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Getting started with ABB Navigate
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Read on to find out what these steps look like in practice for our fictional customer >>
Understanding your operations
Before we begin our ABB Navigate journey, we need to understand our customer…
Description:Well-established food & beverage production facility serving the European market. Part of a group of several plants across Europe.
Size:150,000 m2 (1.6 million square feet), with large sections dedicated to processing, packaging, refrigeration and storage.
Production capacity:300,000 metric tons per annum, with multiple product lines for baking, canning, and bottling.
Understanding your assets
Distribution: 10MW substation responsible for all systems, with multiple step-up and step-down transformers to ensure right voltage supply to each section of the facility. Roof solar panels supply a small amount of additional power.
Backup power: 3x 2MW diesel generators used in case of outage to critical systems such as refrigeration.
Modern vs legacy: Plant operates with a mixture of old and new equipment, with aging transformers operating alongside modern automation systems.
Understanding your challenges
Non-intrusive site assessment to identify gaps
A non-intrusive electrical system health check is often the first step for many facilities in their ABB Navigate journey. Over 250 checks are carried out, including the examination of electrical rooms, switchboards, switchgear, transformers, and various other components. These checks will identify vulnerabilities and risks across the plant’s electrical systems, and because there is no need for a plant shutdown, it can be carried out without disrupting operational continuity.
Following the health check the ABB Advisory team provides a detailed report that serves as a bespoke roadmap for optimizing systems, with identified issues categorised by urgency. This helps to inform decision-making, while allowing the facility to weigh up potential next steps against operational and budgetary constraints.
A comprehensive electrical system health check is also available. This builds on the non-intrusive assessment with more detailed verification. For safety reasons, this assessment must be conducted with a de-energized system.
Update of obsolete single line diagram
It is not uncommon for a plant’s Single Line Diagram (SLD) to be inaccurate or not kept up to date. This can mean that the state of electrical systems, and their ability to cope with different or additional loads, can be overlooked or allowed to lapse. This can result in serious safety risks and compliance issues.
Networking Modelling ensures that the SLD is up to date and reflects the current condition of electrical systems. Once updated, it will immediately help to simplify troubleshooting, ensure safer and more reliable operations, and help to inform decision-making
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Deep analyses of the system condition
A well-designed power system is the backbone of all industrial facilities. An ABB Power System Study provides the plant with the information necessary to upgrade and maintain its power delivery infrastructure. The results focus on reducing operating costs, improving efficiency, increasing reliability and improving system maintainability.
ABB Power Systems Studies are comprised:
Short circuit study
Load flow and power factor study
Arc flash risk assessment
Protection coordination study
Motor protection study
Harmonics analysis
CT/VT sizing study
Relay programming
High level assessment for insights into current energy consumption
The Energy Consumption Assessment combines production and energy data to accelerate the optimization of energy intensity in industrial facilities, while delivering a quick return on investment.
It pulls together digitized data from disparate sources such as energy bills, meters and operations. This data is then normalized to allow easy understanding and comparison, and then examined to uncover deep insights into the plant’s energy performance. Recommendations are then made for potential changes to optimize system operations, and the likely impact they’ll have on energy usage and revenue.
Granular energy consumption assessment
Sub-metering provides a detailed picture of the plant’s energy consumption and the specific areas where energy is used. Detailed metering and monitoring of the entire electrical system can be implemented to understand where the significant energy efficiency pinch points are, and use these insights to identify the most easily achieved and highest impact energy saving opportunities.
Decarbonization and energy efficiency roadmap
The ABB Navigate portfolio includes the provision of consultancy service for decarbonization. This helps companies to set out their own bespoke strategy for achieving Net Zero, which can be a significant undertaking without access to the right resources and expertise.
The service includes:
Definitions of emissions goals
Establishing of sustainability strategy
Creation of investment plan
Energy management consulting
Baselining in real time
KPI setting (e.g. energy intensity)
Compliance with applicable regulations
Automation of energy management systems
Continuous improvement strategy
Creation of short and long-term plan to decarbonize site(s)
Turnkey solution with performance guarantees, without upfront investment
Battery Energy Storage Systems (BESS) collect excess energy from on-site renewable generation, such as roof solar panels, and can also store energy from the electricity network. BESS-As-A-Service allows organizations to enjoy the benefits of battery storage without having to invest large amounts of capital in the required infrastructure.
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Continuing your ABB Navigate journey
ABB Navigate is driven by outcomes. The more we understand your organization, your challenges, and what you want to achieve, the more we can help.
The following pages contain a deep dive into the many tools, solutions and assessments that we can deploy to drive transformative improvements to the reliability, safety, security, and energy and carbon performance of your operations.
