CPC 2017, TUCSON, AZ, 2017-0 1-0 9

The Impact of Digit alizat ion on t he

Fut ure of Cont rol and Operat ions
Alf Is a ks s o n, ABB, Iiro Ha rjunko s ki, ABB, Guid o Sa nd , Pfo rzhe im Unive rs it y
Out line

Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns

Fe b rua ry 2, 20 17 Slid e 2
This is ABB
”Power and p ro d uct ivit y fo r a b e t t e r wo rld ”

Ut ilit ie s Ind us t ry Tra ns p o rt & Infra s t ruct ure

Fe b rua ry 2, 20 17 Slid e 3
Corporat e Research Cent ers

Väst erås SE

Ladenburg DE Krakow PL
Baden CH
Windsor US Beijing CN
Raleigh US
Shanghai CN

Bangalore IN

Close t o major cust omers, universit ies and

ABB‘s business responsible unit s

February 2, 2017 Slide 4

Corporat e Research Chief Technology Officer

Local La b s a nd Re s e a rch Are a s Bazmi Husain

Research Portfolio Manager

Ernst Scholtz, a.i.
CHCRC
St ef an Ramseier
Control
Alf Isaksson
CNCRC
Electromagnetics QinJian Liu
Robert Chin

Materials DECRC

Jens Rocks Jan-Henning Fabian

Mechanics
INCRC
Xiaolong Feng
Akilur Rahman
Power electronics
Georgios Demetriades PLCRC
Marek Florkowski
Sensors
Barbara Panella
SECRC
Sof t ware Mikael Dahlgren
Roland Weiss
USCRC
Switching
Le Tang
Riccardo Bini

Fe b rua ry 2, 20 17 Slid e 5
Out line

Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns

Fe b rua ry 2, 20 17 Slid e 6
What can we expect f rom t he f ut ure?

February 2, 2017 Slide 7

 Pro d uct o ffe ring &
b us ine s s m o d e ls
Indust rial Digit alizat ion Dis t rib ut io n
What d o e s t ha t m e a n? Ma rke t cha nne ls
Cus t o m e r co nt a ct s
Pro d uct d e ve lo p m e nt
Pro d uct io n & m a int e na nce
Energy
Co lla b o ra t io n wit h s ub -
s up p lie rs
Sub- Int e g ra t io n in e ne rg y
supplier s ys t e m
Sub - Maintenance
Purchasing

Distribution

Customers
s up p lie r

Sales
Sub -
s up p lie r
Production

Sub -
s up p lie r
R&D Q, IT, etc

Pa rt ne r Pa rt ne r Pa rt ne r

Fe b rua ry 2, 20 17 Slid e 8
Market Trends
The Five Major Trends t hat Manuf act urers Must Follow
Int e rne t
What the industry really needs
of
Thing s
Lo we r co s t Be t t e r Big Mo re
a nd Pro d uct io n asset
MoSa fe t yy
b ilit s im p lifie d e fficie ncy ut ilit iza t io n Daetffe
a ct ive
d e cis io ns
o p e ra t io ns / ROA

The hyp e

Clo ud
Ana lyt ics Co m p ut ing

Fe b rua ry 2, 20 17 Slid e 9
Today’s aut omat ion syst ems
Aut omat ion Net work and Hierarchy

ERP
(Level 4)

MES / CPM
(Level 3)

Supervisory control
(Level 2)

Regulatory control
(Level 1)

Process
(Level 0)

Fe b rua ry 2, 20 17 Slid e 10
Today’s Product ion Syst em Workf low
Several Hierarchical Decision Layers – To p Do wn
De m a nd s , co s t s
Pla nning Op t im iza t io n!
Pro d uct io n t a rg e t s Pro d uce d a m o unt s

Sche d uling Op t im iza t io n!

Ba t ch s ize s , a s s ig nm e nt s , s t a rt t im e s Pro g re s s , e q uip m e nt a va ila b ilit y
Re cip e
e xe cut io n
Se t -p o int s , co ns t ra int s End t im e s , yie ld s , q ua lit y p a ra m e t e rs
Co nt inuo us
o p t im iza t io n Op t im iza t io n!
Ta rg e t s Me a s ure d a nd e s t im a t e d va ria b le s
Ad va nce d
co nt ro l Op t im iza t io n!
Re fe re nce s Co nt ro ls va ria b le s , m e a s ure d d a t a
Lo w-le ve l
co nt ro l Op t im iza t io n!
Ma nip ula t e d va ria b le s Me a s ure m e nt s , b ina ry fe e d b a ck
Ra w m a t e ria ls Pro d uct s
Pro ce s s
Ut ilit ie s Wa s t e

Fe b rua ry 2, 20 17 Slid e 11
What is happening next ?
Upper levels moving t o t he cloud

ERP
(Level 4)

MES / CPM
(Level 3)

Supervisory control
(Level 2)

Regulatory control
(Level 1)

Process
(Level 0)

February 2, 2017 Slide 12

Fut ure aut omat ion syst em archit ect ure
Trade-o ff b e t we e n e d g e a nd clo ud

On-s it e clo ud
Glo b a l clo ud
p la t fo rm

Fire wa ll
Re a l-t im e b us

De vice s

Fe b rua ry 2, 20 17 Slid e 13
OPTIMAX® PowerFit
Opt imizing cont rol of Virt ual Power Pools

Ta s k
• Ag g re g a t e m a ny s m a ll p ro d uct io n unit s a nd
t re a t t he m like o ne b ig p o we r p la nt
• Exp lo it m ult ip le fo rm s o f e ne rg y (e .g . e l a nd
he a t ) a nd s t o ra g e s
So lut io n
• Build o ve ra ll p la nt m o d e l (e xp lo it ing
Mo d e lica m ult i-p hys ics )
• Fo rm ula t e o p t im izing co nt ro l t a s k a s
m a t he m a t ica l p ro g ra m
• Online o p t im iza t io n o f s e t p o int s a nd p la nt
s che d ule s
Dig it a liza t io n e na b le s t he int e rco nne ct io n o f p o we r g e ne ra t io n, co ns um p t io n, s t o ra g e a nd
p ro d uct io n

Fe b rua ry 2, 20 17 Slid e 14
Out line

Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns

Fe b rua ry 2, 20 17 Slid e 15
Model predict ive cont rol: advancing t he f ront iers
lndust ry re q uire m e nt s vs a va ila b le p ro ce s s ing p o we r

Po we r Ge ne ra t io n

Ele ct rica l

Ce m e nt & Mine ra ls

Pulp & Pa p e r

Ro lling Mills

Re fining

Che m ica ls

Fe b rua ry 2, 20 17 Slid e 16
Case st udy : Mondi Swiecie, Poland
Digest er APC Overview

Op e ra t o r o ve rvie w

APC d is p la y

Fa ce p la t e s

Swit ch APC a nd
Sup e rvis o ry m o d e

Fe b rua ry 2, 20 17 Slid e 17
Case st udy : Mondi Swiecie, Poland
Mid-p o int Ka p p a co nt ro l: Re s ult s b e fo re & a ft e r APC im p le m e nt a t io n

Perf ormance t est run result s Kappa variabilit y reduced by 56.4%

Blow Kappa Test Run

Average Upper Lt Lower Lt Sigma % results
Before APC 88.86 89.00 85.00 3.68 36.8%
After APC 87.93 89.00 85.00 1.61 71.4%
Improvements 0.93 2.08 94% 56.4%
Before APC % of data within Limits 36.8%
After APC % of Data within Limits 71.4%

Fe b rua ry 2, 20 17 Slid e 18
DeepMind AI f or Dat a Cent er Cooling
Reduces Google Dat a Cent re Cooling Bill by 40%

PUE = Po we r Us a g e Effe ct ive ne s s

Fe b rua ry 2, 20 17 Slid e 19 ht t p s :/ / d e e p m ind .co m / b lo g , 20 16-0 6-20

Out line

Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
Eng ine e ring Efficie ncy
Co nclus io ns

Fe b rua ry 2, 20 17 Slid e 20
End of Isolat ed Solut ions
Balancing Bet ween Cont rol Syst ems

Energy availability and pricing

Grid cont rol
(smart grids)

Indust rial demand-side management

Production Management
(P&S, APC, Analytics, …)

Int egrat ion of scheduling and cont rol

Process variations, e.g. quality,

Process cont rol
yield, disturbances (DCS)

© ABB Group
February 2, 2017 | Slide 21
Indust rial demand side management in pulp & paper
Coordinat ion of product ion planning and energy management

Mechanical pulp product ion

 The rm o -m e cha nica l p ulp (TMP) Spot Market Hourly Prices (1st week, December 2014)
p ro d uct io n is hig hly int e g ra t e d
80
wit h o t he r p a rt s o f p a p e r p la nt

Electricity Price [€/MWh]

60
 Mo s t e ne rg y co ns um ing 40
p ro d uct io n s t e p s a re m o ve d t o 20
low cost t imes 0

t1
t6
t11
t16
t21
t26
t31
t36
t41
t46
t51
t56
t61
t66
t71
t76
t81
t86
t91
t96
t101
t106
t111
t116
t121
t126
t131
t136
t141
t146
t151
t156
t161
t166
 Pa p e r o ut p ut o f p la nt is not
reduced Time [hours]
Reduced pulp
production Running Ta s ks wit h iDSM
4
2
0
t11
t16
t21
t26
t31
t36
t41
t46
t51
t56
t61
t66
t71
t76
t81
t86
t91
t96
t1
t6

t101
t106
t111
t116
t121
t126
t131
t136
t141
t146
t151
t156
t161
t166
Fe b rua ry 2, 20 17 Slid e 22 Shift ing p ro d uct io n t o lo w co s t t im e s
Indust rial demand side management in pulp & paper
Evaluat ing market opport unit ies f or t he rm o m e cha nica l p ulp ing (TMP) m ills

Case st udy wit h TMP mill

 Re a l wo rld p la nt a nd Sp o t Ma rke t Ho urly Price s (1s t we e k,
No. of
p ro d uct io n d a t a o f a No rd ic Aug us t 20 14) Savings
st art s
p a p e r m ill 100

Ele ct ricit y Price

 Diffe re nt s ce na rio s e va lua t e d 50 S0 8 0%

[€ / MWh]
0 S1 24 6%

t17
t25
t33
t41
t49
t57
t65
t73
t81
t89
t97
t1
t9

t105
t113
t121
t129
t137
t145
t153
t161
Energy Allowed pulp S2 26 5%
Scenario
cost st orage levels Tim e [ho urs ]
S0 No 20 %-80 %
Sp o t Ma rke t Ho urly Price s (1s t we e k,
S1 Ye s 20 %-80 % No. of
De ce m b e r 20 14) Savings
st art s
S2 Ye s 5%-95%
100
Ele ct ricit y Price

50 S0 7 0%
[€ / MWh]

0 S1 34 4%
t17
t25
t33
t41
t49
t57
t65
t73
t81
t89
t97
t1
t9

t105
t113
t121
t129
t137
t145
t153
t161
S2 33 4%
Tim e [ho urs ]

Fe b rua ry 2, 20 17 Slid e 23
NMPC f or Load Commut at ed Invert ers
Cont rolling 48 MW at 1kHz s a m p ling ra t e

LCIs p la y a n im p o rt a nt ro le in
Goal p o we ring e le ct rica lly-d rive n
co m p re s s o r s t a t io ns . Ena b le LCIs
t o rid e t hro ug h p a rt ia l lo s s o f g rid
vo lt a g e .

– Aut o-generat ed NMPC algorit hm

Solut ion (ACADO/ q p OASES)
– Running a t 1kHz on AC 800PEC

Solut ion running at a key

St at oil/ GASSCO sit es
– Two o ut o f s ix 41.2 MW co m p re s s o r
s t ring s fo r g a s e xp o rt a t Ko lls ne s
Result s – Thre e 7.5 MW b o o s t e r co m p re s s o rs a t
Kå rs t ø
– Firs t s ucce s s ful rid e -t hro ug h
No ve m b e r 20 15

Fe b rua ry 2, 20 17 Slid e 24
Out line

Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in – Mining a s e xa m p le ca s e
The m o d e lling co m p le xit y
Co nclus io ns

Fe b rua ry 2, 20 17 Slid e 25
Mining value chain
Mine - Pro ce s s ing - Po rt

Aut omat ion t ouches every aspect of mining

Mine

Po rt
Pro ce s s ing

Pro ce s s o p t im iza t io n o f t he e nt ire va lue cha in in re a l-t im e

Lo we s t le ve l o f a ut o m a t io n is in t he und e rg ro und m ine

Fe b rua ry 2, 20 17 Slid e 26 In co -o p e ra t io n wit h Bo lid e n

Opt imizat ion of Flot at ion Process
Boliden/ Ga rp e nb e rg

• Bo lid e n s t a t e d t ha t t he p ro je ct
is im p o s s ib le !
• MPC + s t a t ic no nline a r
o p t im iza t io n
• Op t im ize fina ncia l o ut p ut
b a s e d o n d yna m ic p rice
m o d e ls
• Incre a s e d t hro ug hp ut b y 1-2
p e rce nt unit s

Fe b rua ry 2, 20 17 Slid e 27
Underground mine product ion
Blast cycle e xp a nd s t he m ine

Product ion cycle Where aut omat ion can help

Source: 1 A pragmat ic
approach t o mine
aut omat ion, ABB Mining
Conf erence Cape Town,
More t han 50 operat ions in a harsh and high risk 2013

environment whereof 10% is aut omat ed*

In reach is a signif icant product ion increase of 40-50% t hrough aut omat ion

Fe b rua ry 2, 20 17 Slide 28 *Source: Final report Zepa, SMIFU Work package 1, Rock Tech Cent re, 2011-12-15
Aut omat ed scheduling - MineInsight
Short t erm scheduling in closed loop

Real-t ime visualizat ion of act ual st at us and on-line replanning

Scheduler

Wo rk lis t Pro g re s s lis t

Execut or

Wo rk o rd e rs Pro g re s s o f wo rk

Mo nt hly p ro d uct io n p la n
Pe rs o ne ll a nd m a chine a va ila b ilit y
Ma chine cha ra ct e ris t ics a nd d is t a nce s

Incre a s e d we e kly b la s t ing b y 10 % - Incre a s e d ut iliza t io n o f m a chine s a nd fa ce s

A p re d ict ive p ro d uct io n fro m t he b e g inning o f t he va lue cha in

Fe b rua ry 2, 20 17 Slid e 29 In co -o p e ra t io n wit h Bo lid e n

ABB Smart vent ilat ion
Healt hy working environment and Energy ef f iciency

Vent ilat ion where needed Real-t ime f eedback cont rol

Ext e nd e d life t im e o f e xis t ing infra s t ruct ure

Ene rg y co ns um p t io n re d uct io n o f 30 -50 % va lid a t e d o n s it e

Fe b rua ry 2, 20 17 Slid e 30
ABB Mine Locat ion Int elligence™
Increased saf et y and product ivit y

3D visualizat ion on a map Connect ion of people and machines

Ena b le d b y m ine wid e wire le s s co m m unica t io n ne t wo rk t hro ug h WLAN

Fe b rua ry 2, 20 17 Slid e 31
Out line

Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns

Fe b rua ry 2, 20 17 Slid e 32
Modelling vision – Aut omat ion of aut omat ion
Aut omat ically g e ne ra t e m o d e ls fo r co nt ro l a nd o p t im iza t io n fro m CAD
Process graphics in 800xA
Modelica model

CAD

Fe b rua ry 2, 20 17 Slid e 33
Virt ual commissioning
Commissioning us ing a (s im ula t e d ) virt ua l re a lit y

Ma nufa ct uring : Me cha nica l o b je ct s up t o ce lls , line s , incl. 2D o r 3D

s im ula t io n a re co up le d wit h a ut o m a t io n s ys t e m s (ha rd wa re o r s o ft wa re
in t he lo o p )
Pro ce s s a ut o m a t io n m o re d ifficult d ue t o la ck o f e a s ily a va ila b le p ro ce s s
m o d e ls . Curre nt ly p ilo t ing s im ula t io n m o d e ls d e rive d fro m P&I d ia g ra m t o
b e us e d fo r FAT.

Fe b rua ry 2, 20 17 Slid e 34
Learning models f rom hist oric dat a
Finding int e rva ls t ha t a re us e ful fo r m o d e lling

• Me t ho d a va ila b le fo r s ys t e m
id e nt ifica t io n us ing inp ut -
o ut p ut d a t a
• Le s s t ha n 5 % o f no rm a l
o p e ra t ing d a t a us e ful fo r
id e nt ifica t io n
• Ca n (his t o ric) d a t a b e us e d
a ls o fo r a p p lica t io ns le a rning
d e cis io n m o d e ls ra t he r t ha n
p ro ce s s m o d e ls ? Fo r e xa m p le
• Ala rm m a na g e m e nt
• Pro d uct io n s che d uling
• Sup p ly-cha in o p t im iza t io n

Fe b rua ry 2, 20 17 Slid e 35
Out line

Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns

Fe b rua ry 2, 20 17 Slid e 36
Conclusions
Digit alizat ion is Inevit able

Dig it a liza t io n will ha ve a t re m e nd o us im p a ct o n co nt ro l

a nd o p e ra t io ns .
Will b e fut ure b us ine s s d iffe re nt ia t o r a nd g ro wing
a ca d e m ic fie ld .

We s e e s hift s fro m
 Prio p rie t a ry t o o p e n a rchit e ct ure s
 Mult iva ria b le co nt ro l wit h fe w in-o ut t o De e p MPC
 Is o la t e d t o int e g ra t e d p o we r a nd a ut o m a t io n
s ys t e m s
 Lo w le ve l co nt ro l t o o p t im iza t io n o f e nt ire va lue
cha in
 Ma nua l t o a ut o m a t ic g e ne ra t io n o f m o d e ls
 Re a l t o virt ua l co m m is s io ning

Fe b rua ry 2, 20 17 Slid e 37
Acknowledgement s

The aut hors are grat ef ul t o many co lle a g ue s , e s p e cia lly wit hin ABB, fo r d is cus s io ns a nd s lid e s .

In p a rt icula r we t ha nk Ja n Nyq vis t , To m a s La g e rb e rg , Rüd ig e r Fra nke , Ab hijit Ba d we , Le nna rt

Me rke rt , Tho m a s Be s s e lm a nn, Me hm e t Me rca ng ö z, Ra ine r Dra t h a nd Ma rio Ho e rnicke .

Fe b rua ry 2, 20 17 Slid e 38