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14TH DECEMBER 2021 - ABB INDUSTRIAL AUTOMATION - ENERGY INDUSTRIES

ABB AbilityTM – Performance Optimization

SWCC Digitalization Workshop
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ABB Ability™ Performance Optimization
Welcome

Panelist Agenda

1 Introduction to Optimization

Maurizio Barabino Francesco Ghiotto 2 Advanced Process Control

Advanced Applications Manager APC Delivery Manager
ABB IAEN Italy ABB IAEN Italy 3 Break

4 Real Time Optimization

5 Project Delivery

6 Demo

December 14, 2021 Slide 2 © Copyright [2020] ABB. All rights reserved.
—

1 Introduction to Optimization

2 Advanced Process Control

3 Break

4 Real Time Optimization

5 Project Delivery

6 Demo
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Introduction – Performance improvement in case of complex constraints
Operation of power & water sites – complex coordination problem

Control Gap
Utilities Industrial Process
- Interacting systems
- Automation/Control often divided into
multiple DCS/PLC systems
- Different companies involved Power Electrical
generation consumers
- Production Changes
- Electrical Demand Product
- Steam Demand Energy
Consumers
- Final product demand Market
Market
- Dispatching changes
Steam/Heat Steam/Heat
- Constraints
generation consumers
- Open Energy Market
- Environmental limits
- Product quality
- Energy Efficiency
- Public service

December 14, 2021 Slide 4

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Introduction - Advanced Process Control & Optimization
Automation Functional Hierarchy View

- APC and RTO provide coordinated control, using a

standard software solution, to fulfil the customer
needs

RTO
- OPTIMAX® Real Time Optimization (RTO) computes the Target writes
optimal operating point considering non-linear, first
principle models APC
Set Point writes
- OPTIMAX® Advanced Process Control (APC) drive the
plant to optimum operating conditions
ABB or 3rd party DCS

- Allows more flexible strategies – multi objective with Instrumentation

explicit priorities Actuators

December 14, 2021 Slide 5

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Introduction – Advanced Process Control
APC Benefits - Variability of control loops reduction

Advanced Process Control

Variance reduction - Reduces process variability
- Repositions key process variables close to optimal
- Stabilizes process operations
- Increases production/reduce energy consumption, e.g:
- Combustion Optimization
- Steam-Power optimization
- Chemicals consumption reduction
- Product quality improvement
- Increases plant flexibility
Limit/Spec - Fast Startup
- Fast reaction to demand changes
w/out APC with APC
- Inputs quality compensation

December 14, 2021 Slide 6

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Introduction – Real Time Optimization
RTO Benefits – Best Sharing

Real Time Optimizer

- Finds the best solution from all feasible solutions
- Shares the production among several units in the best
way respecting the capability limits
- Respects all technical and economical constraints
(feasibility)
- Minimizes the costs with the same production level or
maximizes the profits according to customer
objectives
- Site energy management
- Virtual power plants
- Petro-chemical plant production optimization
- Pumps/Compressors stations optimization

December 14, 2021 Slide 7 PRV … Pressure Reduction Valves

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Introduction – Inferential Models Fundamentals
To create non-linear inferential models from process data

 Inferential Modeling Platform (IMP) is a software

package designed to allow a straightforward and
efficient distillation of process data into valuable real-
insight production information.
 It includes all the data processing and modeling
technologies necessary to create non-linear inferential
models from process data. These powerful
functionalities are integrated in such a way to unleash all
of their potential while hiding the unnecessary
mathematical details. They include neural networks and
genetic networks, statistical process control and
multivariate statistical process control.
 IMP is a native Windows client-server software package
for the offline development (IMP Model Builder) and
online deployment (IMP Online) of inferential models.

© ABB Group
December 14, 2021 | Slide 8
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1 Introduction to Optimization

2 Advanced Process Control

3 Break

4 Real Time Optimization

5 Project Delivery

6 Demo
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OPTIMAX® – Advanced Process Control
How it works

Technical Details
Process Model
- APC is a multi-variable evolution of the classic
controller
- APC achieves better control results because it includes
a process model, and, therefore, “knows” the dynamic
behavior and all the and controls all the variables at the
same time, in a coordinated fashion
- Since APC includes feedback mechanism, the process APC
model doesn't need to be very accurate and
sophisticated
- The dynamic models predict the model output
response to model input changes taking allowing the
optimization of the future trajectory. This allows
incorporating also possible future disturbances if
known (e.g. variations due to load profile), multiple
objectives with relevant priorities and constraints.

© ABB Group
December 14, 2021 | Slide 10
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OPTIMAX® – Advanced Process Control
Technical Approach

- Define the scope: Unit/section overall management

(instead of single loop)
- Define the multiple objectives with relevant priorities
and constraints as agreed with the customer
- Define the variables to exchange with RTO and DCS
- Create the model using an internal, explicit process
model instead of a black box approach.
- Model is built out of step test data (or historical data) so
lean engineering
- Internal model allows to predict future behavior and
react/anticipate changes Plant Data Process Model
- Provide commissioning and real benefits check

December 14, 2021 Slide 11

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Power Applications

December
Slide 12 14, 2021
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Advanced Process Control Applications – Power Plant
Combustion Control Optimization (1/2): Basic Proposal
Overview
• Solution for optimal Operation of TPP plants strictly concerning
with the combustion. The basic proposal does not include the
presence of advanced instrumentation, which is anyway synergic.
• The Combustion optimization, performed 10 years ago using
Neural Networks, is presently achieved using APC techniques,
which better take into considerations the dynamic phenomena.
• Combustion Optimization is essentially based on the
management of the air (primary and secondary) and OFA shared
for each burner to find the correct O2 excess as best
compromise in emission production, efficiency improvement and
avoiding the formation of unburned residuals

Benefits
• Typical Air Excess Reduction of about 0.4 – 1.0 % with
consequent boiler efficiency increasing of about 0.2 - 0.5 %
• Auxiliary power reduction due to lower fans work
• Emissions CO, NOx reduction

December 14, 2021 Slide 13

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Advanced Process Control Applications – Power Plant
Combustion Control Optimization (2/2): Advanced Proposal
Advanced Instrumentation Improves the Solution
 APC does not require to select one to one link between the
Manipulated and Controlled variables. This allows inserting
in the control any other additional available information
inferential (e.g., fouling and boiler efficiency from
performance monitoring) or physical (from devoted
instrumentation).
 For what concerns the combustion the following additional
advanced instrumentation can be integrated to improve the
quality of combustion, especially in case of frequent
localized troubles due not homogeneous waste, specific
burner trouble, etc.
 CO, O2 monitoring in combustion chamber through ABB
AZ40 Analyzer (Zirconia) or AO2000-LS25 Analyzer (Laser)
operating up to 1600°C for full on-line analysis CO, CO2,
O2, H2O, NH3, H2S, HCl, etc.).
 Temperature of flame monitoring through ABB flame
scanner with integrated temperature probe or derived
from thermo-cameras to setup the optimal flue gas
temperatures profile in combustion chamber.

December 14, 2021 Slide 14

Video Link: https://www.youtube.com/watch?v=bDMajyGpREY
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Advanced Process Control Applications – Power Plant
SH/RH Temperature Control Optimization
Overview
 Delay between attemperation and final temperature
compensation
 Reduction of the effect of disturbance variables like Load, Coal
quality and Heating Value
 Properly decouple control of SH/RH without compromising
efficiency when coupled e.g. :
• SH/RH flue gas damper
• Burner tilts
 Typical variables are the following:
 CV :SH final temperature, RH final temperature, spraying balance on
Main Steam Temperature SH/RH stages
 MV: Condensate flow on SH/RH stages, burner tilts, mills bias, SH/RH
damper, Excess air
 FF: Actual load request[MW], Future load request[MW] from load profile
Benefits
• Stabilization of SH/RH temperature increases ramp rate
APC ON
• Increase of SH and RH average temperature and Reduction of
spraying improve the efficiency

December 14, 2021 Slide 15

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Advanced Process Control Applications – Power Plant
Flexibilization

Overview
• Dynamics Flexibility means to optimize control stability to
enlarge the operating range and to make homogenous the
delays in the different subsystems (air, fuel, water, steam,
power) to maximize the answer
• Startup time reduction means to take explicitly into account the
metal stresses to minimize the timing due to the metal heating.

Benefits
• Minimum Load reduction allows plant operation when the
market energy price is low
• Startup time reduction allows to reduce the cost and
equipment stress in case of frequent start-stop
• Ramp Rate improvement allows to comply with dispatching
requests
Up to 26 MW/min Ramp Rate and 200 MW- Minimum Load (600 MW unit)
30% of time reduction and 15% savings for Fast Startup

© ABB Group
December 14, 2021 | Slide 16
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Advanced Process Control Applications – Power Plant
SCR/SNCR Optimization

Overview
– Solution for optimal Operation of SCR/SNCR
– APC is used to optimize ammonia/urea usage
– Integrated with Load Profile Coordinator allows to anticipate load
changes

Benefits
• Optimization of NOx control – especially in dynamics
• Minimization of ammonia/urea usage
• Minimization of slippage @ low loads
• Benefits – 70-150 k€/year
• Practical benefits
 Management of emission control at stack and also on side A/B
 Management of non-linearities - high load and low load and any
intermediate case
 Management of limits/saturation – e.g. min flow

December 14, 2021 Slide 17

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Advanced Process Control Applications – Power Plant
FGD Optimization
Overview

– Solution for optimal Operation of FGD

– APC is used to optimize limestone injection
– Integrated with Active Power Profile Coordinator – allows to
anticipate load changes
Benefits
• Optimization of SO2 control – especially in dynamics
APC
• Minimization of limestone usage
• Practical benefits
• Automatic handling of FGD slow dynamics
• Automatic control of slurry density
• Automatic control of pH

w/o APC

December 14, 2021 Slide 18

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Desalination (Reverse Osmosis) Applications

December
Slide 19 14, 2021
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Advanced Process Control Applications – Desalination
A complex coordination problem

Control Gap

• Interacting systems
• Automation/Control often divided into
multiple DCS/PLC systems
• Production Changes
• Electrical Demand
• Final product demand
• Changes in the inputs or in the equipment
availability
• Constraints
• Open Energy Market
• Environmental limits
• Product quality
• Energy Efficiency
• Chemical’s consumption reduction

December 14, 2021 Slide 20

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Advanced Process Control – Desalination
Application to Reverse Osmosis Train Control
Overview
 Typical RO system can be modelled with several
outputs and inputs.
 Outputs are permeate flow rate, permeate
conductivity, indicative of the salt content in the
product, trans-membrane pressure, inlet pH.
 Inputs are flow rate of reject water, inlet acid flow
rate.

 The production objectives are to produce the

specified flow rate of permeate, having the desired
salt content, subject to the constraints that the inlet
pH and the trans-membrane pressure are within
specified bounds.

 APC can achieve these goals. A comparison of the

results with APC and PI control reveals the excellent
capability of APC for RO desalination plant
operations.

© ABB Group
December 14, 2021 | Slide 21
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Use Cases

December
Slide 22 14, 2021
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Advanced Process Control Applications – Power Plant
Use Case - Coal Fired Power Plant Combustion & Chemicals Optimization

APC Applications
Combustion Optimization Steam Temperature Opt
– Enhanced Boiler Efficiency – Reduction of steam
– NOx reduction temperature variance

– CO reduction – Increase of average steam

temperature
– Load & efficiency increase
SCR/DeNOx FGD/DeSOx
– Ammonia usage – Limestone usage
3 new hyper-supercritical boilers reduction reduction
with a total of 1,850 MW.
– Increase load flexibility – pH stabilization
Favorable ROI from – Avoid gypsum/ash – Gypsum quality
• Combustion optimization contamination stabilization
• Steam Temp optimization
• Chemical’s savings Challenge based on economic benefits and not only the cost!

© ABB Group
December 14, 2021 | Slide 23
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Advanced Process Control Applications – Power Plant
Use Case – Coal Power Plant Flexibilization

Flexibilization functions incorporated in 2 x 660 MW

coal fired units
 Increase of available Ramp Rate Base Scope
 Reduction of Minimum Technical Load
 Stabilization in SH/RH temperatures
 Stabilization of plant operations
through Advanced Coordinator & Advanced Process
Control
2 coal-fired units 600 MW each
Technical Figures Guaranteed Maximum
Favorable ROI from improvement before Achievable
• Ramp-Rate improvement Ramp rate 8 MW/min 20 MW/min 26 MW/min
• Technical Minimum Load
decreasing Min. Load 270 MW 234 MW 205 MW
DCS Base Layer

© ABB Group
December 14, 2021 | Slide 24
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Advanced Process Control Applications – Desalination
Use Case – SWRO Production Maximization

© ABB Group
December 14, 2021 | Slide 25
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Advanced Process Control Applications – Desalination
Use Case – SWRO Energy Consumption Reduction

© ABB Group
December 14, 2021 | Slide 26
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1 Introduction

2 Advanced Process Control

3 Break

4 Real Time Optimization

5 Project Delivery

6 Demo
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OPTIMAX® – Real Time Optimization
How it works

Inputs OPTIMAX- RTO Outputs

– Production plan and or users – Optimizes over the following
demand forecasting Optimization 24 hours (or more)
– Electrical commitment – Reduces peak load charges
Production Plan Predictive (Planning) Optimization
– Steam/Heat commitment Flexibility – Optimizes approach to the
– El./therm. Min / Max limits Unit Availability P elektrisch market
Optimized
– Time restrictions Q thermisch Schedules
Product prices
– Marginal costs forecast

– Equipment efficiency Real-Time Optimization

– Current process status Real time data
P elektrisch

– Weather Forecasting Optimal

– Raw materials availability
targets for APCs – Selection of the best overall
Actual Prices Q thermisch operating point
– Environmental constraints
– Real-time targets / setpoints

December 14, 2021 Slide 29 PRV … Pressure Reduction Valves

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OPTIMAX® – Real Time Optimization
Technical Approach

• Define the Objective Function

• minimization of the cost or
• maximization of the profit or
• strict compliance to the limits
• Define the technical-economical Model:
• writing the equations with a simulation tool (e.g.,
Modelica, Matlab-Simulink, etc.) or
• using predefined components library or
• using third party existing models or
• realizing a data driven model thru a ML
• Define the Constraints and relevant Priorities
- technical (e.g., min/max capability)
- legal regulations (e.g., emissions limits)
- economical (e.g., contracts, market constraints)

December 14, 2021 Slide 30

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Power Applications

December
Slide 31 14, 2021
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OPTIMAX® – Real Time Optimization
Boilers Optimal Load Allocation

• The scope of Multiple Boilers Optimal Load allocation is to

real time decide the thermal load of each Boiler and the
relevant fuel mix to comply with the required steam
request with minimum fuel cost.
• Constraints are typically due to boiler capability
(min/max), header fluctuation minimization, venting
reduction, etc.
• Typical saving is about 3%.

December 14, 2021 Slide 32 confidential

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OPTIMAX® – Real Time Optimization
Soot-Blowing Optimization

• The combustion generates ash deposits on boiler walls and

heat exchangers, insulating the heat exchanger surface,
reducing heat transfer from flue gas to steam, and increase
heat losses.
• Soot blowing cleans the heat exchanger surfaces increasing
efficiency, but costs steam. It is a plant operational task to
tradeoff between costs for blowing and heat losses. Also
cleaning soot free surfaces can cause tube erosion over
time.
• Soot Blowing Advisory allows adjusting the soot blowing to
the actual operating conditions, maximizing overall boiler
efficiency. It determines the cleanliness of individual boiler
sections, and Optimizer determines the best blowing
strategy that minimizes the total cost (losses due to bad
heat transfer vs losses due to steam blowing)

December 14, 2021 Slide 33 confidential

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OPTIMAX® – Real Time Optimization
Steam & Power Optimization

• Complex with Multiple equipment (Boilers, Turbines, CC HRSG

VHP
Turbopumps, etc.), different for age/size, fuel type (e.g. NG, GT
Cracking
FG mix), efficiency, Different dynamics (fast/slow) TLEs
• Strong Disturbances: Steam demand changes, Energy Boiler
recovery disturbances, Steam consumption related events Condenser
(e.g. trip), Power & steam generation related events (e.g. trip), HP Users
Variable Energy Market prices ST1 ST2 ST3
• Power and steam are strongly interconnected
• Disturbances are interconnected as well e.g. changes in PRV
steam production in e.g. Steam Cracking will have an impact
on Steam Network and total Power generation Vent
MP Users
• Trade offs between power and steam are often possible
TP1 TP2
• Steam & Power coordinated control can do this automatically
LP Users PRV Vent

NG … Natural Gas
December 14, 2021 Slide 34 PRV … Pressure Reduction Valves
VHP, HP, MP, LP … Very high pressure, high pressure, medium pressure, low pressure
—
OPTIMAX® – Real Time Optimization
Steam Network Optimization

 In case of thermal plant providing also cogeneration

heat for industrial purposes, objective of the Steam
Network Optimization are:
 Reduction of the P, T variance at the steam header(s)
to allow the minimization of P,T while maintaining the
delivery constraints.
Users Users
 Reduction of pressure bypass usage, saving the
valuable energy
 Reduction of the variable user demand impact on the
energy production, by using the steam headers
storage capabilities and boilers to compensate
transient energy requests.

Steam Network

© ABB Group
December 14, 2021 | Slide 35
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OPTIMAX® – Real Time Optimization
Enterprise-wide energy management

Value Proposition ABB ABB Ability Energy Management for Sites Aggregator
collaborative
1. Create Visibility support Energy
2. Automate Control Aggregation & markets
Remote services

Forecasting Optimization
3. Optimize Operation EaaS trading
Weather
User Interface
Benefit Monitoring Data Data data
and reporting collection analysis
- Save energy cost and
Enterprise level Site planning
site emissions
User interface
Up to 10 Percent
- Save time on reporting Site X – Local Edge Gateway
and documentation
Up to 20 – 100 h/month Site Site 1 – Local Edge Gateway1
User interface
On-site solution

- Increase revenues by
participating in energy
markets
Up to 5 Percent
For Solar Energy EV Building Combined Power Industrial Grid
storage Charging automation Heat and Power distribution process connection
- Single sites
- Multiple sites

1 To manage critical functions, some functionality runs locally, e.g., functions requiring fast response/ resiliency to internet failure
December 14, 2021 Slide 36
2 Combined Heat and Power (CHP)
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Water Applications

December
Slide 37 14, 2021
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Real Time Optimization - Water
Desalination Plant optimal load allocation and economic goals fulfillment

Optimax RTO for Cost Reduction and Mission to Zero

Typical Goals (What)
– Best Load allocation among different plants and/or trains
– Energy optimization solution for RO train with Energy Recovery Device (ERD)
– Automation solution for membrane cleaning and antiscalant dosage

Technical Solution (How)

– Best allocation considers the product targets and the present status and efficiency of
plants/equipment to determine optimal
– For energy optimization solution , the models of ERD has to be integrated with RO train
model, pumps models, etc. to activate an overall optimization process
– For automation solution, (i) membrane fouling status can be used for estimating antiscalant
dosage (ii) Residence Time Distribution (RTD) study of membrane cleaning process can used
for automation of membrane cleaning cycles

Benefit (Why)
– Minimizes overall energy consumption
– Reduces the chemical consumption, membrane replacement, plant down time and labor cost

© ABB Group
December 14, 2021 | Slide 38
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Real Time Optimization - Water
Pumping Station Optimization (PumpFit)

– PumpFit is an instance of Optimax RTO package devoted to

pumping optimization
– It finds the optimum number of running pumps for lowest
electrical power consumption. Pumps are working at variable
speed (at least one)
– Energy savings up to 37%. In the real case of 3 pumps,
according pump characteristics:

• Case I: 1 Pump at 280 m3/h (7 m) and 50 Hz, PI = 10 kW

• Case II: 3 Pumps at per 94 m3/h (7 m) and 30 Hz,

PII= 2,1 kWx3 = 6,3 kW

PumpFit takes the optimal number of pumps and load

savings up to 30-40 % peak and 5-10 % as average

December 14, 2021 Slide 39

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Use Cases

December
Slide 40 14, 2021
 June 2018 November 2018
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Real Time Optimization – Industrial Site
Use Case: ABB Factory Busch-Jaeger Lüdenscheid – Mission to Zero

Fact Sheet – Mission to Zero Achieved with OPTIMAX®

Create operational visibility
Saved time
 Have a clear picture of consumption versus
energy prices 5 – 20h/m
 Track carbon emissions
Reduced CO2
630 tons/year

Optimal utilization of the connected assets Reduced Cost

 Forecast loads and on-site generation 4,2% 1)

Participation at energy markets Increased

 Enabled the participation at real-time revenues
markets
2 – 5% 2)
 Use dynamic pricing schemes from the EaaS
provider MVV

https://new.abb.com/mission-to-zero/ © Copyright [2020] ABB. All rights reserved.

December 14, 2021 Slide 41 1) compared to non-optimized operation
2) Evaluation ongoing
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Real Time Optimization – Power Plant
Use Case – VPP Next Kraftwerke, Cologne, Germany

Integrating 6,800 units in 8 countries with 6.0 GW Solution: OPTIMAX® for virtual power plants
 In 8 years, Next Kraftwerke grew from a modest start-up to  Given the flexibility of the ABB-supplied control and
one of the biggest virtual power plant operators in Europe. optimization system, Next Kraftwerke grew from a pool of 20
 Next Kraftwerke is based in Germany where renewable energy units to 2,800 in its first 3 years.
counts for more than 1/3 of the country’s power generation.  New customers and generating units are added continually
 Next Kraftwerke‘s virtual power pool links more than 6,800 without interrupting operations because all hardware and
producing and consuming units across 8 countries. The pool software additions are made without system shutdown.
manages around 6,000 MW of capacity.  The solution is a win-win-win for the Next Kraftwerke, the
transmission system operators responsible for the grids, and
the 1000s of small and medium-size producers connected to
the virtual power pool and energy market.

Enabling Next Kraftwerke’s business model – SCALABLE – FLEXIBLE – RELIABLE

December 14, 2021 Slide 42

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Advanced Process Control & Optimization – Cogeneration
Use Case - Industrial Site Steam & Power Optimization

• Project scope: APC+RTO for steam-power optimization

for a large industrial complex:
• 2 Headers: High Pressure about 90 bar, Medium Pressure about
15 bar
• 11 Boilers: 3 gas fired units, 6 fuel oil fired units, 2 electrical
• 3 Steam Turbines: about 90 MW
• 3 Pressure Reducing Valves
• 3 Steam Vent Valves to atmosphere
• Steam Consumers: typical consumption 1200 t/h

• Benefits are related to:

• A global steam and power generation plan optimization, with a
better boiler load allocation;
• A decrease in the amount of steam vented to atmosphere;
• A backpressure minimization, with a consequent increase in the
Steam Turbine generable power.

About 1. 5 M$/year Savings

December 14, 2021 Slide 43

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Real Time Optimization – Water
Use Case – Dusseldorf District Heating Pumping Optimization

Process: 2 Pumping Stations with 3 pumps

each (3x220 kW, 3x100 kW).
Scope: automatic selection of the pumps
to run and relevant load to reduce electrical
power consumption.
Constraints: NPSH limits and automatically
alignment of all pumps operation hours.
Benefits: 5 % decrease of electrical
consumption.

© ABB Group
December 14, 2021 | Slide 44
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Real Time Optimization - Water
Use Case - Basel Water Supply Optimization

• Deviations from the schedule are continuously monitored and schedules are
adapted where necessary.
• The unattended operation is influenced by the operating plan which may
contain some given pump set points or constraints (for example: restricted
pump or reservoir availabilities due to maintenance work).
• The water demand forecast is received every day with an
• hourly resolution. This forecast is determined by prognosis software which
considers the weather forecast for the next 7 days. These data are provided to
customer through an online email service.
• Based on these data and constraints, the Optimizer calculates the optimal
operation schedules for pumps and wells.
• Since the water demand forecast is subject to some uncertainty – and since
wells and pumps may potentially trip – the levels of reservoirs and wells are
supervised and checked against alarm limits by the PLC. An alarm triggers a
recalculation of the optimization and generates new scheduled set points,
which consider the changed conditions. In parallel, the operating personnel is
informed by SMS or alarmed by pager in case their action or approval is
required.

December 14, 2021 Slide 45

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Advanced Process Control & Optimization - Water
Use Case - Wastewater Plant Reverse Osmosis & Bioreactor Optimization, Pumping Optimization

• ABB OPTIMAX APC & RTO takes live data from SCADA
& calculate the optimized targets and set points to
optimize the process for performance and energy,
and chemicals.
• APC controller is coupled with Data Analytics and Soft
Sensors. Its models are linear and built using statistical
data analysis
• RTO uses nonlinear physical models (Activated Sludge
Model ASM-3 for the Bioreactors) and ML models
• ABB OPTIMAX Inferential Platform is used for
nonlinear data driven models and soft sensors
• ABB OPTIMAX Pump Fit automatically runs all pumps
within the upper and lower limits and NPSH,
providing Optimal balancing

December 14, 2021 Slide 46

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Real Time Optimization – Power & Water
Use Case - Water & Power Plant including 5 MSF plants (5x 2000 m3/h), 1 RO plant (6000 m3/h)

Overview

The optimization comprises the areas:

• Work Process Optimization
• Performance Monitoring
• Lifetime Monitoring
• Load Scheduling
• Hybrid Optimization
• MSF Optimization
• RO Optimization

Benefits
• 4% of total fuel consumption

© ABB Group
December 14, 2021 | Slide 47
—

1 Introduction

2 Advanced Process Control

3 Break

4 Real Time Optimization

5 Project Delivery

6 Demo
—
Project Delivery
Physical Architecture

Hardware : very limited, typically

- 1 Virtualization Server for APC+RTO
- 1 Control Room Client (PC)

Software licenses: OPTIMAX – APC and/or

OPTIMAX – RTO

Link DCS-Optimax: typically, via OPC

DCS Changes
- ABB DCS: modifications included
- 3rd party DCS: modifications specification

December 14, 2021 Slide 49

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Project Delivery
DCS Link
• APC does not replace DCS
loops but just provides sets
and bias.
• APC is based on DCS displays
to maximize operator
acceptance
• APC related alarms and events
are logged in DCS
alarms/events
• APC displays are designed to
allow fast and efficient
monitoring & command of
APC applications
• Recent but also legacy DCS
systems

© ABB Group
December 14, 2021 | Slide 50
—
Project Delivery
DCS connection experiences

ABB has APC references on top of all the most

popular DCS & PLC in the world such as:

• ABB 800xA
• ABB Symphony Harmony & Melody
• ABB Freelance
• Honeywell
• Emerson
• Invensys
• Siemens S7
• Yokogawa
• Rockwell

© ABB Group
December 14, 2021 | Slide 51
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Project Delivery
Development
Summary
Feasibility
Study
• Main milestones of an optimization project:
• Acquisition of process data and information for a
preliminary cost-benefit analysis (ROI estimation)
• Design including Documents, Historical Data Collection
and/or Step tests, Model Identification
• Functional Design Issue & Model Building
• Integration with DCS, Commissioning and Preliminary
Tests
• Observation period including Fine Tuning, Final Tests and
issue of the Final Report for Benefit Confirmation
• Team: 2-3 resources on average, DCS integration as
part of implementation team
• Duration: typically, 6 to 12 months
• Cost depending on problem sizing/complexity and
integration/involvement of 3rd parties
• Maintenance & Support is a common practice for the
majority of customers

© ABB Group
December 14, 2021 | Slide 52
—
Project Delivery
The Team

- ABB Central & Southern European Hub is the leading

center on APC for ABB

- Team located in Italy and Germany: 20+ resources

- 120+ man-years of APC/RTO experience

- First APC own project in our region executed in 1996

- Resources are internal. Significant part is in ABB

Service organization

December 14, 2021 Slide 53

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Advanced Process Control Applications
Delivery model

- Product/solution portfolio flexible to comply with

different needs in different sectors

- Focus on applications and service delivery. Licenses

and software are small portion of delivery

- Long terms maintenance & support provided by ABB

service organization

December 14, 2021 Slide 54

—

1 Introduction

2 Advanced Process Control

3 Break

4 Real Time Optimization

5 Project Delivery

6 Demo
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OPTIMAX® – Advanced Process Control & Optimization
Energy Management for Sites Demo

December 14, 2021 Slide 56

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OPTIMAX® – Advanced Process Control & Optimization
Live Demo setup

Energy pricing

OPTIMAX - Project scope: APC+RTO for steam-power

RTO optimization considering fuel price and user’s
requests
Targets - Simulation of process/DCS logics via ABB Ability™
800xA softcontroller
APC
- OPTIMAX® Web HMI used for monitoring and
command of Energy Management and, also, Steam
800xA - ABB Ability™ 800xA HMI for basic supervision of
Base Control (DCS) Softcontroller APC and RTO

Process

December 14, 2021 Slide 57

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So, let’s talk
Question & Answers