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Issue 3 / 2006The ABB India Magazine

CONTACTThe ABB India Magazine2

Editorial Team

Harmeet S Bawa – Head, Corporate Communications

Suma Boby – Executive Editor

Namita Asnani – Power

ABB Limited, GF-Corporate Communications, IndiaKhanija Bhavan, 2nd Floor, East Wing, 49, Race Course RoadBangalore - 560 001.

abb.co.in/contactemail: [email protected]

Design – Shilahar Associates

Dear friends,

As we integrate with the world economy, Indian industry istranscending geographical borders and realizing that 'factoradvantages' are only a part of the story. Real and sustainableadvantage comes from 'competitiveness' in the form of acomplete value proposition which includes factors like price,quality, productivity, efficiency, aesthetics, delivery systems etc.

Automation technologies help to ensure an optimum balancebetween labour and technology, enabling streamlining ofmanufacturing processes, as well as greater control &integration of systems across the value chain for higher efficiency& productivity. Automation is also playing a key role in helpingbusinesses improve return on assets and facilitating real-timeinformation and speed of decision making.

The level of automation technologies deployed in India is stilllow and in order to catch up with the rest of the world, theindustry must adopt best-in-class automation technologies.Automation solution providers are combining their domainexpertise and engineering know-how to achieve seamless andreal-time integration of manufacturing and business processes.

Globally, the paper industry produces over 300 MT of paperp.a, with North America and the Scandinavian countriesaccounting for around 55 per cent of the output and Asiaaccounting for around one-fourth. The Indian paper industry,ranks 15th with an installed capacity of around 7 MT andaround 550 paper mills across the country, and providingemployment to around 1.5 million people.

Demand, during the next decade, is expected to grow to about15 MT across all major categories of paper and paper products.Moreover, consumers are becoming more and more discerning.It is time for the Indian pulp & paper industry to claim its rightfulplace in this growing economy and even look beyond borders.This sector is one of the best examples of the crucial roleautomation technologies play at the Primary, Plant andEnterprise levels, to enhance efficiency, increase productivity,streamline processes, ensure control and optimize paper quality.

This issue of CONTACT focuses on key aspects, challengesand solutions for the Pulp & Paper industry and also bringsyou the range and unique value proposition ABB offers to thisfast growing sector.

Yours sincerely,

Ravi Uppal

Contents

Global Roundup 3

India Roundup 5

Customer InterviewPradeep Dhobale, CEO - ITC PSPD 9

Feature StoryThe world of paper 11

Recent successes 14

New Technologies 15

Technology Digest 16

Living our commitment to Sustainability 20

Channel Line 21

Tech Bytes 22


CONTACTThe ABB India Magazine 3

Global Roundup

ABB recently won an order from Terna SpA, a leading energycompany that operates the Italian transmission system to delivera High Voltage Direct Current (HVDC) power system connectingthe grids of Sardinia and peninsular Italy. The 1,000 MW HVDCundersea link will carry surplus power between the Italian mainlandat Latina and the island of Sardinia. Italy is one of the world'sbiggest importers of electrical power and the connection will deliverelectricity to one million homes.

ABB will design and deliver two converter stations, one in FiumeSanto, Sardinia, and the other in Latina, on the Italian mainland -both in existing 400 kilovolt (kV) substations. The stations at adistance of 420 km apart will include converter transformers as wellas air-insulated and gas-insulated switchgear. Power cables will belaid beneath the Tyrrhenian Sea at depths of up to 1,600 meters. In

HVDC undersea power link

Ferrari the world famous automaker hasselected ABB's PASS M0 hybridswitchgear for the high-voltage substationthat feeds the legendary Maranello complexof assembly lines, offices, museum and racetrack with power. It was the innovativedesign, simplicity and proven reliability ofthis pioneering technology (more than 1500units have been sold to customers in 35countries since 2000) that appealed to Ferrari.

ABB's Plug and Switch System (PASS) M0switchgear has revolutionized substation

PASS on the race track

design. It combines all the functions of acomplete Air Insulated Switchgear (AIS)

bay in a single ready-to-install module thatrequires 60 percent less space than theconventional AIS alternative and takesjust a few hours to install.

The Ferrari-owned substation wasscheduled for modernization to securereliability and meet the growing need forelectricity at the complex. As with allsubstation upgrades, compact design andreliability of switchgears were fundamentalrequirements and ABB technologies thepreferred option.

An ABB automation solution for 17 printingplants will enable the U.S. edition of TheWall Street Journal to appear in a new,slimmer format that will save publishers -Dow Jones, an estimated $ 18 million inannual production costs and secure printquality. The solution is currently being

Making headlinesinstalled and commissioned at all the 17Dow Jones printing plants in the UnitedStates in preparation for the launch of thenew-look Wall Street Journal in January2007. The ABB solution consists of 58MPS Control Consoles for the 19 printingpresses and an MPS Production pressmanagement system for each of the 17printing plants.

MPS Production is a press automationand management system that handlesthe planning and production of the printproduct, optimizing print quality andreducing waste. The MPS Control Consolesenable operators to control and operatethe entire printing process from a singleworkstation. ABB has supplied similarsolutions for customers in Europe, Northand South America, and Asia and is the

recognized leader in control and automationtechnologies for the newspaper printingindustry worldwide.

addition to handling the power exchange, this sophisticated HVDCsystem can stabilize voltages and frequencies on Sardinia.

ABB remains the world leader in HVDC transmission technology,with 55 HVDC projects improving the transmission capacity ofutilities around the world by more than 45,000 MW.



ABB, recently signed an agreement withThe Dow Chemical Company as one of twopreferred suppliers for IEC switchgear andmotor controls. The three-year pact,covering a variety of electrical switchgearand control products, complements anexisting strategic agreement with Dow forABB Industrial IT control systems. ABB isnow the designated strategic supplier of

Strengthening bonds with Dow Chemicalslow-voltage switchgear and motor controlcenters, plus medium-voltage switchgearto Dow facilities that operate accordingto International ElectrotechnicalCommission (IEC) regulatory standards.The products agreement continues along collaboration between ABB andDow, which operates more than 150manufacturing sites worldwide.

Arizona Cardinals' new state-of-the-artretractable stadium roof employs ABBDrives to open and close the giant panels.Retractable roofs have become a popularfeature at professional sports venues asthey become bigger and more complex indesign and scale. Architects and engineersare looking for bold new ideas. Only aselect number of companies have theknowledge and expertise to mechanizeand control these immense structures,which, themselves, become architecturalfeats. Uni-Systems, based in Minneapolis,

Let the games begin!Minnesota, partnered with ABB andselected the ABB ACS800 drive toprovide optimum control of the roof'storque-distribution system.

An important factor in choosing the ABBdrives was the inherent risk associated withrunning a roof on a sloped track. ABB'sVariable Frequency Drive (VFD) allows fortests to drive torque before each roofmotion, to ensure that each drive wasoperational and capable of a 100-percenttorque output. Before each motion, theProgrammable Logic Controller (PLC)

checks the torque output from the VFDs at0 Hz, before committing to opening themotor brakes.

ABB has recently won a contract fromthe mining and minerals group LKAB toraise productivity at an iron-ore mine inKiruna, Sweden. ABB will supply hoists,used to haul ore to the surface, as well ashoist-control systems and drives to helpincrease production at Kiruna by 25percent. ABB's technologies will helpsupport extending the depth of the

Productivity in miningmine by about a third to 1,365 metersbelow the surface.

ABB will supply ACS6000SD variable speeddrives, 5600 kW synchronous machines andAC800M control systems to four existingunderground hoists. In addition, ABB willprovide a new turnkey mine hoist with completemechanics and brake system at surface level.

ABB is working with Algerian oil and gascompany Sonatrach to expand existingcompressor and power systems in theHassi R'Mel fields. Under the project,three existing compressor stationsserving the Hassi R'Mel natural gas fieldswill be expanded. ABB's scope of supplyincludes engineering, procurement,construction and commissioning of thenew stations, including new turbocompressors, upgrades to existing

Developing the energy sectorcompressors, and gas coolers. ABBwill also provide new low-voltage andmedium-voltage power distributionsystems and enhancements to existingautomation systems.

The improvements in the Hassi R'Melfields will support an expected increase innatural gas exports to Europe of some 30billion cubic meters per year within the nextfive years.



ABB has designed, engineered andimplemented a state-of-the-art SCADA/DMS system at Reliance Energy (REL) forthe Mumbai Transmission & Distribution(T&D) network. The commissioning of thisadvanced system now enables REL toserve its 2.5 million consumers in a servicearea of 384 sq. kms. with enhancedreliability and efficiency.

The SCADA/DMS is a single, integratedsystem for generation, transmission anddistribution networks with centralizedcontrol and monitoring and providesvisibility for the company's entire T&Dnetwork. The system helps REL maintainsupply under normal conditions besidesproviding for speedy restoration of powerin case of outages.

The system also includes a complete set ofDistribution Management applicationsincluding quick islanding and load sheddingbased on real time data that operatesduring contingencies, helping preventblackouts. The system monitors andcontrols about 60 main transmission &distribution substations spread across thesuburbs of Mumbai as well as thesubstation at the Dahanu Thermal PowerStation located 110kms from Mumbai.

Real time monitoring and control with SCADA

India Roundup

Benefits

� Faster response time, fault isolationand supply restoration.

� Operational flexibility

� Helps in better planning andimproved management of theelectrical network

� Reduction in losses and trouble callmanagement

� Enables better service to the endcustomer

consumers aware of the company's recentinitiatives and to allow them to experienceand appreciate the scale of SCADA.

ABB's Corporate Research Center in Bangalore, India (INCRC) hasqualified for the Capability Maturity Model Integration (CMMI® ) level2 and obtaining the ISO 9001:2000 certification. INCRC is thefirst Research Center in ABB's global R&D network to achieve thishonour - a testimony to the quality, dedication and commitment ofthe Bangalore unit.

The certification follows a recent TUV assessment based on anintegrated approach combining the Standard CMMI® AppraisalMethod for Process Improvement (SCAMPISM) – Class Amethodology and the requirements of ISO 9001:2000,concurrently. The TUV Rheinland team audited INCRC througha rigorous 70 day long appraisal process. The appraisalteam included 4 auditors from TUV and 8 trained assessorsfrom INCRC.

The deployment of an integrated Quality Management System(QMS) was a key element in the certification. QMS facilitatesseamless integration of processes deployed across theorganization towards providing research services, software

Certification for Corporate Research Center in Bangalore

In another significant project win, ABB hasdesigned, engineered and implementedanother state-of-the-art SCADA/DMSsystem at BSES Discoms in Delhi. Thesystem remotely monitors the health ofBSES Rajdhani & BSES Yamuna distributionnetworks in real time covering all of the 117Grid Stations. BSES is also expanding thereach of the system to cover its network of11kV transformers and feeders.

With this system, BSES aims to reduce thefault restoration time by over 60 percent -from a current average of 110 minutes toless than 45 minutes! BSES has alsolaunched a unique program - called "SCADADarshan" - for RWAs and students in Delhi.The hour-long program is aimed at making

Mumbai

Delhi

engineering and software application solutions in the areas ofPower Products, Power Systems, Automation Products andProcess Automation.



Proper planning and decision making arecritical for durability and efficiency. It is thereforeimportant for utilities to have the tools tosystematically analyze cost/performancetrade-offs within the financial constraintsimposed on them. Similarly, changes areoften required with reference to standards,guidelines and procedures. Interpretingsuch changes and developing newoptimization methods and state-of-the-artsoftware to assist utilities in meeting thesechallenges is where ABB has vast experience.

Power systems consulting services enablescustomers to plan, operate and maintaintheir systems in a more economical andreliable way.

ABB offers expertise in Power Systems Consulting

The ABB Consulting group is a globalteam of more than one hundred powersystems experts with local presence inthe USA, UK, Germany, Spain, Sweden,Italy, India and China. ABB consultantsare backed up by over 6000 product,systems and service specialists inlocations close to our customers,enabling the company to identifyand implement total system solutions.Backing ABB's consulting businessis domain expertise and field experienceaccumulated over decades in thepower industry as well as the globalpresence that brings best practicesfrom all over the world to help utility

ABB's Power Systems Consultingoffering includes:

� Planning for grid upgrades

� System performance issuesrelated to voltage, thermal anddynamic stability constraints

� Evaluating and enhancing gridreliability

� Forecasting demand growth fordistribution companies

� Benchmarking utilities relative toglobal 'best in class' peer groups

� Asset evaluation and reliabilitycentered maintenance planning

� Technical due-diligence in supportof mergers and acquisitions

ABB's Training Center at Vadodara hasbeen developed as a hub of learning forPower Technologies. The world-classfacility, offers specialized training on powertechnology products, systems andsolutions to ABB's customers, employees,students from technical institutes andvendors. ABB has similar centers inBangalore, Mumbai and Nashik as well.These training centers were developed tohelp customers stay ahead by providinghands-on experience and in-depthclassroom instruction for sharpeningexisting skills and integrating advances intechnological innovation.

The demo room is equipped with awide range of live products including aSCADA system (integrated with theoutdoor switchyard), protection relays,OLTC, Ring Main Unit and control panel.The outdoor switchyard has operatingmodels of high voltage and mediumvoltage circuit breakers, disconnectors,capacitor bank, transformer bushings,power and distribution transformersamong others.

World-class learning hub for power technologiesEach training programme is tailor-made to fulfillthe specific requirements of customers. Thetraining center has hosted several importantcustomers from India and abroad. Some of therecent patrons of the training center includePGCIL, NHPC, ONGC, NTPC, AmbujaCements, Indian Railways, GAIL, L&T,DMRC and several State Electricity Boards.Investment beneficiaries include customersand ABB Group company representativesfrom Bhutan, Syria, Oman, Taiwan,Bangladesh, Vietnam, Indonesia, Australia,South Africa and Morocco among others.

Facilities include:

� Sophisticated learning aids likemulti-media presentations, simulationsand product cut-outs

� Demo room with operating modelsof a wide range of products

� Practice benches for hand-on training

� Well-equipped classrooms withe-learning facility

� Outdoor switchyard with operatingmodels of HV and MV product

Scope of training modules include:

� Operation and maintenance

� Condition-monitoring

� Erection and commissioning

� Protection and distributionautomation

� System engineering

� Settings and general protectionschemes

customers improve their businessperformance.



The Chief Minister of Karnataka state,HD Kumaraswamy and the State PowerMinister HD Revanna recently performed a'Bhoomi Pooja' (a symbolic ceremony tobless the ground and bring good luck)alongwith several state dignitaries andKPTCL officials, to mark the commencementof a greenfield 220 kV sub-station project atHolenarsipura Taluk, located west ofBangalore and appx. 20 km from Hassan.The project is being executed on a turnkeybasis by ABB for the state's leadingtransmission utility, Karnataka PowerTransmission Corporation Ltd (KPTCL).

Speaking on the occasion, the ChiefMinister said, "The substation is extremely

CM flags off turnkeysubstation project in Karnataka

important to this region and once complete,Holenarsipura and the surrounding areas willbe greatly benefitted with improvedavailability and quality of power.

This significant project has been entrustedto ABB and we expect completion inaround nine months. I am sure ABB andKPTCL will work together to ensure timelycommissioning."

The project encompasses a 2 X 100 MVA,220/66/11kV sub-station and constructionof a 220 kV Loop-In Loop-Out (LILO) linefrom the Shimoga-Mysore 220 kV Line tothe proposed 220 kV S/S at Kadavinakote( Holenarsipura Taluk ). The proposedsub-station and transmission lines will cater

to the load of areas in and aroundHolenarsipura taluk which is currently fedfrom the 220/66kV sub-station at Hassanthrough 66kV transmission lines. Thesetting up of the station at Kadavinakoteand construction of the transmission linewill help increase the quality of power byincreasing the voltage profiles andreducing losses.

ABB has an enviable track record backedby expertise and experience to deliversuch projects to the highest standardsand on time. ABB will work closely withKPTCL and the Govt of Karnataka toensure that the region benefits fromreliable power supply.

ABB has successfully engineered andcommissioned a fibre-opticcommunication network for RelianceEnergy Limited (REL) providing it with aconverged and reliable solution forVoice, SCADA and IT applications. Thecommunication network encompasses52 locations including the GeneratingStation at Dahanu (1000MW), 220kVTransmission Substations and 33kVReceiving Stations.

Previously, SCADA & IT Traffic washandled through separate networks.

With ABB's solution, REL now has anintegrated network for SCADA & ITapplications that substantially reducesinfrastructure and management costs in achallenging power transmission anddistribution environment. Thecommunication network enables remotemanagement of receiving stations from acentral location as well as improvedreliability/availability of the network withABB's state-of-the-art networkmanagement system. The solution is basedon a ring topology with a Master Control

Center (MCC) at Santacruz and a Back-up Control Center (BCC) at Aarey 220KV substation.

Fibre-optic communication network for Reliance Energy


Integrated Building system solutions

Ensuring critical uptimeABB India has recently won an orderfor providing power to IBM - BharatiTeleventures' Datacenter in Noida.The 3 tier Central Primary DataCenter is designed for 99.98%uptime and is built to consolidateand facilitate archiving and retrievalof data from different Data Centersacross the country.

The project scope includes distributionof UPS power to the servers through alarge network of bus trunking systemsand equipment like AutomaticTransfer Switches, Power DistributionUnits, Earthing Systems & Lighting.

Real estate projectsABB India is supplying an Electrical andEnergy Management System for theBoulder Hills Township in Manikondanear Hyderabad. The super luxurytownship spread over 550 acres isbeing built by Dubai based EmaarProperties in partnership with AndhraPradesh Industrial InfrastructureCorporation Ltd. The township

includes 460 villas, 15 commercialcomplexes, 12 residential apartmentsand an 18-hole international standardgolf course. ABB's scope of supplyincludes 33 KV switchyard extensions,11 KV Distribution Panels, Fifty Six 11KVA Compact Sub-Station, 420 kmsof cable, street lighting and EnergyManagement System.

ABB will also provide turnkeyelectrical solutions for the Hill CountyResidential Township in Bachupalli,Hyderabad. The township is spreadover an area of 500 acres and isbeing built by Maytas Infra PrivateLimited. The township will housevillas, residential complexes andrecreation facilities. ABB's scopeof supply includes 33 KV switchyard, 33 KV RMU, 33/11 KVtransformers, 11KV/433 transformers,HT / LT cabling, street lighting andearthing work.

Quality Certification

ABB Building Systems includingcomplete HVAC, electricalcontracting, Integrated BuildingManagement Systems and AfterSales Services has been Certified forISO 9001:2000. QualityManagement System as well as ENISO 9001:2000 by RWTUVSystems GmbH. The certification isa validation of ABB's commitmentto the highest quality standards.

ABB recently won a contract forrevamping the HVAC system at ONGCin Bombay High, which is India's largestoffshore oil field situated approximately161 kms north off the Mumbai coast.The project also includes instrumentationand architecture for 4 clusters ofplatforms The scope of the orderincludes design, engineering, supply,installation, testing, commissioning, hookup, post commissioning services and onthe job training for ONGC personnel.

In another recent success ABB has beenentrusted by Reliance Life Sciences Pvt.Ltd. to supply and deliver HVAC andBuilding Management System (BMS) ona turnkey basis for its upcoming facility,at their biotech park in Mumbai. Thescope of work encompasses design andengineering, equipment supply, erection,testing, commissioning and validation of

HVAC and BMS for industries

HVAC and BMS. ABB solution will helppreserve the required clean room needsapart from the right pressure, humidityand temperature requirements.


Customer Interview

Can you give us an industryperspective on how the Paper &Pulp sector is emerging in India?The demand for paper products hastraditionally been growing in line with GDP.Till last year, this was around 7 per cent andnow we are talking about 8 - 10 per centlevels, so we expect the sector to see ahealthy growth rate going forward.

I hasten to add that the extent to which wecan tap this opportunity depends a lot onwhether the pulp & paper industry makesthe right investments at the right time andproactively addresses cost and quality issues.

To put things in perspective, India is whereChina was nearly 20 years back, whichwould mean a per capita consumption ofpaper of about 6.8 Kg/person/year. TodayChina has crossed 50 Kg per capita andeven the world average is at about 45. Infact, developed countries like USA andGermany are as high as 300 Kg per Capita.Even if we want to reach the China level inthe next two decades, paper consumptionin India has to grow nearly 10 times fromthe present base.

India's present capacity stands at about 7million tons and is projected to reach 15million tons in the next 10 years. The Indianpaper & pulp industry recognizes thegrowth potential and most establishedpaper players in the country are in capacityexpansion and augmentation mode. In manycases, the scale of investment is fairly highin the region of Rs 500 crore and above.

What are ITC's capacity expansionplans?

ITC has a combined capacity of around400,000 tonnes per annum. The

The paper chase!ITC - Paperboards and Specialty Papers Division (ITC - PSPD) or ITC Bhadrachalam as it is popularly known, is among the

leading names in the paper industry. Employing the most contemporary technologies, ITC - PSPD has risen to become one

of South Asia's largest manufacturer of Packaging and Graphics Boards. We met up with Mr Pradeep Dhobale, CEO of the

division to gain some insights into the Indian Pulp & Paper industry and learn more about the recipe behind ITC's success in

a competitive and highly quality conscious market. Mr Dhobale played a vital role in the planning and commissioning of ITC's

US $ 150 million expansion project. Under his exemplary leadership, ITC Bhadrachalam Paperboards has emerged as the

largest single location paper mill in the country and has achieved a dramatic turnaround, in terms of returning to profitability.

Bhadrachalam mill (capacity 300,000 TPA)is the largest single location mill in thecountry. Currently we are looking at abrownfield expansion of around 120,000tonnes at Bhandrachalam. This wouldrequire about 500,000 tonnes of woodwhich translates to around 25,000 hectaresof land to sustain this production. Since wehave the finances to invest, our expansionplans depend mainly on how much rawmaterial we can get on-stream and how fast.

How do you address some keyenvironmental & social issues?

We at ITC take our environmental responsibilityvery seriously and even go beyond thebasic requirements of the Pollution ControlBoard. The Bhadrachalam mill was the firstin the country to be an ECF (ElementalChlorine Free) mill. Chlorine as a bleachingagent is cheap and has been traditionallyused in the industry. When chlorine reactswith Cellulose fibre, it creates a pollutingcompound which can be cancerous whenexposure is high and continuous. The useof Chlorine is still not banned in India andthe Government has allowed upto 2008 toimplement ECF technology. ITC introducedthis in 2002 and all our expansion plans arebased on this technology.

Unit Bhadrachalam

• Production capacity of 300,000TPA of virgin and recycled boards.

• Commissioned India's firstElemental Chlorine Free Fibreline,with a capacity of 100,000 TPA.

• ISO 9001 and ISO 14001accredited

• OHSAS 18001 certified

Pradeep DhobaleCEO - ITC PSPD

Chemical Engineer (IIT - Mumbai),Professional training in paper makingtechnology at mills in France andSweden, General Management trainingat Management Development Center,Chelwood of British AmericanTobacco Co. UK

Mr Dhobale began his career as amanagement trainee with ITCBhadrachalam Paperboards Ltd in1977, quickly moving up the ranks tobecome the Managing Director in 1999.

Following the amalgamation of ITCBhadrachalam Paperboards Ltd withITC Ltd in March 2002, he took chargeof the Paperboards & SpecialtyPapers Division as CEO

Industry thought leader

Vice President - Apex Council of IndianPaper Manufacturer's Association

Vice Chairman - CII - A.P. State Council

Past President - Indian Pulp & PaperAssociation


Similar to cloning technology and ECF,we are also the first paper company todevelop technology for fly ash bricks.All paper industries use a lot of coal,and we generate almost 250 tonnes of ashper day. Power plants also use a lot of coaland dump the ash slurry in lagoons whichcan lead to contamination of ground water.This is no longer considered as anenvironment friendly activity. TheGovernment has only 'recommended' thatlagooning should be stopped.

At ITC, with an investment of Rs 20 lakh webuilt a plant that used the ash to convertinto fly ash bricks. For our mill, we neededfour plants and we encouraged the localentrepreneurs to set up these plants. Ourown factory and colonies are built with flyash bricks and this helped prove to thecommunity that these bricks are strong.We then worked with the District Collectorto convince him about environmentfriendliness of fly ash bricks. Thereafter, theauthorities have been recommending that allgovernment funded buildings in the areashould be built only with these bricks.

Today, no company in this industry cansurvive without paying due regard toenvironmental issues. We, on our part areproud to have made a positive impact tothe environment and the community. Iwould also like to pass on a large part ofthis credit to our discerning customers,who often insist on products that areenvironmental friendly and are made usingenvironmental friendly techniques.

Unit Tribeni

• Production capacity - 33,000 TPA

• 50 year tradition of specialty papermaking

• ISO 9001 and ISO 14001accredited


How has automation made adifference to your operations?

We were among the first mills in the countryto use automation technologies extensivelyto build and maintain our leading edge in theindustry. Our Bhadrachalam mill is arguablythe most automated mill in the countrytoday. We started the factory in the 1980swith single loop controls and then tookseveral automation steps in phases. In the90's we implemented Distributed ControlSystems (DCS). 2 years back we investedin Manufacturing Execution Systems (MES).We are now on the verge of going in for afully integrated ERP system. Automationalso helps us to optimize costs andimprove quality. Our 'paper' is practically,untouched by hand!

Automation is also playing a critical role inour material handling functions. For exampletill the late 90s our production was at85,000 tonnes with 1400 employees. Thisyear our production stood at 300,000tonnes with around the same number ofemployees! In one word - 'productivity' andlargely driven by automation.

An Automatic Storage and RetrievalSystem (ASRS) is used at our warehouse.The warehouse stores about 3500 tonnesof paper and has a movement of 600tonnes a day. A typical warehouse like thiswould require around 200 people - we haveone! The entire warehouse is managed withrobotic cranes and palletizing.

But I hasten to add, that automation doesnot take away jobs - it only frees vital humanresources for more gainful engagement.People will continue to play an important rolein our's and any business. What automationallows us to do is to add fewer numbersduring our growth phase and enablesproductivity and scalability. Higher output inthe factory requires more raw material andmore jobs get created in plantations.

From a market competitivenessperspective, as customs duty comes

Unit Kovai

• 65000 TPA of recycled boards

• Increased flexibility & lower lead time

• ISO 9001 & 14001 accredited


down, India will be a huge market not onlyfor domestic paper mills but for internationalplayers as well. This will mean addedpressure to keep costs in check andautomation will play a major role in helpingpaper mills to optimize costs, ensure qualityand increase efficiency.

What's your experience of workingwith ABB?

ABB has played a crucial role in automatingthe plant and implementing our stringentQuality Control System (QCS). Our ULMAWeb Inspection system can spot defectsupto 0.2 mm diameter and record thecoordinates. This was a major investmentfor us and probably the first of its kind inIndia. We reposed our confidence in ABB'stechnology, domain expertise and globalexperience. Our automation systems havehelped to create value in the factory andbring us a higher Return on Investment(ROI) through cost optimization, qualitycontrol and productivity.

ABB has high-end technology, with a widerange of products and solutions for the pulp& paper sector. Since advanced automationis still new to India, we would like to seegreater collaboration between users andproviders, especially in terms of optimizingthe equipment to maximum advantage. Wewould also like to see a greater emphasison service needs to on-site support. In fact,we are looking forward to a regularengagement with the technology providersfor maintaining some of our capitalequipment. ABB certainly has the domainexpertise and are recognized power andautomation technology specialists.


Feature Story

The Pulp and Paper Industry is an integral part of India’s recent industrial resurgency and one of the 35 identifiedhigh priority sectors. India is currently ranked fifteenth among global paper producers and is quickly movingforward. According to the Indian Paper Manufacturer's Association, the Pulp & Paper sector provides employmentto over 0.3 million people directly and 1.0 million people indirectly. The growth in this sector is expected to bedriven by several factors including GDP growth, population growth, increase in literacy levels, growth of servicessector and government policies on foreign investments. The prospects are bright and by 2020, several analystspredict production to reach levels of 15 million tons with writing and printing paper experiencing the highest growth.

The world of paper

MarketSynopsis Market Overview

Production 5.8 MTNo. of Paper Mills in India Over 600No. of Mills > Capacity 50000 T/A < 25Share of large mills >40%Per capita consumption 5.5 kgConsumption 5.2 MT

Volume sharing by type of mills

Market Size(04-05) : 5.7Mn TPA CAGR : 6%

Source: ICRA

India’s demand to grow @ 6% CAGRas against 2.8% globally

Demand & GrowthSegment wise

MarketSynopsis

Source: ICRA

MarketSynopsis Snap Shot – Paper sector

(*000 tones)

2001 2002 2003 2004 2005 %CAGR 2009(E)

Capacity (*000 TPA) 6676 6909 7040 7290 7540 3.3 8750

Effective Capacity 5809 6034 6160 6390 6640 3.6 8000

Production 4673 4831 5202 5530 5856 7.2 7200

Effective Capacity Utilization% 80.4 80.1 84.4 86.5 88.2 3.4 90

Demand 4614 4854 5152 5452 5776 5.7 7140

Imports 134 173 200 250 190 (2.5) 400

Exports 193 150 150 170 270 12.8 250

Source: Bank of Baroda Risk Management research reports



Paper Products

Substation

Pulp Mill Applications

Pulp Mill

Process Control

Paper

Open Control System

� Industrial IT Extended System 800xA

� Advanced Process Control

� On-line Optimizer

� Process and Control Optimization

� Process Information Management

CPM Solutions

� Production Planning and Optimization

� Production Tracking

� Quality Management

� Customer Service Management

� Energy Management and Optimization

ABB's products, solutionsand services covers theentire value chain in thepulp & paper mill from fieldinstrumentation, electrical anddrive systems to AutomationOpen Control System (OCS)and ManagementInformation Systems.

ABB’S integrated soluABB’S integrated solu

Electrification

� Power Distribution

� ProcessElectrification

� BuildingElectrification

ABB provides a full range ofcomplete lifecycle servicesfor all systems and productsfrom spare parts andequipment repair, remoteservices and training,maintenance, and evolutionsupport to complete assetmanagement.

ABB providescomprehensive integratedsolutions to meet everyrequirement of the pulp andpaper industry - from settingup entire plants to specificneeds related to the pulp &paper manufacturingprocess.


Pulp

Chemical Deliveries

Paper mill

Drive Systems

� AC Drives

� DC Drives

� Direct Drives

Quality Control

� Scanners

� Controls

� Measurements

� Profilers

Web Inspection

� Web Imaging

� AutomaticBraking System

While others are onlybeginning the effort to bringfundamentally differentsystems together in acommon user interface,ABB has been using acommon platform for bothcontrol and user interfacefor all its new productssince the introduction ofIndustrial IT in 2001.

ABB's pulp and papercustomers can now realizethe advantages of a systembased on an architecturethat ties together all majorautomation systemscommonly found in a pulpand paper operation.

utions for pulp & paperutions for pulp & paper

Services� Engineering� Installation� Commissioning� Start-up� Training� After Sales Services

ABB provides paper millswith the tools, technologiesand know how, helping millsto help them perform safer,smarter and better withsubstantial cost savings.


Recent successes

Monitoring production with drives

ABB is supplying drive technology to the M-real Biberist mill in Switzerland. M-realwill rebuild its coating machine for increased production and machine efficiency.ABB´s drive system, including 49 drive sections, will run and monitor the entirecoating machine production line. The drive system includes application software,70 motors and new generation MultiDrive ACS800 industrial drives. The reel widthof the coating machine is 5.1 m and design speed increases from 1200 to 1400m/min. ABB's drive technology will increase production capacity and improvepaper quality. M-real Biberist mill produces 420,000 tons of wood-free coated(graphic paper) and wood-free natural paper (office paper) annually.

Paper Productivity

The Andhra Pradesh Paper Mills Limited (APPM) is one of the largest integratedpulp and paper manufacturing mills in India. At present, APPM manufactures1,60,000 TPA from its two units in the East Godavari District of AP. The millcomprises 5 paper machines at Unit APPM and 3 at Unit CP producing paper andboards of different MG and MF varieties in the range of 21 to 250 GSM. APPM'sproduct range is comprehensive and covers a wide spectrum of writing andprinting paper, packaging paper, specialty paper, paper boards and newsprint forboth domestic and export markets.

ABB worked with APPM to help set up a 550 TPD, state-of-the-art, pulping facilityat its Unit APPM. The scope of the work encompassed complete design, supply,engineering, testing and commissioning of 11 kV/6.6 kV Switchgear, Power andDistribution Transformers, Neutral Grounding Resistor Panels, LT Bus Ducts, HT/LTCables, 415 V LT Power Control Centre and Motor Control Centers, LightingTransformers, HT and LT Motors, 7.2kV Capacitors, 415 V Automatic PowerFactor Controller Panels, Plant Illumination, Annunciation Panels, Batteries andBattery Chargers, UPS and AC Drives as well as the complete automation of theplant. ABB's automation system integrates all mill operations, connecting the maincontrol room to the system servers as well as all the applications and processcontrols including Pulp Mill and Recovery Island.

This is the first-of-its-kind facility with centralized control roomfor pulp mill with 23 operator stations

Enhancing paper quality & efficiency

ABB is supplying Quality Control Systems (QCS), Distributed Control Systems (DCS) and PaperMachine Drives for Century Mill's new paper machine. Century Mill is one of India's leading pulp &paper producers with five paper machines (PM I-V) and a capacity of 1,60,000 tons per annumsoon to be enhanced to 2,45,000 tons. Maintaining correct tension demands high accuracy andconstant torque at high speeds. ABB drives help keep the finished product correctly tensioned,while the products are wound onto reels during the final stages of manufacture. ABB's solutionwill enable Century Mill to benefit from improved quality and reliability by fine tuning processesand making corrective production and maintenance decisions before problems occur.


ABB has recently introduced the flexibleIRB 6650S-90/3.9 m - a shelf mounted,six-axis robot with an enhanced workingenvelope over previous models. With areach of 3.9 metres, the IRB 6650S iscapable of full vertical and horizontalstroke motion - as well as providingincreased reach forward and down.With virtually no footprint, the shelf-mounted robot provides ample space tohandle large parts - allowing for shortercycle times. The IRB 6650S is an attractivealternative to a linear, 3-axis robot,

conventionally used in injection mouldingapplications. Based on 6-axis technology,the robot is superior in versatility, reach andprecision. The IRB 6650S is an ideal solutionfor large injection moulding machinesrequiring over 1,000 tons of clamping force.The flexibility of the six-axis robot means noidle time between shoots, facilitating post-process applications like flaming, spruecutting, tape dispensing and assemblyoperations. This allows plant designers toreduce the number of downstream stationsand decrease plant throughput times.

New backward - bending 6-axis robot

New Technologies

ABB’s innovative PASS switchgear

ABB’s PASS (Plug and Switch System)hybrid Air Insulated Switchgear (AIS) and

Gas Insulated Switchgear (GIS) conceptprovides a fully integrated and self-contained switchgear module that hasrevolutionized outdoor substation design.

It combines all the functions of acomplete AIS bay in a single ready-to-install module that requires 60 per centless space than the conventional AISand takes just a few hours to install.PASS is available in two models, thePASS M00 up to 100kV rated voltage,2kA rated current and breakingcurrent up to 31.5kA and the PASSM0 up to 170kV rated voltage,2.5kA rated current and breakingcurrent up to 40kA

ABB showcased its latest high-endtechnology offering for power plantprotection, the Generator CircuitBreaker (GCB) at a seminar in NewDelhi. The seminar drew participationfrom power generating companies,EPC's and consultants.

GCBs are core components of amodern power plant, protecting boththe generator and the powertransformer. ABB's GCBs are widelyused in all kinds of power stationsnamely hydro, combined cycle,pumped storage, thermal, nuclear and

gas turbine power plants. The breakers arealso suited for retrofitting in existing powerplants and are available for both indoor andoutdoor application.

Faults at power stations can cause severedamage to critical equipments, long-term

outages and heavy economic losses.When compared with conventionalmethods of protection, generator circuitbreakers offer faster and superiorprotection. Application of GCBs offersbenefits like simplified plant layout andoperational procedures, reduction instress on components in normal serviceand better and faster fault protectionthus significantly reducing extent ofdamages for minimized repair costs andoutage time. ABB's GCBs are the onlyones in the world, which can switch faultcurrents up to 200,000 ampères

Power plant protection with ABB's GCB

Special features

• All the functions of a bay arecombined in a single module

• The operating and interruptingfunctions are integratedwithin a housing in SF6

• Fully transportable and easyto install

• Guaranteed reliability

• Extremely versatile whensubstation layouts/planningsolutions are drafted


ABB IndustrialITTrue Integration Story

Technology Digest

transactions taking place daily or at an evenslower pace.

Conventionally most of this information isavailable in various automation islands,which can communicate with each other byexchanging predefined data arrays. Dataexchange can be accomplished in differentways. Without generic standards, differentvendors have developed proprietarycommunications. When using opencommunication protocols instead ofconstructing proprietary communicationsystems, much of the one-off work, as wellas vendor dependence, can be avoided.Even so, although the protocols allowfreedom to communicate, most of the dataexchange remains tailored for a certainpurpose, delivering a vital, but relativelysmall amount of available data andsometimes creating bottlenecks for criticalfunctions. Programming continues to becarried out by specialists from vendors ofdifferent automation islands. It is quite clearwhy generic communication protocols arenot enough. Tighter integration is necessaryto avoid the burden of constructingcommunication rules separately for differentparts of the system, not to mention theadditional communication hardware.

Automation technology can beoptimised for one type offunctionality, but can it be for many?

In paper making, a typical form of integrationin the past has been the combination ofpaper machine drive control and processcontrol. From the machine control point ofview, the combined drive control andmachine control itself is a natural fit.

In ABB's automation concept this firstcombination has already been successfullyimplemented since the mid 80s. TheIntegrated MD16 control concept wasbased on the ABB MasterPiece/200platform. 10-20 systems annually, making atotal of 190 systems, were delivered overthe period 1985-1995. During that period,almost one fifth of all ABB drive systemdeliveries comprised integrated systems,the rest being distributed control systems.

Pitfalls of Integration. The benefits of theintegrated systems were obvious: efficiencyof process management and maintenance;common operator interface and tools,fewer spares, a fast response and accessto all control parameters, and above all,reduced total life cycle cost.

Open communication standards were yetto come, meaning that automation wasbased on proprietary communication. Sucharchitecture was designed for database andI/O handling, and the fast control tasks hadto be solved with assembler programs andspecial software. This led to solutions whichwere no longer user friendly.

The issue still remains. In some recentcases where drive control has beenintegrated with an alien process controller,specific fast drive control tasks havesubsequently been reprogrammed into athird, drive specific controller just to ensurecorrect operation. The planned savings(reduced engineering, fast start-up, uniformtools, etc) became obsolete.

The handling of all the measured data withconventional database architectures,designed for batch processes, is not

Information System

Automation System

Electrical and Drive Systems

Field Instrumentation

Example of delivered fully integrated greenfield plant solution.

Today's trend is global integration in manydifferent ways. Companies seek synergies,focus on core operations and find ways tocut overlapping in these activities. This trendis reflected in the different operational levelsfor improving efficiency, while not permittingany compromise on the flexibility and highefficiency achieved in smaller entities. Eventhough different mills - or system suppliers -have stronger individual competencies insome areas, e.g. in process automation, theneed for in-depth expertise in all areasshould not be undermined. The paperprocess is one operation where mergingmore and more functions under the samecontrol areas has been going on for as longas solutions for process automation havebeen developed. The main dilemma hasalways been the different process taskssetting different requirements for controlfunctions. Primary design parameters ofintegration include both softwarecharacteristics and the hardware capacityto execute the desired task. With anincreasing number of different tasks and aperpetual need for even faster execution,the data processing demands in papermaking become more difficult to meet.Device level control tasks are a major challengefor the integrated automation concept.

Integration relies on data communications.Open communication protocols are notenough.

The demand for a higher level of integrationin process automation is now based largelyon a general demand for on-line informationfor the rationalisation of operation &maintenance. Processes include tens ofthousands of signal and control points,varying from millisecond transmissionspeeds up to several minutes, with random


always efficient enough to ensure fast andaccurate control. The integrated solutionneeds to be designed with featuressupporting very different dynamics tothose required for process control only.With special assembler software for fastcontrol tasks, the solutions (like MD16)become apparently “clumsy” and costly forusers. There was a price pay for the specialcapacity. The investment cost was higher,capable vendors were few and the degreeof vendor dependency was apparently acustomer concern, too. It was not yet timefor the true integration story.

Benefits:+ optimized CPU performance+ optimized communication+ synchronized time throughout whole system,

including drives+ advanced drive control features like patented

adaptive load change compensator+ same tools/documentation/spares+ single point programming and diagnostic

access from OperateIT+ system scalability, same controller for all

purposes permits optimal usage of controllerperformance

+ worldwide proven standard solutions includingsafety risk analysis

+ local engineering in 12 countries - totally 300persons working for P&P Drives

+ remote support: call center or networkconnection

The true Industrial IT integration of theprocess and drives.

Integration of the process and driveswith a dedicated drives controller.

Benefits:+ both vendors have proven solutions &

optimized equipment. Scope of delivery welldefined - minimal technical risks.

Distributed systems; steps toward thefuture. On the other hand, the main streamwas smaller control entities. Most customerspreferred to split investments to permit awider range of vendors to compete forsmaller entities and distributed controls,thus leading to lower investment costs.

Naturally there are technical drivers too, thatspeak for distributed drive controlsolutions: simplified control area, flexibility,capacity reserves for dedicated drivefunctions, easier standardisation(modularity), and so forth. As a result of thisdevelopment, almost all ABB papermachine drive systems since 1995 havebeen delivered with dedicated drive controls.

+ standard OPC interface+ advanced drive control features like patented

adaptive load change compensator+ drive vendor gives full support up to OPC

interface+ remote support: call center or network

connection+ worldwide P&P drives network to support

customer.Local engineering/ expertise.

Disadvantages:- separate programming tools- separate controller spares

Integration of the process and driveswith multiple communication links tothe process controller.

Benefits:+ same hardware for drive and automation

controller+ same programming language

Disadvantages:- communication via general purpose

fieldbuses, limited data, e.g. control of torqueselector, change of master/followercombination, clock synchronization fordiagnostics purposes not possible fromautomation system

- protocol converters needed for each drive- no hard real-time in Windows based

automation systems- process experts still needed for both drive

control and automation(not enough with only programming knowhow)

- service needed separately for drives andautomation

- drive tools not integrated into automation platform- no worldwide support and local control

expertise for drive control

The main focus in the distributed systemapplications has been the ability to executefast control loops and dedicated functionsfor special paper making processes.One of the most common of these is theflying splice function, where the paper webis changed from one roll to another at fullspeed in continuous production. Suchdemanding processes can exist in anykind of production machines, as well as inmodern finishing machines. Sometimes,despite the simplicity of the apparentfunction itself, there are complicated loadcompensation, or other optimisation,functions which are extremely demandingfor the speed of communication. Suchfunctions are often necessary, for example,in tissue machines or in on-line calendering.Centre winding is applied in many modernconcepts, and winders already operatingat a web speed of above 3000 m/minrequire very accurate control functions tobe successful.

Optimizing the machine controls.With complete automation deliveries, whereABB automation platforms and drives havebeen selected as a truly integrated solution,the paper machine control logic as well hasbeen integrated in this same platform. Itoffers the same I/O, the same tools,excellent data communications and CPUutilisation which is optimised for eachcontrol area. The I/O is accomplished withABB's S800 units, machine control isinstalled in ABB's Advant Controller (450)stations, and the drive controls are locatedin ABB's Advant Controller (80) stations.The machine supplier is liable for themachine control functions presented as alogic diagram. The HW and application SWof the machine control has been included inthe overall ABB System, includingElectrification, Drives & Automation.

There is, however, a distinct difference ininstalling fast drive control functions in aconventional type of automation system.Without sufficient design features in theautomation system, an inadequateresponse to essential drive functions candeteriorate machine runnability.

Basic functions or everythingincluded?

There are many justified advantages whenintegrating either machine or processcontrol, or both, in the drive control. Someof these become questionable if notcarefully evaluated and properly engineered.Today, when creating demanding drive


controls in a process controller, thecomplete requirements must be known.Since no single 'right' solution exists as withrespect to system integration, thecustomer and system supplier mustthoroughly weigh up the issues below, inorder to arrive at the best possible endresult for a certain application.

Common automation technology is notenough. The two main considerations are;1) the amount of required communicationhardware in the control command chain,2) the data processing and transmissioncapacity of the complete communication chain.

One example of the specific needs of thecontrol on the device level is the calculationof the motor flux vector positions 40,000times a second, or reversed: once in 25microseconds. Many measurements andfunctions have to be extremely fast. Nodoubt there is a need for a very specificdevice level controller with dedicatedsoftware for motor control. Besides,without this particular capacity, the papermachine would suffer from bad runnability,e.g. loss of speed feedback from pulseencoders or other disturbances. Runningadvanced machines with the requiredefficiency without pulse encoders, as withABB's Direct Drive, would not be possible.The second level in the command chain isthe application controller. Usually the fastapplication tasks, as mentioned earlier, aredealt with at this level. The fast commandexecution requires the rapid collection of avast array of measured data. For instance,obtaining web break and splicing reportswill need a specific execution capacity fromthe hardware and software or master/followerfunctions requiring a millisecond levelcommunication speed. Sometimes it is alsonecessary to install the speed control for aninverter in the application controller. This willplace an additional load on the controller.

Again, such functions as advancedtension control (in fast load changesituations) would not be possible withoutthe dedicated capacity in the applicationcontroller.

When all requirements are carefully studied,the dedicated drive system controller isoften found to be the most practicalsolution, especially when seamlesscompatibility with the other components ofthe process automation can be ensured.

Open protocol data links createovershoot of redundancy. Is explainedabove, drive converters inevitably includesophisticated internal command structuresand data processing software. Dedicatedcontrollers usually communicate by meansof the internal link and with the same comm& structures. To communicate with invertersby open communication protocols, eachdrive unit requires a separate device, ageneral purpose protocol converter, to beable to transmit data to an alien controller.This can constitute a significant hardwarecost in paper machines with a large numberof drives, e.g. in coating machines whereunit power and cost per unit is low. Theextra cost is caused by those protocolsthat are in fact created for merely modestcommunication needs for simple fielddevices, such as valves, and so on.

Additionally significant hardware redundancyon the lower device level occurs, in contrastto the redundancy eliminated on thehigher automation level, between thededicated controller and the processautomation. By using ABB DriveIT andControlIT products, the above linkageduplication can be avoided.

Diagnostics with a limp. Due to theuse of the internal communication links,the application controller has all-inclusiveaccess to any measured data in the driveconverters. Some fast functions need fastand thorough status information, butrecording converter dataloggers withhigh sampling rates - either for on-line drivediagnostic needs or for offline troubleshooting tools - must also be performedextensively, in order to quickly analyse theroot causes of web breaks, trippings, andso forth. If such data snapshots are notavailable, trouble shooting will requireadditional measurements and severalrepetitions of the problem.

Increase of functionality compared toprocessing capacity requirements.

Documentation seamlessly integrated into thediagnostics system.

Incomplete functionality will cause a increasingneed for support during the investment life cycle.

The wider the integration is, the greaterthe probability that a available data isdisregarded due to lack of in-depth focus.In the worst case only the most essentialoperations are ensured, and diagnosticsfunctions do not meet the new flexibilityrequirements in today's paper production,resulting in deteriorated availability. Again,the net data transfer capacity must beadequate. The specified baud rate does notindicate the transfer rate of core data in theactual data messages. Even with a highapparent speed, depending on thecommunication means, the secondary databits might take up the lion's share of thecapacity, thus hindering efficient diagnosticand control functions.

Apparent savings in investment phasemoved to engineering and support afterstart-up. Application engineering requires alot of unique solutions for different papermaking processes and different machines.Software engineering is the processautomation expert's daily bread. Acompetent automation specialist, with areasonable knowledge of drives, hasenough process know-how to make designspecifications for drives functionality.Focusing on the explicit drive control needsof difficult process parts and the differentrequirements mentioned above alreadypresent a much higher challenge, which maynot, though, necessarily be overwhelming.In-depth focus on drives is necessary. Butthe unique nature of the solution mightcreate a hurdle. A unique solution often hasan unpredictable cost impact on engineering.It might lead to unexpected re-engineeringneeds - most probably in start-up, finetuning or later, in production batch changes.

Without carefully and widely standardisedsolutions, making changes and obtainingsupport can be difficult or time consumingTo construct these standards will takehundreds of projects, and to build up askilled global support network requiresdozens of engineers and experts - notprogramming experts, but drivesapplication experts. Regardless of whetherdrive controls are integrated or not, an


AspectObjectTM system facilitates seamlessmillwide integration.

application expert is needed. Also when awide expert network exists, a vast amountof feedback from a wide range ofapplications can be used to makestandardised solutions.

Increasing efforts are nowadays beingmade to create remote services andremote diagnostics. This can be efficientonly when supported by efficient tools,unrestricted data access, proper in-depthexpertise and adequate resources.Whether the solution to any problem isfound quickly or not depends on the in-depth focus area of the expert. Usuallyhuman limitations are a hindrance to thepossession of a very wide area of in-depthexpertise by one person along the wholeprocess, machine control and drive chain.Consequently, with an increasing amount ofinformation available, the intelligentdiagnostic systems will play an increasinglyimportant role in the future. To createautomated system intelligence, experienceand in-depth know-how must be extremelysolid. The expression "seamless integration"will take on a new meaning.

Uniformity - including documents andall?. Uniformity in simple terms means thesame look and feel of controls, parts,documents, configurations and tools. Toachieve this, some degree of engineeringand display programming is required fromthe customer. The same look & feel can beeasily engineered in operator displays. Such'integrations' have often been effected tohelp system runnability. However, trueintegration goes further: the uniformity mustinclude e.g. a name-based configuration ofdrive systems, quality control systems,web inspection systems and processcontrollers. It should include data collectionbetween systems by uniform interfaces:having the OPC interface brings us onlyhalfway there, since it must be pre-designedwith detailed uniformity, too. Differentdiagnostic, programming and maintenancetools attached to one system platformshould work in a uniform manner.One whole subject in its own right is in-

depth product documentation, which oughtto be available directly from systemservers. It requires a significantdevelopment effort even to create a uniformdocumentation for such a wide range ofproducts as those included in process,drive and machine controls. From the drivespoint of view it is a great advantage to linkHW and application SW using ABB’sAspectObjectTM.

ABB's automation and drive platforms haveincluded characteristics such as the DriveSupport tool, & ABB's IndustrialIT solutionsadds to these features.

Thanks to the uniformity of the ABB Drivesand Automation solutions, ABB'scustomers can obtain 24h 365d papermachine drive application support worldwide.

Scalability to add processor capacity.Until now, optimising the investment costhas driven the development of distributedcontrol systems. When the industry isfacing faster order delivery cycles, tightercontrol of assets, a faster developmentpace for new paper types and even newfunctionality of paper products, a new kindof flexibility in production processes isrequired. Whether integrated control has abetter response to these requirements thana small-scale system is not so self-evident.

Broader information availability byintegration merely gives access to a vastamount of process data. Increasingintelligence in field devices add to thatinformation handling load. Intelligent filteringin the middle controller layer is justified, if notessential. Furthermore, if that intelligence iscapable of polling automation componentsexternal to itself and it detects possibleproblem causes, the system serves machineavailability even better than the merelycombined control of different functions. Forexample, ABB's AdviseIT for OperatorDiagnostics is a tool, or module designedto probe the drive status and a combinationof desired external signals. The middlecontroller layer is, of course, replaceable bya fully integrated solution providing that thefunctionality remains equal.

The commercial advantages of the scalabilityof the system are quite obvious, dependingon the scope of the investment or rebuild.

IndustrialIT - the true Integration Story

Integration of process, machine & drivecontrols must not lead to moving costspocket to-pocket, or shifting costs to alater point in the paper machine life cycle. Itis difficult to see the whole life cycle at thebeginning of an investment and this mustnot be merely a matter of blind faith. Trueintegration can certainly be a giant leap tobetter paper making processes andcustomer success. If all the pitfalls arerealised and poorly supported solutions canbe avoided, the anticipated cost efficiencycan be achieved.

When the options are carefully studied, thededicated drive system controller can oftenbe the most practical solution, especially ifseamless compatibility to the other parts ofprocess automation is ensured.

From the customer's point of view the mainfocus is normally on production volume,product quality and the life time cost of thesystem. Factors to be taken into accountwhen deciding on the paper machine drivecontrol and integration in other systemsmust include:

Functionality

• Ability of control system to perform fastdrive functions

• Reliability of control system• Ease-of-use and runnability of the paper

machine (e.g. Object and Aspect systemto navigate all the elements)

• Availability of Drives data at Control level• Documentation of Drives and Control• Uniformity of all basic tools for design

and maintenance• Intelligent data logging tools• Readiness for remote diagnostics

• Productisation level of drives HW andapplication SW

• Uniform procedures for project execution• Safety requirements (Machine Directive)• Availability of local certified personnel• 24h/365d application support• Process Application Services

Life cycle cost

• Control HW + Inverter HW• Commissioning cost• Start-up on time• Maintenance cost• Cost of updates and revisions of HW & SW• Cost due to unplanned stops.

ABB’s IndustrialIT AspectObjectTM system linkedto the DriveIT.


Living our commitment to Sustainability

ABB retained its place in alist of the world's mostsocially responsible

companies compiled by FTSE, acreator of indices for investorsincluding the U.K.'s benchmark FTSE100. ABB is part of the FTSE4 Goodfamily of companies selected for theirsocial, environmental and humanrights record. Coca Cola, Hitachi, Statoiland Deutsche Bank are among theother companies included in theindices. FTSE, which is jointly ownedby the Financial Times and theLondon Stock Exchange,introduced the FTSE4 Good seriesof indices five years ago to facilitateinvestment in companies that meetits criteria for social responsibility.

ABB rated among theworld’s most sociallyresponsible companies

ABB employees hadjust completed aproject in Yogyakartaon the Indonesian

island of Java when a powerful 6.3magnitude earthquake struck the area.They immediately began to helprelieve the suffering of the homelessand injured. Within seconds, at least600,000 people lost their homes.Not only were trucks and pickupsfrom the ABB construction site putto good use, but ABB employeespitched in to help out personally.

The pickups helped drive doctors toremote locations, enabling them toprovide direct local assistance andcarry the sick and injured to hospitals.The trucks were used to transportfood and relief supplies fromgovernment collection points to areasaffected by the earthquake. Twosoldiers were assigned to each of ourtrucks for protection against looters.In addition, the Power Division Serviceunit pledged 25,000 Euros to helpthe Indonesian earthquake victims.

ABB helps earthquakevictims in Indonesia

ABB helps fulfill primary schooldream in BangaloreThe NGH school for economically andsocially disadvantaged children,supported by ABB on the outskirts ofits Bangalore production hub, wasbursting at its seams with the strengthrising to nearly 1000 students from toGrade 1 - 7 (Ages 6-13). ABB steppedin to support the school authorities andthe local community to help constructand commission an extension in theform of a separate primary block whichwas recently inaugurated by BiplabMajumder (Head AP Division & COO,ABB India). The Primary School blockcomprises six classrooms and willhouse around 300 children aged 6-8yrs. (Grades 1-3). Besidesconstruction of classrooms, theproject included provision of drinkingwater, washrooms, furniture and otherbasic infrastructure. Severalcommunity members, including thePresident of the school developmentcommittee, the village head, theprincipal, teachers and students of the

school were present on the occasion.After the ribbon cutting and lamplighting ceremony, the children sang aninvocation song. Mr. Huchappa, theschool Principal thanked ABB for thetimely and ongoing support and theteachers pledged to continue workingfor this vital cause. ABB supports tensuch schools around the country indifferent ways.

ABB sets up computerlab in North Karnataka

In line with ABB's philosophy of makinga difference to the communities itoperates in, ABB India recently helpedset up a new computer lab and madecomputers available for the Government

First Grade College in HolenarsipuraTaluk, Karnataka. The Hon'ble ChiefMinister, of Karnataka, Shri HDKumaraswamy and Power Minister,Shri HD Revanna inaugurated the labat a ribbon cutting ceremony attendedby ABB representatives, the Principaland students.

"I am happy to see that corporatesare taking initiatives to help enhancethe quality of education in towns suchas Holenarsipura. I must thank ABB fortaking the initiative to help set up themuch needed computer lab at thiscollege", said Shri HD Kumaraswamy,at the gathering


Channel Line

Name: R. SurenderCEO

Family:Wife and two children

Hobbies:Relaxation, book reading

Life philosophy:Must maintain a work-life balance.Business is just a part of lifeand we must be content withwhat we have.

Personal Fact File

How long have you been an ABBchannel partner?

We have been an ABB channel partner forover eight years, dealing primarily in PLCsand drives. We have also recently begundealing with some of ABB's LV range ofproducts like soft starters and switchgear.

What are some of the benefits ofbeing an ABB channel partner?

ABB commands good brand equity in themarket, making it easier for us to sell theproducts. They have very soundtechnology and product features. ABB'sonline management system is good and weuse it regularly. However I do feel thereneeds to be some improvement withrespect to database management

How has business been in recenttimes? And what is the potential?

Business has been good. Most of ourcustomers are in the Pharmaceutical,Heating Ventilation Air Conditioning (HVAC)and packaging/material handling business.The industry is positive and we are looking

Name: Rajendra AgarwalProprietor

Family:Wife and two children

Hobbies:Badminton, playing cards andwalking

Life Philosophy:We should live with respect.Money is not everything

Personal Fact File

Agarwal Engineering Sales & Service(AESS) has been an ABB channel partnersince 1980 and deals with ABB's widerange of motors. Mr Rajendra Agarwal,proprietor, AESS says, "Initially the motorbusiness was very small but it has grownover the years. I am proud to say that wehave grown with ABB. ABB has one of thewidest range of motors in the market today."

Commenting on the business growth,Mr Agarwal, says "We have beenconsistently growing at a rate of 35%over the last 3-4 years and hope tomaintain this growth in the next couple ofyears. Our business is very service orientedand ABB has supported us well with theirengineers and timely attendance toproblems. Along with ABB, we havefocused on building customer loyalty andtoday most of our customer relationshipsare over 15 years old."

Agarwal EngineeringSales & Service, Hyderabad

Emation, Hyderabad

at increasing our business. Currently we seebuoyancy in the pharmaceutical business.We would gradually like to partner ABBin their Building Management Solutionsbusiness as well. We can definitely helpmuch more in the pharma sector, as thepartnership strengthens in different areasand products.

We do see potential in the commercialbuilding segment and there seems to begrowth in the pulp and paper industry aswell. Last year we grew at 60% but thisyear we are being conservative and hopeto grow around 30%. We are expandingfast and are looking at other locations inHyderabad and also hope to start an officein Vishakpatnam soon. We are currently 16people and have a completely networkedoffice with high speed internet connectivity.

Mr Agarwal's son, Rajeev oversees the dayto day operations of AESS and isresponsible for leveraging ABB's onlinechannel partner system. Talking aboutplacing orders online, he says "We havebeen using the online system for over 4years now and process our orders throughthis system. Though the system is effective,there is scope for faster processing anddelivery conversion to be quicker."


Tech Bytes

Precision welding

A laser-welding system using two ABB IRB 140 robots is helping to build the world's largest particlephysics accelerator - the Large Hardon Collider (LHC) at the European organization for NuclearResearch (CERN) in Switzerland. The IRB140 has one of the fastest cycle times of any articulatedrobot. On completion in 2007, the LHC will consist of two 27 kilometer tubular rings in a large tunnel100 meters underground, and be used to recreate conditions in the universe just after the Big Bang.

Welding applications are extremely demanding. A single detail in the assembly requires 0.3 mmdiameter spot welds every 1mm in axial length. Welds are only 30 microns in diameter and must becentered within 10 - 15 microns to be effective.

Productivity with NEMESIS

ABB's NEMESIS (Novel Enterprise Manufacturing Execution and Scheduling Information System) is apowerful data - gathering and analysis tool that supports production managers in their task of finding andalleviating weaknesses in the production process. It permits existing plants to produce more goods, to ahigher quality, at lower cost and in a more responsive manner.

NEMESIS covers plant scheduling, execution, quality management and reporting. Orders are automaticallytransferred from the plant's ERP system to scheduling system, to be scheduled against the current factoryload. The system helps increase plant visibility and flexibility, which can permit an informed and safereduction of inventory levels.

E-panel – a revolution in medium-voltage switchgear

Universally recognized as a paradigm shift in communications technology for power distributionsystems, ABB's waveguide concept enables medium-voltage switchgear to communicate data viaelectromagnetic waves without the use of electrical or optical links. Data is transmitted at almostthe speed of light and without interference and transmission loss.

ABB is launching the technology in the ZX family of medium-voltage gas insulated switchgear underthe name E-panel. Modules equipped with waveguide are able to communicate with their entireenvironment in accordance with the IEC 61850 standard.

Please share some more details on the innovative plug-in technologyfor reliable, safe and maintenance free power.

The ZX series leaves the ABB factory as completely tested panels, due to the plug in busbar system. The SF6 switchgear isexemplary in terms of safety, economy and availability. Their compact design permits installation even in the most constrictedspaces. The hermetically sealed stainless steel enclosures make the systems shockproof and protect the high voltagecomponents from all environmental influences, providing maximum availability over the entire life span of the switchgear.

You ask - We answer

Mr Tapash Roy,Dy Manager, CESC Ltd

IEC 61850 compliant substation equipment

ABB is set to be the first maker of substation automation equipment to have a complete set of productsbased on the same platform that comply with a global standard set in 2004 by the InternationalElectrotechnical Commission. The IEC 61850 standard reduces complexity by introducing a singlelanguage where many existed before, reducing the potential for errors and delays in projects.

Having a single standard therefore helps customers lower maintenance and operating costs. ABB'sequipment can be used with any other that complies with the new standard and can be reconfigured fornew applications, giving the customer long-term flexibility by ensuring that installations can easily beexpanded or modified in future.


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Harmeet S Bawa, Head, GF-Corporate Communications, ABB India

India's economic growth and industrial resurgence continues to gather momentum. We hope you enjoyed this issue ofCONTACT, focused on the Pulp & Paper sector, in addition to our regular features. We welcome you feedback as we continueto strive towards enhancing your reading pleasure through this shared knowledge platform .

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