One plant, one system: Benefits of integrating process and power automation

This paper discusses how a single integrated system architecture benefits plant operators, engineers, and managers. By taking a one plant, one system approach, end users of process and power automation systems can realize the benefits of an integrated system including increased energy efficiency, improved operator effectiveness, increased plant availability, reduced maintenance costs, and lower lifecycle costs. The architecture is based on Industrial Ethernet standards such as IEC 61850 and Profinet as well as fieldbus technologies. Emphasis is placed on connecting the substation automation system with the process control system via IEC 61850. The energy efficiency gains from integration are discussed in a power generation use case. In this use case energy efficiency is realized with integrated variable frequency drives, improved visibility into power consumption, and energy efficiency through faster plant start-up times. Substation visibility is becoming more critical in modern plants and facilities. IEC 61850 can be leveraged to provide substation visibility in a cost effective way. The substation standard as well as other open fieldbus standards can be used to create a plantwide asset management strategy. End user benefits are discussed for integrated electrical asset management. Condition based monitoring examples include Low Voltage (LV) motor starters via Profibus and Profinet while protective relays are integrated with IEC 61850. Benefits of integration help not just the process engineer but the power engineer as well. A discussion of Disturbance Recording (DR) integration is made. An integrated system allows for remote access to the DRs and automated analysis of the recordings. Faster analysis of plant disturbances means faster problem resolution and root cause analysis which equates to increased plant up-time. Several actual implementations of the one plant - one system architecture are discussed. The first case is capital expenditure (CAPEX) savings where- cost avoidance is achieved in a substation wiring project. Next, a power management success story from a major oil and gas company, Petrobras, is discussed. In this case, Petrobras utilized integrated process and power automation to lower CAPEX, operational expenditure (OPEX), and explore future energy saving opportunities. In a third case, the one plant - one system approach allows E.ON, a Swedish power company, the ability to perform remote control of hydropower plants from its dispatch center in a cost-effective way. Lastly, a success story from Boliden´s Aitek open pit Copper and Zinc mine is discussed. With integrated electrical, process, and maintenance systems, Boliden is able to operate and maintain the mining site from a single control room. Parts of this paper were originally published for the Power Gen International 2010 event as “Power up your plant: An intro to integrated process and power automation”. Updates and additions have been made throughout the document.