Process Control Systems Quality Control Systems Analytics PID

Process Control Systems Quality Control Systems Analytics PID Control Loops Medium Voltage Drives Low Voltage Drive Systems © Copyright year ABB. All rights reserved. - 1 3/19/2018 Rotating Machines Remote Diagnostic Services Portfolio

Remote Diagnostic Services - Introduction RDS General Information Remote Services Overview n Remote Diagnostic Services (RDS) n RDS Support Process n RDS Connectivity Solution n Asset Types Supported © Copyright year ABB - 2 - n Select Asset Type ? End Presentation X

Remote Diagnostic Services RDS General Information Designed to help customers to… n n © Copyright year ABB - 3 - Remote Diagnostics minimize maintenance costs n Support. Line maximize equipment productivity optimize process throughput • Availability (24 x 7) • Speedy Response • Proactive Service Select Asset Type ? End Presentation X

Remote Diagnostic Services RDS General Information RDS Programs: n Troubleshooting – On-demand connectivity to assist in diagnosing a specific system event or failure via a secure highspeed remote connection. n Periodic Maintenance – asset monitoring and collection of asset parameters for detection of variances from benchmark performance. Includes detailed quarterly health check reports. © Copyright year ABB - 4 - n 1 -800 -HELP-365 Continuous Monitoring – Real-time uninterrupted monitoring of critical asset conditions which are compared to predefined thresholds. Alarms auto generate an entry in ABB’s case management system for immediate resolution. Select Asset Type ? End Presentation X

RDS - Periodic Maintenance RDS General Information Quarterly health checks reports include: Asset status overview n Event summary for the period n Software / firmware revision analysis n Recommended preventive actions based on changes in operating parameters n Recommended corrective maintenance based on event and error reports © Copyright year ABB - 5 - n Select Asset Type ? End Presentation X

RDS - Periodic Maintenance RDS General Information Quarterly health checks reports include: Asset status overview n Event summary for the period n Software / firmware revision analysis n Recommended preventive actions based on changes in operating parameters n © Copyright year ABB - 6 - n Recommended corrective maintenance based on event and error reports Select Asset Type ? End Presentation X

RDS - Continuous Monitoring n Event based monitoring of asset performance n Detection of significant events and variances from benchmark n RDS General Information Notification based on business rules: Low-level alarms: Local alert on maintenance console n Medium-level alarms: E-mail ABB Support Center n High-level alarms: Send alert to ABB Support. Line text pager n n ABB responds to alerts or customer call-ins: © Copyright year ABB - 7 - n n n Contact customer Initiate remote connection Diagnose event data Create incident report All incidents are tracked in ABB’s Support. Line case-tracking system for site history. Select Asset Type ? End Presentation X

Remote Diagnostic Services RDS General Information Features n Around-the-clock access and technical support n Remote access-on-demand n Secure broadband connection n E-mail/Pager Alerts n Predictive and preventative Maintenance n Access to a wider range of ABB’s technical expertise Benefits © Copyright year ABB - 8 - n Optimize Asset Availability and Performanc e Reduced overall maintenance costs n Optimized asset performance n Real-time access and support n Fast and automated information retrieval n Condition reporting enhancements Select Asset Type ? End Presentation X

RDS Enhances Site Maintenance/Service RDS General Information Enhance Site Based Service Continuous monitoring of critical assets n Pre-notification of developing adverse conditions n More efficient response to unplanned system events n Site Service Enhanceme nts Remote expert support for in-house troubleshooting efforts n © Copyright year ABB - 9 - n Direct access to alarms, events, and error logs n Recommendations for corrective and preventive maintenance n Support for managing system upgrade and migration planning Select Asset Type ? End Presentation X

RDS Global Scope of Coverage Action Center Regions RDS General Information Northern Europe and Asia © Copyright year ABB - 10 - Americas Europe, Middle/Near East, Africa Select Asset Type ? End Presentation X

RDS Connectivity Solution RDS General Information Software/Hardware Required n Firewalls – Described n Connection – Topology n Security Measures n SSL Defined n Advantages over Dial-Up or VPN © Copyright year ABB - 11 - n Select Asset Type ? End Presentation X

RDS Node – Software/Hardware Requirements RDS General Information Trouble Shooting and Periodic Maintenance n Customer Provides access to workplace machine n Operating System - Windows 2000/XP Pro n Internet Access Continuous Monitoring ABB Provides RDS Node (AO Workplace) n LAN Connection for Internet Access n Connection to OCS and Space for RDS Node © Copyright year ABB - 12 - n Select Asset Type ? End Presentation X

RDS – Secure Connections RDS General Information Blocked: Connection initiated by inbound attempts. Allowed: Connection initiated © Copyright year ABB - 13 - Typical firewall configurations: § Allow outbound HTTP and HTTPS connections § Web browsing relies on typical rules § Blocks inbound connections to most computers by RDS Service Agent RDS Connectivity: § Secure tunneling technology (ABB’s RDS Service Agent) preserves and extends security at customer locations § Bi-directional communications § Does not compromise customer firewalls § No VPN to configure and maintain § Supports TCP/IP sockets, serial, and Telnet connectivity Select Asset Type ? End Presentation X

© Copyright year ABB - 14 - RDS – Secure Connection Topology Select Asset Type RDS General Information ? End Presentation X

Security Measures RDS General Information Remote Diagnostic Services provide the following measures to insure data security: n Utilize customer standard firewalls (or custom firewalls for direct connections) to protect devices from public access n Enables customer to set level of access to specific devices and information n Logs all remote sessions n Allows customer to designate which information can be transmitted out of facility n Encrypts data using Secure Socket Layer (SSL) protocol to prevent interception © Copyright year ABB - 15 ABB - 3 BUS 004 417 Security Select Asset Type ? End Presentation X

SSL Defined RDS General Information What is Secure Socket Layer (SSL)? SSL is encryption technology that addresses threats to information sent over the Internet: n n © Copyright year ABB - 16 - Third party alteration of your data. n Secure Data seen by an unauthorized third party. Third party impersonation of the intended recipient. SSL encryption technology assures the confidentiality and integrity of any information sent over the internet. A message is coded so that it cannot be decrypted by anyone but the intended recipient. If someone tries to alter an encrypted message, it will not decode correctly and the proper recipient of the message will be alerted to the fact that the message has been tampered with. Select Asset Type ? End Presentation X

Advantages Over VPN and Dial-Up RDS General Information Advantages over VPN n No need for additional VPN hardware and software on either side. ABB and customer can make use of their existing network infrastructure. n Easy to install RDS Service Agent on RDS Node at customer’s site. Advantages over Dial-Up Dedicated phone line for the device is not required n Off the LAN connections bypass the protection of corporate IT n Slower than high-speed Internet, can slow down interactive sessions. n Setup is time consuming for non-existing dial-up lines n © Copyright year ABB - 17 - n Easier to Install RDS Node n Easier to make a remote connection. Select Asset Type ? End Presentation X

Remote Diagnostic Service Applications RDS General Information Click the links below for additional information regarding the following asset types: Process Control Systems Quality Control Systems Analytics PID Control Loops © Copyright year ABB - 18 - Medium Voltage Drives Maximum Asset Availability and Performanc e Low Voltage Drive Systems Rotating Machines Select Asset Type ? End Presentation X

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Process Control Systems RDS for Process Control Systems Remote Diagnostic Services for Process Control Systems supported: 800 x. A n Harmony n MOD n Master n © Copyright year ABB - 20 - n System Six Maximum Asset Availability and Performanc e Select Asset Type ? End Presentation X

RDS Continuous Monitoring RDS for Process Control Systems RDS-Continuous Monitoring provides: Instant notifications through alarming and messaging n Quicker diagnostics from more readily available information n Automatic case creation and notification of ABB Technical Support for critical asset conditions n Asset Firmware/Hardware version management n Loop topology presentation n Key performance indicator trending & predictive maintenance n Historical data collection n Remote visibility for system status and performance information © Copyright year ABB - 21 - n Select Asset Type ? End Presentation X

The following Conditions are Monitored RDS for Process Control Systems Communication System Node Performance Statistics n NIS Event and Error Counters n Loop and Node throughput n Loop topology n Module Status Module alarm event notification n Power Supply Status n CPU and Memory Utilization n Operator Console Health Disk space, CPU and Memory Utilization n Verify critical processes are running © Copyright year ABB - 22 - n Select Asset Type ? End Presentation X

Firmware Management RDS for Process Control Systems © Copyright year ABB - 23 - Is your system up to date? Select Asset Type ? End Presentation X

Event and Error Counter Trending RDS for Process Control Systems © Copyright year ABB - 24 - Will these error rates go away on their own? Select Asset Type ? End Presentation X

Node Performance Trending RDS for Process Control Systems © Copyright year ABB - 25 - How much longer do you want to run with the high possibility of data loss? Select Asset Type ? End Presentation X

Alarm List – Real Time Notification RDS for Process Control Systems © Copyright year ABB - 26 - For example, learn about module failures right away. Select Asset Type ? End Presentation X

RDS for Process Control Systems Value Assessment Troubleshooting Benefit Value Cost ROI $47 K *$13. 5 K $33. 5 K Value Cost ROI $92 K *$30 K $62 K Value Cost ROI *$37. 5 K $114. 5 K Faster problem resolution -> less downtime (est. 4 hrs. /yr) $40 K Less training required for onsite personnel $5 K Lower travel costs $2 K Total Value Periodic Maintenance Benefit Troubleshooting benefits $47 K Lower maintenance costs (proactive recommendations) $5 K Less downtime due to proactive maintenance actions $40 K Total Value Continuous Monitoring © Copyright year ABB - 27 - Benefit Periodic maintenance benefits $92 K Lower maintenance costs (Proactive & Preventative Maintenance Procedures) $30 K Less downtime due to proactive maintenance actions $30 K Total Value $152 K * Costs will vary depending on system configuration. Does not include one-time installation fee. Select Asset Type ? End Presentation X

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Drives & Drive Systems RDS for Drives & Drive Systems Remote Diagnostic Services for Drives & Drive Systems Drives Supported Low Voltage Drive Systems n ACV 700 n ACS 600 n ACS 800 n DCV 700 n DCS 600 © Copyright year ABB - 29 - Medium Voltage Drives n ACS 1000 n ACS 5000 n ACS 6000 Select Asset Type ? End Presentation X

Drive Software Tools RDS for Drives & Drive Systems RDS Monitoring provides: Remote Access to existing ABB Drive. Ware enables RDS Troubleshooting and Periodic Maintenance © Copyright year ABB - 30 - n Select Asset Type ? End Presentation X

System Drives – Value Assessment n RDS for Drives & Drive Systems Troubleshooting Benefit Value Cost ROI $52 K *$12 K $40 K Value Cost ROI *$32 K $74 K Faster problem resolution -> less downtime (est. 4 hrs. /yr) $40 K Less training required for onsite personnel $5 K Lower travel costs $2 K Less onsite consulting time $5 K Total Value n Periodic Maintenance Benefit $52 K Lower maintenance costs (proactive recommendations) $10 K Less downtime due to proactive maintenance actions $40 K Lower travel costs © Copyright year ABB - 31 - Troubleshooting benefits $4 K Less onsite consulting time $10 K Total Value $106 K * Costs will vary depending on system configuration. Does not include one-time installation fee. Select Asset Type ? End Presentation X

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Quality Control Systems RDS for Quality Control Systems Remote Diagnostic Services for Quality Control Systems QCS Assets Supported: Frames & Sensors n Supervisory Control n Smart Advisor Camera System n © Copyright year ABB - 33 - n Ulma Web Imaging Maximum Asset Availability and Performanc e Select Asset Type ? End Presentation X

Frames & Sensors Supported Sensors Frames n RDS for Quality Control Systems n Ash n Basis Weight n Caliper Color Gloss n Smart Platform: 1200 Moisture Smart Platform: 700* n Smart U-Frame* n Reflection Smart Platform* n IR Sensors *SP 360. 0 or later with MPRC board 086444 -004 or later n Opti. Pak n Reflection IR Coat Weight** n Fiber Orientation** n Temperature** n Microwave** n X-ray Coat Weight** © Copyright year ABB - 34 - n **Continuous Monitoring availability limited Select Asset Type ? End Presentation X

Conditions Monitored RDS for Quality Control Systems RDS Monitoring provides: n Record and compare actual scanner & sensor parameters to benchmark Voltages n Temperatures n Internal check samples n Software revision levels n Sensor setup parameters n Sensor standardize variables n © Copyright year ABB - 35 - n Sensor measurement variables n Scanner setup variables Select Asset Type ? End Presentation X

Frame & Sensor Conditions Monitored RDS for Quality Control Systems Sensor Measurement Health n Standardize predictive checks n Standardize reactive checks Excel Based Sensor Reports are collected analyzed but no AMs are tripped. n Standardize n Calibrate Sample n Sample Check Sensor Hardware Health n Basis Weight n Number of shutter movements n Source decay monitoring n Sensor Alarms Scanner Health © Copyright year ABB - 36 - n Predictive Flex Cable Failure n Excessive scanner offsheet time n Number of Scans n Flex Cable warning flag n Frame Temperature n Frame blower plugging n Monitor both IR head water flow indicators Select Asset Type ? End Presentation X

Frames & Sensors Value Assessment n RDS for Quality Control Systems Troubleshooting Benefit Value Cost ROI $47 K *$12 K $35 K Value Cost ROI $92 K *$24. 5 K $67. 5 K Value Cost ROI *$33 K $119 K Faster problem resolution -> less downtime (est. 4 hrs. /yr) $40 K Less training required for onsite personnel $5 K Lower travel costs $2 K Total Value n Periodic Maintenance Benefit Troubleshooting benefits $47 K Lower maintenance costs (proactive recommendations) $5 K Less downtime due to proactive maintenance actions $40 K Total Value n Continuous Monitoring © Copyright year ABB - 37 - Benefit Periodic maintenance benefits $92 K Lower maintenance costs (Proactive & Preventative Maintenance Procedures) $30 K Less downtime due to proactive maintenance actions $30 K Total Value $152 K * Costs will vary depending on system configuration. Does not include one-time installation fee. Select Asset Type ? End Presentation X

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Analytics RDS for Analytics Remote Diagnostic Services for Analytical Equipment Assets Supported: • Continuous Gas Analyzers (CGA) • Chromatograph (GC) © Copyright year ABB - 39 - • Fourier Transform Infra-Red (FTIR) Select Asset Type ? End Presentation X

Analytics RDS for Analytics RDS Monitoring provides: Remote Access to existing ABB Analytics Software to offer RDS Troubleshooting n Periodic Maintenance © Copyright year ABB - 40 - n Select Asset Type ? End Presentation X

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PID Loop Performance Monitoring RDS for PID Control Loops Remote Diagnostic Services for PID Process Control Loops Performance Monitoring ABB Control Systems n Emerson Control Systems n Honeywell Control Systems n Siemens Control Systems n Invensys Control Systems n © Copyright year ABB - 42 - n Others that support OPC communications Select Asset Type ? End Presentation X

Loop Condition Evaluations RDS for PID Control Loops Loop Conditions Tuning Problem n Loop or Setpoint Oscillations n External Disturbances n Non-Linearity n Unreliable Data n Harris Index Acceptability n Setpoint Crossings n Variability n © Copyright year ABB - 43 - n Auto/Manual n Cascade Tracking n Response Speed n Loop Performance (Summary Condition) Select Asset Type ? End Presentation X

LPM Features – Data Collection RDS for PID Control Loops RDS Monitoring provides: Configure database by loops n Simultaneous data collection for multiple loops n OPC connectivity n Direct connection for Infi 90 n © Copyright year ABB - 44 - n Data collection stored as object on navigation tree for future retrieval More direct connections in next release Select Asset Type ? End Presentation X

LPM Features - Tuning n RDS for PID Control Loops Tuning 5 Tuning methods available (manual, lambda, Dominant pole placement and IMC for both PI and PID) n Simulation against both disturbances and set-point changes n Feedforward control tuning n © Copyright year ABB - 45 - n Graphical and numerical tuning evaluation tools (both in time and frequency domain) n Tuning results saved in Logs for future reference and history Select Asset Type ? End Presentation X

Loop Performance Audits RDS for PID Control Loops Performance Audits Is the loop tuning too sluggish? n Is there excessive noise on the PV signal? n Is the overall statistical behavior of the loop good? n Does the loop show signs of persistent oscillation? n Are there problems with the valve? n Is the tuning causing excessive valve wear? n Does the valve show signs of leakage when shut (flow loops)? n Is the actuator saturated for significant periods of time? n © Copyright year ABB - 46 - n Is the setpoint oscillating (cascade loops)? n Does the PV track the SP (cascade loops)? n Is the overall control performance good? Select Asset Type ? End Presentation X

Periodic Maintenance - Reports RDS for PID Control Loops Audit Reports n Loops are grouped both by Area and by Category n Up to 41 different KPI’s reported n Quarterly reports provided ? Poorly performing loops n Select Asset Type Overall performance n © Copyright year ABB - 47 - n Corrective action recommendations End Presentation X

PID Control Loops – Value Assessment n Troubleshooting Benefit Value Cost ROI $50 K *$14 K $36 K Value Cost ROI $95 K *$25 K $70 K Value Cost ROI *$40 K $115 K Tuning assistance -> less product losses (est. 4 hrs. /yr) $40 K Less training required for onsite personnel $5 K Lower maintenance costs (ABB Expert solves problem faster) $5 K Total Value n Periodic Maintenance Benefit Troubleshooting benefits $50 K Lower maintenance costs (proactive recommendations) $5 K Less downtime due to proactive maintenance actions $40 K Total Value n Continuous Monitoring Benefit © Copyright year ABB - 48 - RDS for PID Control Loops Periodic maintenance benefits $95 K Lower maintenance costs (Proactive & Preventative Maintenance Procedures) $30 K Less downtime due to proactive maintenance actions $30 K Total Value $155 K * Costs will vary depending on # of loops. Does not include one-time installation fee. Select Asset Type End Presentation ? X

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Rotating Machines RDS for Rotating Machines Remote Diagnostic Services for Rotating Machines Electric Motors n Pumps n Fans and Blowers n Compressors n Generators n Gearboxes © Copyright year ABB - 50 - n Select Asset Type ? End Presentation X

RDS – Rotating Machine Interface RDS for Rotating Machines RDS Monitoring provides: Base line information for asset n Changes on machine are updated automatically n Machine status can be retrieved manually © Copyright year ABB - 51 - n Select Asset Type ? End Presentation X

RDS – Rotating Machine Detailed View RDS for Rotating Machines © Copyright year ABB - 52 - Detailed status and information about the asset under evaluation Select Asset Type ? End Presentation X

RDS – Rotating Machine - Analyses RDS for Rotating Machines © Copyright year ABB - 53 - Trending of indicators for comprehensive analysis Select Asset Type ? End Presentation X

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