS upgrade in 10 days of plant outage
– Training simulators
– HMI upgrade in 2 days of plant outage
– Design, engineering, installation, commissioning
and lifecycle services

August 30, 2018 Slide 3

—
Power Generation, ABB India
Capabilities, experience and application

Grid Operator Electrical Integration

Remote Plant Optimization Operator training Interface
mmonitoring with OPTIMAX® simulator

Unit Protection
Switchyard Bay Control
Turbine Plant
automation SCADA
Automation
ABB Ability™ Power Instrumentation
Symphony Plus Generation
Care Excitation systems

#1 DCS in Power Generation

50+ GW 8+ GW 800 MW 900 MLD

Fossil Power Plant Hydro Power Plant Solar Automation Water Treatment &
Automation Automation Distribution

August 30, 2018 Slide 4

 #1 DCS in Power Generation
—
Unified Automation Platform
ABB Ability™ Symphony® Plus

The scalable control platform masters challenges of current and

future needs
– Flexible architecture and system scalability: from small to very
large plants
– Simple and easily adaptable to a broad range of plant
configurations and applications ABB AbilityTM
– Integrated Historian and Alarm Management System Symphony® Plus
(EEMUA191) Process Control Electrical Control
– Electrical and Device Integration (IEC61850)
– Safety systems (SIL2 and SIL3) for critical applications
– Reduced energy consumption and cabinets footprint
– Secure with built-in security features preventing from
unauthorized access
– Create digital backbone for future ready automation

August 30, 2018 Slide 7

—
Flame Scanners
Flame analysis for predictive maintenance

Benefits

– Monitors flame intensity, flicker frequency, amplitude and flame

temperature
• Covering entire flame spectrum
• Multitude of fuel types
– Predictive maintenance
• Spot deterioration in the burner for predictive maintenance
SI
– Build advanced control strategies using advance information
L2
about flame
– Built-in analytics for improved operations
• Determine the quality of the flame to indicate the changes in
burner flame
• Predicts the unsafe/no-flame condition

August 30, 2018 Slide 6

—
Solutions for Hydro and Thermal Power Generation
Integrated solutions
Complete engineered and integrated automation/optimization and
electrification solutions
Automation
– Distributed control systems
– Turbine control (governor)
– Safety systems (SIL2 and SIL3)
– Training simulator
– Plant performance monitoring & operation
– Asset management
Instrumentation
– Field instruments and metering devices
– Control valve & actuators
– Flame detection
– Vibration monitoring,
– Partial discharge detection,
Electrical Equipment
– Power train from generator terminals to grid connection, incl. bus duct,
generator circuit breaker, step-up power transformer, HV connection
and substation
– Synchronization and protection
– MV/LV auxiliary switchgears and transformers
– UPS systems, emergency power supply
– Cabling
Service
– Power Generation Care

August 30, 2018 Slide 7

—
Turbine Automation
Integrated solutions

Turbine-specific products and solutions

– Total solution for turbine control and condition monitoring (S+ Turbine) Diagnostic Excitation (AVR)
fully integrated into Symphony Plus
Generator protection
– Valve positioning module, supporting redundant and multi E/H interface
– Turbine speed collection and protection module, 2oo3 design with Rotor stress monitoring
independent implementation and fully integrated with controller, SIL 3
certificated
– Auto synchronization module
– Condition monitoring module with analyst & diagnostics
– Turbine control simulation system
Governor
– Hydraulic solutions
– Integrated AVR and GP&C
– RGMO Condition monitoring
Hydraulics
– Fast ramp up
Automatic start-up
Valve actuators

> 3000 turbine control projects worldwide including hydro

August 30, 2018 Slide 8

—
Turbine Automation
Integrated solutions

Control system: EHC system services

new and retrofit
– Steam turbine – Electronic over speed
– Combustion turbine protection system

– Hydro turbine – LVDT upgrade

– RGMO

Complete or partial MHC to Analysis

EHC upgrade
– Trip system upgrade/ – Condition monitoring
refurbishment – Rotor stress analysis
– Hydraulic power unit – Simulation
replacement/upgrade
– Fast ramp up
– Actuator replacement/
refurbishment
> 3000 turbine control projects worldwide

August 30, 2018 Slide 9

—
Excitation Systems
Products, systems & applicaitons

Industries
Power; Chemical, Oil & Gas; Pulp Power; Marine; Traction; Power; Chemical, Oil & Gas;
Power Marine
& Paper; Sugar Wind Minerals & Mining; Metals

Power
 Generator synchronization
 Paralleling of lines
 Synchronous generators and
motors
Applications
xx Power xx
 Synchronous generators and  Gas turbine starter  Onboard DC-grid systems
motors  Generator excitation
 Rotating compensators and  Synchronous compensators
converters

SYNCHROTACT® UNITROL® 1000 UNITROL® 6000 MEGATROL UNIREC

© ABB Group
SYNCHROTACT 5
  UNITROL 1005  UNITROL 6000 Light, Medium and  MEGATROL Light  UNIREC Basic
 August 30,
SYNCHROTACT CSS  UNITROL 1010 (AVR) X-power (AVR/SES)  MEGATROL Medium  UNIREC GENREC

2018 |
SYNCHROTACT MSP  UNITROL 1020 (AVR)  MEGATROL Power  UNIREC EXC

August 30, 2018 Slide 10

 —
Power Generation services
Long term commitment to maintain your control system

Limited or no support Continuous support by ABB ABB Control Systems

– Procontrol P13
Additional features
– Symphony
System ROI

Enhanced system
Recent references
Basic service
support ABB Ability™ Symphony Plus
Evolution support
Evergreen system – 4x500 MW NTPC Kaniha, P13 upgrade
– 1x200MW RRVUNL Kota

No support • PR07a processor upgrade for FSSS

System degrades – KPCL Bhadra
• Fiber IPB ring network

At Commissioning time At Commissioning time

ABB support committed for another 15 years… up to 70% savings compared to rip & replace

August 30, 2018 Slide 11

—
Key Market Trends
“Big shift” in power and automation

Utility power generation challenges ABB Ability™ solutions

– Pressure to reduce maintenance budgets and extend life of
assets
– Given uncertain market conditions
– Uncertain of costs and impacts of operating base load units as
swing units, starting and ramping units more frequently
… increase plant availability, optimize lifetime, operational
performance and reduce emissions
… optimize the Virtual Power Plant, by closing the loop between
the generation units, storage devices, flexible consumers and the
central energy management

– Tighter emissions requirements means making trade offs

between output and emissions
– With larger fleets of power plants, capturing lessons learned at
one plant and applying across the fleet to improve reliability,
availability and performance

August 30, 2018 Slide 12

—
Power Generation Digital Solution Portfolio
Improved efficiency, reliability and availability

Advanced applications Other applications

– Reduction in fuel consumption and increase Operation optimization
Engineering &
in power output analysis – Performance monitoring
– Minimize atmospheric pollution – Advanced control
– Increase availability and reduce downtimes – Training simulators
– Increase life time of plant components Production Maintenance optimization
– Maintain production efficiency even under operations Information
management – Vibration condition monitoring
ever- changing market conditions management
– Sensor and plant equipment diagnostics
– Improve operator effectiveness
– Life time consumption
Services
– Loop tuning
– Cyber security
– Energy efficiency

August 30, 2018 Slide 13

—
Key Market Trends
“Big shift” toward digitalization

Utilities Industries ABB Ability™ Solutions

Key drivers Key drivers

Generation mix Higher input cost pressures
Reduction in technical minimum Fuel purchase decisions
Partial load operations Reliability & stability of operations
Merit order and grid demand Workforce transition

August 30, 2018 Slide 14

—
Power Generation Digital Portfolio
Comprehensive plant wide solutions

Performance Monitoring

Combustion Optimization
BoilerLife

Flame Monitoring

Vibration Monitoring

Boiler Start-up Optimization

Flexible Operations

Continuous Emission
Monitoring (CEMS)

Soot Blowing Advisor Pump Efficiency Monitoring Digital Twin for Power Plant

August 30, 2018 Slide 15

—
Advanced Process Control
For flexible plant operations

Benefits
– Improvement in unit heat rate
– Improvement in boiler efficiency by 0.2%
– Increased life of critical equipment like boiler &
turbine
– Reduced downtime & reduced human intervention
– Reduced auxiliary consumption
– Improve control response time
– Stress free environment in control room and
optimum use of operation resources

- Unit heat rate (up to 1%)

- Boiler efficiency (up to 0.4%)
- Life of boiler & turbine

- Control variability (65%)

- Operation efficiency (>60%)

August 30, 2018 Slide 16

—
Digital Twin
Simulate, validate and optimize plant operations

Benefits
– Optimize plant operations using steady state
process simulation
– Estimate economic or cost impact of process
deviation and equipment maintenance
– Decide operation strategies
– Supports/influence fuel purchase decisions for
most optimum operations
– Recognize deviations from optimal performance
Actual generation closely follows
– …
estimated generation

August 30, 2018 Slide 17

—
Digital Engagement Platform
Delivery of Advanced Digital Services

Check details of control

system license
Check list of digital
available services

Contact ABB Local

Ready access to Control
Service
System documentation,
videos & tutorials

Access to control
Check Cyber Security
system Trainings
Status & bulletins for your Download system
control system software
End customer Control
System administrator

Check Performance
(100+ KPIs) of your
control system

End customer Maintenance

engineers

August 30, 2018 Slide 18

—
Collaborative Operations
Digital engagement platform for service delivery

Customer subsystems IoT Gateway, Edge Storage, Visualization,

computing central warehouse, web & mobile interface
analytics

Boiler data

central monitoring,
Operation
databases predictive maintenance,
expert services, trainings
Maintenance
data

Ingestion & Visualization,

Customer data Storage Analytics
transformation reporting, interaction

August 30, 2018 Slide 19

—
Power Generation Services
Preventing system obsolescence

Using past investments… … to solve future needs

‘Evolution without obsolescence’ policy grants backward compatibility Power Generation Care solutions match operational and maintenance needs
between ABB`s new offerings and heritage systems, and support across of a power generation facility; planned delivery transforms routine
the investment life cycle maintenance tasks and frees resources to proactively focus on power
production

All ABB legacy systems supported

• P13, Advant, Harmony, Melody Increase performance and efficiency, extend asset life, complement
technical resources, protect financial and intellectual investments, maximize
reliability
Seamless evolution to new Symphony Plus control technologies tailored to
specific needs and budgets

Advanced service solutions provide continuous automation and control system upgrades
that make the most of your investment, while reducing operation and maintenance costs

August 30, 2018 Slide 20

—
Power Generation Services
Main benefits of our service portfolio

ABB’s evolution approach to control system modernization versus the rip and replace alternative
ABB’s evolution approach Rip and replacement alternative
Retains proven control application software Control code re-engineering or translation is required. New algorithms result in
Process control remains the same as before different process control behaviors and require retuning
Retains plant knowledge base, operations an maintenance philosophy Plant personnel need to learn a new system
Upgraded system hardware retains familiar maintenance procedures New documentation and new C&M procedures are different and unfamiliar to
plant personnel
Preserved investment in control system I/O Requires massive change-out of system hardware (I/O, controllers,
communication infrastucture, HMI and, as a minimum, specialty I/O
terminations)
Minimal commissioning and start-up (no retuning of loops) Long commissioning and start-up periods (reconfiguration and retuning of
loops)
Results in: Results in:
- Minimal loss of production - Greater loss of production
- Minimal risk - Increased risk
- Lower project costs - Higher project costs

Up to 70% in savings compared to rip & replace strategy

August 30, 2018 Slide 21

—
Accelerating sustainable growth
in Hyderabad
ABB Technology Day

—
27TH AUGUST, 2018

Cyber Security for Power Systems

Vijayan SR, Digitalization Lead, Grid Automation
—nhanced Automation
E

 IP based communications:
- IEC 61850 based SA systems
- IEC 104 based communication to control systems
 Phasor Measurement and Wide Area Monitoring
 Stability Analysis
 Demand Side Management and Demand Response
 Asset Management/Asset Health Monitoring
 Management Tools
 Integration of different systems (OT – IT integration)
– SCADA, OMS, GIS, Asset Mgmt. etc.
The
— growing impact of cyber security
Unauthorized access or attack
Maintenance Network Control Network disturbance, malware,
Center Center Cyber attacks

Computer
GPS
HMI
Time Server
Engineering
Workstation Router
Firewall
VPN
Gateway

Station LAN
Data storm by a
Faulty Device
Infected
Mobile USB
Unauthorized data
Person storage
IEC 61850 / Station bus

Infected
Notebook

Unauthorized
Electronic Security perimeter Person
Physical Security perimeter
—yber Security Standards
C
Key Cyber-Security initiatives

Standard Main Focus Status

NIST SGIP-CSWG Smart Grid Interoperability Panel – Cyber Security On-going *
Working Group
NERC CIP NERC CIP Cyber Security regulation for North Released,
American power utilities On-going *
IEC 62351 Data and Communications Security Partly released,
On-going *
IEEE PSRC/H13 & Cyber Security Requirements for Substation On-going*
SUB/C10 Automation, Protection and Control Systems
IEEE 1686 IEEE Standard for Substation Intelligent Electronic Finalized
Devices (IEDs) Cyber Security Capabilities
ISA S99 Industrial Automation and Control System Security Partly released,
On-going *
Cyber
— Security Mitigation
What does it mean?

“Measures taken to protect power

and automation systems against
unauthorized access, attacks,
disruption or loss.”

August 30, 2018

Cyber
— Security – Mitigation Techniques
Hardening
Insure all hosts run at a minimum level. Only mission critical software, services, ports and devices are
allowed.
Access Control
Strong authentication and Role Based Access Control (RBAC) is a natural requirement in any security
architecture, but is never stronger than the implementation.
Intrusion Detection/Prevention
Deploy sensors or agents on all hosts, perform log management of all devices, and use security
information and event management (SIEM) to detect and possibly respond to anomalies in the system.

Patch Management
Processes and technology to insure that all available security updates that are verified not to interfere with
system operation are installed in all hosts.

• Electronic Perimeter
Introducing firewalls in the appropriate access points in the networks, defining DMZs

• Physical Perimeter

| Slide 28
Substation
— Automation Systems
Advanced security architecture
Security Maintenance Network Control Security Legend:
Center Center Zone 3
Zone 4
SDM
600
Disable Ports /services

USB Removable Media

Access

Individual User
Computer GPS
HMI Accounts
Time Server
Engineering
Workstation SDM Router
Firewall 600 Malware Protection
VPN
USB
Gateway
Firewall
Security Zone 2 USB

Router
Station LAN

Encrypted
Communication
IEC 61850 / Station bus
SDM Central security logging
600 /Account Management

Local security logging

Security Zone 1
Electronic Security perimeter Patch management
Physical Security perimeter
Power
— Grids Cyber Security Care
Three steps to cyber security protection
Assess
ABB carries out a cyber security
assessment and an interview with
you to understand your processes
and procedures.
A detailed cyber security
assessment report is then
produced and provided to you
along with a set of recommended
actions for improved cyber
security.
Cyber security vigilance is a long term sustained approach
August 30, 2018
Implement
ABB provides recommended
actions for you to implement
based on the cyber security
assessment and our domain
expertise.
Upon agreement ABB implements
the recommendations to your
system, ensuring your critical
systems are more secure.
Sustain
By appointing ABB as your cyber
security partner; you enter a care
agreement which ensures you
benefits from ABB’s huge domain
expertise across the globe.
Your power systems will be
regularly assessed and monitored
by the cyber security service team
for any potential cyber security
infringements.
ABB
— Cyber Security Care
Six layers of protection

Security Assessment and Monitoring

• Fundamental in order to keep a system

constantly secure.
• Overseeing the cyber security status of your
system
• Collects system data for comparison against
industry best practices and standards to
detect weaknesses within your system’s
defense.
• Pinpoints areas that require action to help
protect your system by ensuring it has
multiple layers of security.
• 24/7 Security event monitoring

August 30, 2018

—
—
ABB Technology Day
Accelerating sustainable growth

—
MONDAY, AUGUST 27, 2018

Measurement matters
Enhance productivity and plant availability
M. Somnath, Measurement and Analytics
—
Accurate and reliable measurement solutions
For every application in your plant
Improve emissions Optimize overall plant
monitoring and control with ABB
combustion efficiency measurement devices
with flue gas analyzers

Ensure safety with Maximize boiler life

comprehensive and efficiency with pH,
pressure and conductivity, silica, and
temperature measurement hydrazine analyzers

Durable flow, pressure and Maximize turbine life

temperature sensors for and efficiency with pH,
tough applications like conductivity, silica,
pulverized coal hydrazine and hydrogen
and fly ash purity analyzers

Reduce operational Save fuel with accurate Optimize combustion Reduce pressure Increase boiler efficiency Reduce steam
variability with control of condensate with accurate natural gas loss and increase and reduce fuel usage with losses with ABB’s
accurate valve level in boiler feedwater composition analysis for efficiency with ABB’s DP electric and pneumatic unique swirl flow meter
automation combined-cycle plants flow solutions damper control solutions

August 30, 2018 Slide 34

—
Accurate measurement, reliable performance
Offering simple solutions to your challenging application

Tighter control and safety with temperature and pressure measurement

The challenge
• Maximizing boiler operation without compromising safety -
increase of 10°C (50°F) in temperature can double the speed of the
chemical processes taking place in a boiler

The solution
• Measure temperature and pressure around the steam loop
with ABB’s measurement products

• Suitable for applications up to 1,800°C (3,272°F) and 600 bar

(8,706 psi)

• Typical measurement points include stack, boiler, boiler drum,

deaerator plant, steam line, generator, cooling water system

• ABB’s diaflex seal technology ensures pressure sensors do not

fail even in toughest applications e.g. high abrasion

August 30, 2018 Slide 35

—
Feed water, steam and process liquid analysis
Increasing availability by measuring water quality
Controlling boiler chemistry for maximum water & steam quality
The challenge
• To ensure high quality of Water and Steam in the power plant
cycle for boiler & turbine protection and ensuring maximum
efficiency.

The solution
To continuously monitor multiple chemical parameters in the
water circuit with ABB Analyzers –

• pH analyzers - sensors with the shortest depth measurement

and auto-calibration features.
• Conductivity analyzers with wide range measurement
capability for ionic content.
• Dissolved oxygen analyzer for monitoring to prevent
oxidation and scaling.
pH sensors
• ABB’s Navigator 600 series Silica and Phosphate analyzers
come with extensive diagnostics and accuracy- substantially
cutting costs of maintenance
• Sodium analyzers with no diffusion tube, wide range and
sample temperature compensation.
• Hydrazine analyzers with pH and temperature compensation
• We have also Aluminum, Ammonia, Chlorine, Dissolved
Conductivity sensors Navigator 600
oxygen, Flouride, Iron, Manganese, Nitrate, etc

August 30, 2018 Slide 36

—
Accurate measurement, reliable performance
Offering the solution to your challenging application
Maintaining the right air/fuel mix Reducing process variability

The challenge The challenge

• Insufficient air supply will result in incomplete combustion
The solution
• Close control with ABB’s Contrac actuators for best in class
accuracy and speed
• High responsiveness and positioning accuracy of ±0.05 %
• Operators achieve optimum fuel, air and operating pressure
ratios
• Provide fast and accurate control valve positioning to
reduce process variability
The solution
• ABB’s Iconic TZID-C200 high performance digital positioner
offers unsurpassed accuracy and speed
• Fast response due to high air flow capacity of up to
40Nm³/h (23scfm)
• High seating load with air supply pressure of up to 10 bar
(145psi)

August 30, 2018 Slide 37

—
Accurate measurement, reliable performance
Offering the solution to your challenging application
Deriving combustion efficiency Measuring calorific values

The challenge The challenge

• Finding the right air to fuel ratio for efficient combustion
The easy-to-install insitu solution
• Measuring flue gas oxygen with ABB’s AZ20 and Oxygen
with COe with AZ40 combustion gas oxygen analyzers.
• Probe is inserted into a flue and accurately measures
combustion gas oxygen content
• Applications from -20 to 800°C
(-4 to 1472°F)
Calculating the calorific value of a natural gas sample requires
gas composition information
The solution
• ABB’s PGC1000 and NGC8206 field mounted gas
chromatograph analyzes natural gas composition in
combined cycle power plants
• Gas sample data is used to inform other devices in the
combustion process
• Achieves optimum combustion conditions

August 30, 2018 Slide 38

—
Accurate measurement, reliable performance
Offering the solution to your challenging application

Optimizing combustion and reducing emissions through continuous monitoring for flue gas

The challenge
• Reduce pollution from gaseous stack emissions

The solution
• ABB CEMS gas analyzers provide continuous emissions
monitoring and full compliance with local legislation

• Modular Advance Optima system and EasyLine series with

infra-red or ultra-violet photometric analyzers

• Paramagnetic analyzer or electrochemical cell measure NO,

NO2, SO2, CO, CO2 and O2 in one unit

• ACX system for extractive continuous gas analysis , ACF-NT

Fourier Transform Infra-Red (FT-IR) spectrometer based turn- Analyzer
key system for incineration processes
Gas Probe System Sample Line Sample Gas Conditioning

August 30, 2018 Slide 39

—
Innovation and technology that make a difference
Looking beyond the measurement

Digital Sample handling Dynamic QR Code Verification tool

• Collect real time measurement and
alarm data
• Reduce downtime & increase
availability of analyzers by 15%
• Instant product identification &
system diagnostics
• Dynamically generated QR codes on the
analyzer display for easy communication
• On-site, in-situ condition monitoring for
checking product accuracy and health,
without removal from process
• Fingerprint on-demand feature

• Predictive actionable insight • Remote troubleshooting support • Verify a range of ABB flow meters

• Pay for performance

August 30, 2018 Slide 40