If the building space is modular, eco-friendly and augmentable over time, it’s best done with ABB Building Solutions. Energy distribution and automation suiting the spaces.
— Industrial Building Solution If the building space is modular, eco-friendly and augmentable over time, it’s best done with ABB Building Solutions. Energy distribution and automation suiting the spaces.
— Index
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— Building Segment Overview
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— Building Segment Overview Segmentation
In a certain sense, the technology is transversal, but the solutions are effective when the technology is calibrated to the application. The best technical and economic compromise, the best design solutions are the result of experience, system choices and component choices. The careful and detailed analysis of the needs of the case of interest defines the user case.
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— Building Segment Overview Segmentation
— Residential
— Commercial
— Institutional
— Infrastructure
— Industrial
Single Family • Houses
Hospitality • Hotels, Resorts, Motels • Dormitories, Lodgings, Rooming • Cruiser ships Office • Low/Mid/High-rise • Multi-purpose • Laboratories • Call centres • Single/Time-share property Retail & Mall • Stores, Hypermarkets • Retail chains, Malls • Restaurants, Food chains • Showrooms Leisure Facilities • Casinos, Theme parks • Sport stadiums, gym-pools • Museum, Theatres
Healthcare • Hospitals • Nursing, Retirement homes • Elderly Care, Day Care • Multi-centres Educational • Schools, Universities, Colleges • Research facilities • Archives, Libraries Public • State/city buildings, Halls • Post-offices • Temples, Historic • Police, Military, Prisons
Transportation • Airports, Ports, Stations • Bus/Truck/Train terminals • Parking facilities • Tunnels
Manufacturing • Factory • Manufacturing • Transformation • Packaging
• Private dwellings • Single Apartments
Multiple Family • Multi family dwelling • Apartment’s complex
Storage • Warehouses • Cold storage plants
Others Industrial • Chemical, Pharmaceutical • Processing • Telecom
Others Infrastructure • Water/Sewage treatment
• Power Plants • Agricultural
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— Building Segment Overview Core needs
Currently, the strategic lines that guide the definition of the characteristics of a building are aimed at satisfying 4 classes of fundamental needs:
— Health & comfort
— Life cycle cost and value
— Environmental footprint
— Future proof assets
These classes of basic needs can be translated into 7 performances that measure the quality of the building itself. Transversal aspects common to all the required performances are scalability and modularity, more important the more rapidly the market demands change.
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— Building Segment Overview Building performances
— Connectivity
— Efficiency
— Total Cost of Ownership
— Sustainability
The building enables its intelligent components to connect providing proper cyber security, preventing software vulnerabilities
The building optimizes the energy consumption and supports the efficient use of resources.
The building gives the transparency of the operating and maintenance
The building aims to reduce the CO 2 footprint of its operation in accordance global standards for people and planet.
costs. Warnings occur before a major fault.
and minimizing risks associated with data flow and storage.
— Flexibility
— Productivity
— Well-being
The building technology allows it to adapt easily to new usage requirements.
The building increases the productivity of employees, sets the right conditions (light, air quality, temperature …) adapting to the occupancy and expected performances.
The building technology keeps employees and visitors healthy.
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— Industrial Solution
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— Industrial Vertical Profile Introduction
Definitions of Manufacturing Industries
The Manufacturing sector The Manufacturing sector comprises establishments engaged in the mechanical, physical, or chemical transformation of materials, substances, or components into new products. al to achieve the digital reality in hotels of the future Manufacturing is the making of goods Manufacturing is the making of goods. The items that are manufactured may be completed products or they might consist of components that contribute to a whole that's produced in another facility. Manufacturing facilities typically feature production lines or areas that are dedicated to producing one or more items. A facility might manufacture products to stock stores or make them to order, producing items only as they're requested by a buyer. The manufacturing industry is essential to produce everything from clothing and food to tires and toothpaste.
Establishments in the Manufacturing sector are often described as plants, factories, or mills and characteristically use power-driven machines and materials-handling equipment. However, establishments that transform materials or substances into new products by hand or in the worker's home and those engaged in selling to the public products made on the same premises from which they are sold, such as bakeries, candy stores, and custom tailors, may also be included in this sector. Manufacturing establishments may process materials or may contract with other establishments to process their materials for them. Both types of establishments are included in manufacturing.
Categories of Manufacturing Industry
Manufacturing Industries
Oil, Chemical and Plastics
Metal and Machinery
Transportation Manufactoring
Textile and Apparel
Electrica and Electronics equipment
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— Industrial Vertical Profile Trends and key challenge
Below are some of the key challenges faced by Manufacturing Industries globally and some of these challenges is likely to be continued in coming year.
Global supply chain
Cyber-attack
Sustainability
An ever-increasing array of contradictory and dynamic
Control systems are based increasingly on software. Computer systems now include a very wide variety of smart devices. Control systems typically include three threat categories: hacking, general malicious software and errors committed by employees. Protect the reliability, integrity and availability of power and automation technologies against unauthorized access or attack
Achieving carbon-neutrality will be necessary yet little differentiating for manufacturers of industrial products — but helping others becoming carbon neutral presents a trillion-dollar opportunity. Heat recovery, optimization of cooling, pumping systems and water consumption. Appropriate computer- based and cloud-based production processes. Implementation of LEAN and 6sigma manufacturing principles. Use of renewable sources such wind and solar. Electric motors are perhaps the biggest consumers of electrical energy. Replacing older has resulted in an efficiency increase of up to 5%. The use of variable speed drivers can achieve an economy of 20% to 50% depending on the load in
question and startup condition. Non- renewable energy conservation Equipping roofs and parking spaces with power generated solar panels which may be routed to supportive assets - e.g. administrative buildings or lighting for warehouses. By substituting the utility power with a renewable one for plant infrastructure, the manufacturer replaces non-renewable energy from fossil fuels with naturally sustainable ones from the Sun, together with the constant study of technology for securing future investments Use of Factory Energy management system such as ABB OPTIMAX and ABB Microgird solution .
parameters (such as trade barriers, political instability, epidemics, and natural disasters) will force companies to square the circle, to actively manage the risks — and to stay flexible
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— Industrial Vertical Profile Trends and key challenge
Digitization
Lack of talent (Cost of talent)
Safety
Digitalization is about extracting value from data through analyses .One example is that in order to maintain the process, production lines are monitored every day and measures are taken to maintain steady performance of the line. Data is collected and categorized according to the critical factors which affect the production lines. To maintain optimal usage of machinery, the energy control system monitors the power quality factor by gathering the data which helps to determine how power quality can be improved this is required so robot can operate for long period and minimizing breakdown.
One way which ABB can help companies is tacking this challenge to increase the use of automation inside the factory. here are countless tasks and processes manufacturers can automate, but it often makes sense to start with the basics like data collection and reporting.
Beware of hazardous chemicals, moving and rotating mechanical parts, electric shocks, dust explosions, fires. ABB has number of system that can address the electrical safety of the worker
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— Industrial Vertical Profile Manufacturing industry lifecycle
Lifecycle of Manufacturing industry will consist of 6 processes
Plan
Design
Assassment
Construct
Operate and Maintain Operations & Maintenance (O&M) phase is typically the longest phase within the facility lifecycle. In this phase, the owner will use the facility for its intended purpose, and they will need to operate and maintain the functionality of the facility.
Refurbishment
Planning stage, the Owner of the facility will need to define their project needs, identify the general budget and schedule, and potentially identify a site for the building The final outcome of the planning phase is a 'Program', or in some countries, a 'Brief', which clearly defines the owner's needs and a plan to design and construct the facility.
Within the design phase, a designer will interpret the needs of the owner into a design for the facility which is to a level of detail that it can be built.
Building assessment phase this between design and construction phase The Phase can consist of multiple sub phases which involve approval from government Bodies, regularity authority and environment agencies be involved in this phase can be.
Construction phase, a contractor will lead the assembly and construction of the facility. This will include the procurement of all the elements needed to build the facility, including arranging for the elements to be transported to site.
Refurbishment is the process of improvement, decorating and re- equipping. It may also include elements of retrofitting with the aim of making a building more energy
efficient and sustainable.
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— Industrial Vertical Profile Manufacturing industry lifecycle
Planning Phase
Design Phase
Building Assessment phase
During the planning stage, the Owner of the facility will need to define their project needs, identify the general budget and schedule, and potentially identify a site for the building. The owner may employ the services of an architect, contract developer, or other professional to help them defined their needs, and identify the resource requirements. The final outcome of the planning phase is a ‘Program’, or in some countries, a ‘Brief’, which clearly defines the owner’s needs and a plan to design and construct the facility. They will also need to identify, and sometimes purchase, a site for the facility.
Within the design phase, a designer will interpret the needs of the owner into a design for the facility which is to a level of detail that it can be built.
There is one more phase that is between design and construction phase which is called Industrial Building Assessment phase. the Phase can consist of multiple sub phases which involve approval from government Bodies, regularity authority and environment agencies this can process can change from region to region and type of the Manufacturing industry that is being built.
Typical process that can be involved in this phase can be:
• Assessment of the environmental impact of industrial buildings carbon footprint (CF)and water footprint (WF) • Life Cycle Assessment of Construction Materials. • Energy consumption during construction Phase • Energy consumption of machinery that to be deployed inside the factory • Construction and demolition waste (CDW) Calculation • Assessment of how to reuse the Construction waste
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— Industrial Vertical Profile Manufacturing industry lifecycle
Construction Phase
Operations & Maintenance Phase
Refurbish Phase
Within the construction phase, a contractor will lead the assembly and construction of the facility. This will include the procurement of all the elements needed to build the facility, including arranging for the elements to be transported to site. After arrival, the building component will be assembled on- site and tested to ensure the appropriate level of quality. The constructed facility will also require any inspections by governing authorities to ensure that it is safe to use for it’s intended purpose. For a building project, the primary construction phase typical ends when the contractor obtains a ‘Certificate of Occupancy’. The Certificate of Occupancy is issued by the local governing authority or code office, and it certifies that the building complies with the codes and requirements and that the owner can occupy the building.
The Operations & Maintenance (O&M) phase is typically the longest phase within the facility lifecycle. In this phase, the owner will use the facility for its intended purpose, and they will need to operate and maintain the functionality of the facility. In some research, up to 80% of the entire lifecycle cost of a facility is spent in the operations phase. This phase is also sometimes referred to as Facility Management (FM), and an owner may perform the facility management services within their own internal employees, or they may hire a 3rd party FM service provider.
Refurbishment is often used interchangeably with renovation or restoration (which is to do with restoring a building to its former condition). In general, refurbishment can encompass such works as ‘cosmetic’ renovations (such as painting and decorating), upgrading, major repair work, alterations, conversions, extensions, and modernizations. The lifecycle of a building can be significantly extended by effective refurbishment. As every building is unique, not only structurally, technically, and typologically, but also in local context, the correct approach to refurbishment should be assessed according to the particular conditions. Designers should seek to understand the actual uses of existing buildings and communicate with diverse stakeholders from the initial project phase to the end of the refurbishment.
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— Industrial Vertical Profile Manufacturing industry lifecycle
Greenfield vs. Brownfield investments
GREEN FIELD INVESTMENT
BROWNFIELD INVESTMENTS
Companies that want to expand their interests internationally generally make physical investments and purchases in another country. This is known as foreign direct investment (FDI). They purchase, lease, or otherwise acquire assets in their host country including facilities such as plants, office space, or other types of buildings. These acquisitions may come in the form of new or existing facilities.
In a greenfield investment, parent company opens a subsidiary in another country. Instead of buying an existing facility in that country, the company begins a new venture by constructing new facilities in that country. Construction projects may include more than just a production facility. They sometimes also entail the completion of offices, accommodations for the company's staff and management, as well as distribution center.
Brownfield investments, on the other hand, occur when an entity purchases or leases an existing facility to begin new production. Companies may consider this approach a great time and money saver since there is no need to go through the motions of building a brand new building.
Investors Coonstruct New Facility
Redevelops existing facility
Requires more time
Requires less time
Doesn't require cleanup cost
Cleanup costs are incurrent
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— Industrial Vertical Profile Emerging trends – Industrial IoT
The Industrial Internet of Things is the use of connected smart devices in industrial applications for purposes such as automation, remote monitoring, and predictive maintenance. The IIoT is a more robust version of the Internet of Things.
Visibility of operation
Predictive maintenance
Industrial business is complex by nature • Long life cycles to modernize machinery Isolated business processes Security and liability challenges
Advantages Of industrial IoT
End-to-end traceability
Integrations and platform must run for a long time • Machines cannot easily be replaced Must run > 10 years
Must be interoperable to avoid vendor lock-in
Real-time decision making
Require ecosystem to optimize automation processes and enable new business models
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— Industrial Vertical Profile Customer needs
For the manufacturing industry, our research shows 9 sub-needs to be addressed, which are anchored in the 4 customer needs categories.
Environmental Footprint
Health and Comfort
Corporate social responsibility • Manufacturing companies are required to implement clear and auditable sustainability policies, to demonstrate their commitment to corporate social responsibility. A large part of those objectives is related to assessing and reducing the resources and emissions associated with production. Resource efficiency • Alongside the environmental benefits of reducing consumption of electricity, gas and water involved in the production process, additional efficiency gains can be made with a more efficient operation of the building.
Employee safety & security • Providing a safe working environment which attempts to eliminate all risks for employees, alongside stringent incident-avoidance policies, are the highest priority concerns within manufacturing plants. Workers need to feel safe whilst operating equipment, and when using break rooms, parking and circulation spaces. Employee satisfaction • Comfortable modern amenities help attract and retain talent, and all employees benefit from the best environmental conditions onsite, all of which align with social sustainability goals.
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— Industrial Vertical Profile Customer needs
Life Cycle Cost and Value
Future Proof Assets
Utilities stability • Having a solid strategic renewable energy production and buying program allows industries to be more resilient in the face of fluctuating energy prices market. Production continuity • Factory owners want to get to market in the least amount of time as possible. An uninterrupted production depends on many factors such as the availability of competitively priced energy supply, qualified staff, and sustained investments in the factory, all of which require production managers to keep an eye on several inputs. Investment appeal • Using components with low environmental impact to drive clean production attracts green fund investors.
Expansionreadiness • Production is driven by market demand, and a modular factory with interoperable components can quickly ramp up to meet the needs of customers creates a competitive advantage. Equipment resilience • Factories prefer to avoid the replacement of components and parts over the lifetime of operation, which also contributes to reducing the long-term footprint of the factory. Industrial settings require swift action to preserve optimal production parameters. • liability issues.
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— Building segment performance for retails and malls
The 7 building performances exist to ensure that the solutions deployed in Manufactoring is holistic and cater to the core needs of involved stakeholders. In other words, this is a people & planet first approach, and the careful selection of ABB building technology serve the purpose of enabling the performances to achieve our common goals.
— Sustainability
— Total Cost of Ownership
— Efficiency
— Flexibility
— Connectivity
— Well-being
— Productivity
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— Building segment performance for industrial
— Flexibility
— Well-being
Control and reassign resources rapidly with modular building setup. Being ready to scale-up power supply and distribution to increase production. The manufacturing industry is under constant pressure to adapt and evolve to meet consumer demand, which means successful factories are flexible and dynamic. On the building side, sensor driven LED-lighting and intelligent building controls enable reconfiguration of floorplan services with minimal effort. Systems can be tailored to provide a variety of different operating characteristics to meet changing needs. The use of modular construction allows quicker addition of new building sections, and up-to-date information about the existing building is needed to accelerate the issuance of reconstruction or refurbishment project permits.
Safety and security are first concern in industrial environment and ideal indoor conditions for healthy and comfortable office staff & production workers. In manufacturing plant, a primary function is building ventilation to maintain acceptable indoor air quality standards and prescribes appropriate ventilation rates (ASHRAE Standard 62). Local, state, or provincial, and federal occupational health agencies also set additional strict specific standards for air contaminants, including carbon monoxide, ozone, volatile organics, formaldehyde, silicone, glues, epoxies, and other air contaminants of special concern. These tightened requirements result in enormous amounts of building air being exhausted rather than recirculated. Pressurization schemes that either attempts to keep air out of space or keep air within a space depending upon the process are involved. Clean areas require clean supply air and typically are pressurized positively to adjacent spaces to keep the air from those spaces out of the clean area. Air movement can be critical with processes that have high latent loads. In case of emergency, an evacuation program based on reliable emergency lighting solutions help guide the employees to safety.
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— Building segment performance for industrial
— Sustainability
— Total Cost of Ownership
— Efficiency
CSR reporting with reliable and transparent data for reduction of scope 1, 2 and 3 emissions with extensive energy management program and sustainable power policies Due to large roof layouts and exterior parking, many manufacturing industries maximize their onsite renewable production by installing solar panels in those areas. Combined with energy storage and distribution systems, onsite renewable production has great potential to reduce CO2 emissions. Moreover, real-time monitoring of equipment condition and energy consumption helps optimize operation, enabling peak- shaving and demand response strategies.
Long lasting equipment compliant with industrial conditions and requirements avoid early replacement. Continuous and uninterrupted energy supply to achieve production objectives. Increased production, lower prices, and improved quality and variety, all while maintaining a commitment to sustainability are challenges that affect the profitability of factories. Operational budgets are of prime importance for industries, which often operate non-stop under market pressure. Because the production process is repeated indefinitely, seemingly small energy savings end up having significant impacts on the balance sheet. The more granular an asset management system is, the more opportunities for such savings can be uncovered. Investing in components and monitoring systems allow to maintain the highest power quality and avoids damaged equipment, lost productivity, material losses or missed delivery schedules.
Achievement of production and environmental KPIs with integrated energy and asset management and detailed load profile analysis to enable proactive resource management and AI optimization Resource efficiency is crucial for profitability, and when it comes to the operation of a production facility, the opportunities are varied and numerous. Integrated building controls allow to take advantage of free cooling during nighttime as a simple way to increase energy efficiency. Motion sensors combined with LED-lighting controls enable interim light reduction settings to reduce energy usage in areas with no activity for a preset time. Heat capture systems that recover heat from a process by routing hot water or steam condensate through a heat exchanger where the energy is used for other process systems, or other uses such as HVAC heating and domestic water heating. In some cases, process waste heat can also be used for space heating. The use of energy recovery products is becoming more available as a standard offering such as heat exchanger skids/packages, air-to-air and water-to-air systems.
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— Building segment performance for industrial
— Productivity
— Connectivity
Employee performance is driven by safe and comfortable working spaces and continuous monitoring and advanced data analysis to avoid downtime related to technical faults Process and manufacturing facilities are big electric consumers. The biggest challenges for them are availability of reliable and clean power. When power failure or quality problems occur, production is directly impacted. Such problems can be as obvious as electrical components that are damaged or fail prematurely, or as subtle as equipment that randomly malfunctions. Implementing power conditioning systems solve power quality issues, and help operators achieve increased production outputs whilst protecting crucial operations.
Connected equipment to enable optimized asset management. Production line and device level condition monitoring with consolidated data overview. Continuous equipment and power condition monitoring facilitates decision making at all levels to improve operation. Automated alarms for temperature fluctuations in the warehouse help preserve the quality of products and materials; a consistent temperature is a mission critical requirement for many industries, hence the importance of the building management being well informed with connected sensors.
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— Testimonials from ABB technology users
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— Testimonials from ABB technology users
— At the forefront of electrification and sustainability
EUROPE
NORTHVOLT SWEDEN
Electrification is an important part of creating a more sustainable society. For example, in the automotive industry, many manufacturers are converting to carbon- neutral vehicles. Ford has said that by 2022, electrified cars will outsell those with an internal combustion engine. Volkswagen has announced that its last generation of cars with internal combustion engines - with some exceptions - will roll out in 2026. To succeed, high quality batteries will be required. Volkswagen collaborates with Swedish company Northvolt, whose vision is to develop the world's most environmentally friendly battery and to establish one of Europe's largest and most advanced lithium-ion battery factories. In the summer of 2019, the first shovel was taken to Northvolt Ett, the company's so- called Giga factory in Skellefteå, which will be its primary production unit. The large- scale production will initially have a production capacity of 16 gigawatt hours (GWh) per year, which corresponds to approximately 300,000 electric car batteries. By 2024, capacity will increase to 32 GWh; with long term capacity projected at 40 GWh per year. Sustainability permeates Northvolt's culture and the giga factory is thought to be the world's most environmentally friendly battery factory. Its production process is as sustainable as the products it makes. For the operation at Northvolt Ett, only renewable energy from hydropower will be used.
Electrification solutions: • Power Management System control system • 2 main transformers 145 / 33kV, 120MVA • 33kV GIS switchgear 94 panels, total length 80 meters • 60 distribution transformers • Approximately 35 km of high voltage cable • Approximately 30 km of control and fiber cable
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— Solution architecture
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— Building typology Manufacturing enviroment
The entire Manufactoring building may or may not contain different areas dedicated to specific functions.
01. Staff parking 02. Enterance and lobby 03. Factory manager office 04. Open space 05. Training room 06. Factory canteen 07. Control room
10
08
05
11
08. Laboratory 09. Processing 10. Cold room 11. Packaging area and storage facility 12. Fleet parking 13. Mechanical/plant room 14. Electrical room
04
03
09
12
02
06
07
13
14
01
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— Building typology Manufacturing enviroment
— Staff parking
— Lobby and common areas
Enterance and lobby These are common are which staff ad factory worker used to commute to different spaces inside factory • HVAC Control – AHU Control, Air Quality • Lighting Control – Occupancy Control, Day Light control , On Off Control • HVAC Control – Smoke Control system • Power Distribution – Sub Distribution Board / Distribution Board • Emergency lighting – Emergency Luminaries and exit sign.
Staff parking is the space where Employees Park their car and the same area where factory employees and subcontractor arrives through factory buses or private transportation. Executive Staff come in their car and park their car as designated Areas. In these Parking Area some of the parking spots is dedicated to Electrical Vehicle cars to charge their car freely which is power through solar PV Panels. • Lighting Control – Timers, Light Sensor Interface • EVCI – Terra Chargers • Power Distribution – Packaging and Solution • Energy Management – Optimax • Energy Management – BMS / Active Energy • Drives and Motor –Low Voltage Motors
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— Building typology Manufacturing enviroment
— Lobby and common areas
— Lobby and common areas
Factory manager office This space is primary in use by factory manager From here he can log into different system and view different system status related production, power distribution system and Energy consumption of the factory.
Open space The open space office is in use by the staff from account, finance and Factory Operation team, Automation team, HSE Team and facility staff . It very important to provide them comfortable, secure, and convenient environment so that they work proactively and focus on their work. • HVAC Control – AHU Control, Air Quality, VAV Control • Lighting Control – Occupancy Control, Day Light control, On Off Control • Emergency lighting • Power Distribution – Distribution Board • Emergency lighting – Emergency Luminaries and exit sign.
• Room Wiring and control – User Interface for Lighting and FCU control • Lighting Control – Occupancy Control, Day Light control, On Off Control
• ABB Ability – Energy and Asset Monitoring • ower Distribution System – ABB ZEE600 • HVAC Control – Integra or ASPECT • Emergency lighting – Emergency Luminaries and exit sign.
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— Building typology Manufacturing enviroment
— Training room
— Factory canteen
It’s a space where staff and worked gather for training on Health and safety, training from OEM who supplied different system inside the factory and annual gathering with staff and workers. • HVAC Control - AHU & FAHU Control and Monitoring • Power Distribution – Sub Distribution Board / Distribution Board • Lighting Control – On off control, Dimming Control and Occupancy control, Daylight • Saving, Curtain Control . • Drives and Motor – HVAC Motors and VFD • Drive and Motor – Smart Sensor • Emergency lighting – Emergency Luminaries and exit sign.
It’s a large space inside the factory where factoryworker during their shift take their breakfast, lunch and dinner depending on what shift they are working . it very important to maintain good quality of the air in this area because of large number of people are gathered and sitting near to each other. • HVAC Control –FAHU Control and Monitoring, Air Quality • HVAC Control – Exhaust Fan control • Power Distribution – Sub Distribution Board / Distribution Board • Lighting Control – On off control, Dimming Control and Occupancy control, Daylight Saving • Drives and Motor – IEC Low Voltage Motors ,HVAC VFD, Smart Sensor • Emergency lighting – Emergency Luminaries and exit sign.
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— Building typology Manufacturing enviroment
— Control room
— Laboratory
The control room is some sense very different from the control rooms of the other building types. For Manufacturing industries in can be inside the factory and sometime outside the factory in separate floor. A large space of the complete floor dedicated. • HVAC Control – VAV Control ,FCU Control , Air Quality • Power Distribution – Sub Distribution Board / Distribution Board • Power Distribution – UPS • Energy Management – Optimax • Energy Management – BMS / Active Energy • Lighting Control – On off control, Dimming Control and Occupancy control, Daylight Saving
The purpose of the laboratory within the laboratory is to check the incoming sample that will be sent to the processing area to ensure that it meets the required quality standards. The sample is also brought for inspection from the processing area for quality control purposes and to verify its compliance with the different regulatory standards respected by the factory.
• HVAC Control - VAV Control , FAHU Control , Exhaust Control • HVAC Control – Smoke Control • Motor and driver - IEC Low Voltage Motors , Smart Sensor ,HVAC VFD • Power Distribution – UPS • Emergency lighting – Emergency Luminaries and exit sign.
• Drives and Motor – IEC Low Voltage Motors , Smart Sensor • Emergency lighting – Emergency Luminaries and exit sign.
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— Building typology Manufacturing enviroment
— Processing
HVAC Control – FAHU Control Air treatment for mission critical facilities like food processing area and laboratorie requires special attention. It should be filtered to a certain extent so no contaminants would enter the laboratory space. Heavy filtering requires fine filters, introducing a substantial pressure drop in the system. So, when selecting a variable speed technology, it’s critical to make sure the fan can overcome such a resistance. Thus, modern EC fans are often not able to overcome the resistance and create a high pressure in the system, and are being replaced with traditional motor technologies like induction, permanent magnet or SynRM offered by ABB. ABB offers up to IE5 efficiency motors for the highest energy saving in the system. ABB HVAC drives on top increase the savings further, while maintaining the overpressure or under pressure in the laboratory and keeping the air pure
• HVAC Control – FAHU Control • HVAC Control – Exhaust Control • HVAC- Industrial Dust Collector • Lighting Control – Dimming – On Off – Lux Level Control • Emergency Lighting • Power Distribution – UPS • Power Distribution – Power Conditioning • Power Distribution - MCC • Power Distribution – Low Voltage Switch gear • Emergency lighting – Emergency Luminaries and exit sign. • Drive and Motors - HVAC Drives, IEC Low Voltage Motors • Drive and Motor – Smart Sensor Industrial Dust Collector An industrial dust collector is a type of air pollution control equipment used in factories, plants, warehouses and other industrial or commercial settings to meet environmental and workplace safety requirements.
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— Building typology Manufacturing enviroment
— Cold room
Cold rooms can be also called refrigeration chambers which are designed to maintain certain conditions inside. Cold rooms are used for storing temperature-sensitive products. The design behind cold rooms that allows them to function efficiently isn’t so different from any other refrigeration system. Cold rooms use compressors, condensers, fans, and evaporators to maintain temperature within the unit. After a gas refrigerant gets compressed in the compressor it expands, and the gas absorbs energy. The hot gas flowing from the compressor passes over the evaporator coils and, after liquifying under high pressure, this cools the evaporator coils and the surrounding air. To maintain temperature, cold rooms must also be well insulated.
• HVAC Control - Cold Room Monitoring • Motion – HVAC Drives, IEC Low Voltage Motors, Smart Sensor • Lighting Control- On Off Actuators • Power Distribution – Main Distribution Board ,UPS • Emergency Lighting
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— Building typology Manufacturing enviroment
— Packaging area and storage facility
— Fleet parking
In Packaging there are number of processes which is related to palletizing of product. The Products packed here can go to large warehouse facility or can be dispatched to the retailers.
In this space large truck at parked inside the factory premises collect the packed material from factory and then take it to their relevant destination for warehouse or either relaiters . At spare time these EV Truck can be powered from Electrical vehicle charging infrastructure that is being powered from renewable energy source.
• Power Distribution- Main Distribution Board. • Power distribution – Power Conditioning • Power Distribution – UPS • HVAC Control – AHU Control
• Lighting Control -Timer, outside Light Sensor Interface • EVCI – Terra Chargers • Power Distribution – HVC BUS & TRUCK • Energy Management – Optimax • Energy Management – BMS / Active Energy
• HAVC Control – Smoke Control system • Lighting Control – Day Light Control • Lighting Control – DALI • Emergency Lighting • Drives and Motor – IEC Low Voltage Motors , Smart Sensor
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— Building typology Manufacturing enviroment
— Mechanical/plant room
— Electrical room
A plant room is a room or space in a building dedicated to the mechanical equipment and its associated electrical equipment. Depend upon factory size the number of mechanical room will change in factory .in Most cases will have mechanical room spread across the building and near to the area where they are serving. Mechanical room can have below mechanical devices • HVAC Control - Chilled Water Circulation – Primary and Secondary • HVAC Control - Heat Exchanger • HVAC Control - AHU & FAHU Control and Monitoring • HVAC Control – Boiler’s control • HVAC Control – Chiller control • HVAC Control – Exhaust Fan control • Lighting Control – On off control, occupancy control • Drives and Motor – IEC Low Voltage Motors, and HAVC VFD, Smart Sensor, Industrial cooling direct drive motor and VSD packages
There are various electrical located inside the Factory some are near Processing Are where there is large utilization of electricity these room contain equipment sub as main distribution board, sub main distribution board. On the other hand Main Electrical room or some time outside the building where there is dedicated room or it can be inside EHouse which is located in factory premises. The EHouse can MV SWG ,transformer and Low Voltage SWG. • Power Distribution -MV Primary Switchgear, MV Secondary Switchgear, • Protection relay • Power Distribution – LV SWG, MCC panel • Power Distribution – Packaging solution, Microgrid • Power Distribution – Battery Energy storage • Energy Management -Ekip Up, CMS 700 • HVAC Control - AHU Control • Emergency Lighting
I NDUSTR I AL BU I LDI NG SOLUT ION
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— Portfolio Overview
Power Distribution
Energy Management
Lighting Control
Solution Portfolio Overview
Motor & Variable Speed Drives
Emergency Lighting
Room Wiring and Control
EV Charging
HVAC Control
I NDUSTR I AL BU I LDI NG SOLUT ION
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— Reference Architecture Industrial
INDUSTRIAL
DIGITAL PLATFORM
ABB APPS • ABB Energy & Asset Manager • ABB Ability™ Energy Manager Multisite • ABB AbilityTM Optimax • Active Energy Management • Naveo®Pro APP •
ABB OFFERING
3° PARTY APPS • API
ABB Ability TM
INTEGRATION OFFERING
• Open Architecture • Specialized Apps • Subcription Services
APPLICATION INTERFACE
IP Network
LOCAL SUPERVISION
ABB SUPERVISION SYSTEM • ABB Local Supervisor • BMS (HVAC, drives, motors) • + Room Control + Lighting Control • + Energy management + EML
Process Automation System 800xA
ZEE 600/ ABB Zenon Backup Server
ZEE 600/ ABB Zenon Main Server
ABB OPTIMAX
ABB Ability™ Edgenius E3100B
Matrix / Nexus / IT 800 NetxAutomation /EisBaer OPC UA
BACNetIP OPC Modbus TCP/IP IEC61850
Room Wiring & Control Gateway
Industrial Edge Gateway
Smart Sensor Gateway
Naveo®Pro/ Nexus®Pro Gateway
Modbus TCP/IP
Application Control/KNX IP
Application Control/KNX IP
EQ Matic /CMS
CBXi /FLX
BACNet Interface
CBXi /FLX
OPC UA
POWER DISTRIBUTION
HVAC CONTROL
LIGHTING CONTROL
ROOM WIRING & CONTROL
EMERGENCY LIGHTING
DRIVES & MOTORS
ENERGY MANAGEMENT
ACCESS CONTROL
EV CHARGING
• AC Wall box • DC Wall box • DC fast charger • DC high power charger • Fleet charging
• Circuit Breaker • Panel • MV Relay • LV Switchgear • Uninterruped • Power Supply • Transformer • Sub Distribution Panel • Consumer Units • Invertor • Utility Meter • Solar Panel • Wind Turbine • Energy St rage Solutions LV Switchgear M tor control center Automatic transfer switch • Motor protection and control • UPS and PCS • Main Distribution board • Sub Distribution board • Automation Enclosure Skid Solutions Compact Secondary Substation MV s itch ear MV circuit breaker Digital system Relay Prot ction Electrical Houses Air Circuit breaker LV Busway
• Sub meter • Water meter • Gas meter
• AHU & FAHU Control • Chiller Control • Boiler Control • Fan Coil Unit • VAV and VRV Control • Circulation Pump Control • Touch Screen • Thermostat • Temperature Sensor • Humidity Sensor • VOC Sensor • CO2 Sensor • Occupancy Sensor • UV treatment • Cold Room Monitoring
• ON/OFF Controller • DALI Dimmer • Direct Dimmer • Low Voltage Dimmer • Occupancy sensor • Timer • Brightness Sensor • Shades / Blinds / Curtain Controller • Passive infrared sensor
• Scene Switch • Room Controller • Occupancy Sensor • Touch Panel • Multimedia Control • Socket Outlet • Multimedia Connector • USB Power Adaptor • Thermostat
• Exit pictogram • Self Contained Light • Self Contained DALI Light • Central Battery System • Explosion Proof Lighting
• Variable Speed Drive • Motor • Smoke extraction motor • Low Voltage Motor • Wireless Condition Monitoring Sensor
VIDEO MONITORING
FIRE & SAFETY
PROCESS AUTOMATION
ROBOTICS
I NDUSTR I AL BU I LDI NG SOLUT ION
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— Reference Architecture Industrial
INDUSTRIAL
DIGITAL PLATFORM
ABB APPS • ABB Energy & Asset Manager • ABB Ability™ Energy Manager Multisite • ABB AbilityTM Optimax • Active Energy Management • Naveo®Pro APP •
ABB OFFERING
3° PARTY APPS • API
ABB Ability TM
INTEGRATION OFFERING
• Open Architecture • Specialized Apps • Subcription Services
APPLICATION INTERFACE
IP Network
LOCAL SUPERVISION
ABB SUPERVISION SYSTEM • ABB Local Supervisor • BMS (HVAC, drives, motors) • + Room Control + Lighting Control • + Energy management + EML
Process Automation System 800xA
ZEE 600/ ABB Zenon Backup Server
ZEE 600/ ABB Zenon Main Server
ABB OPTIMAX
ABB Ability™ Edgenius E3100B
Matrix / Nexus / IT 800 NetxAutomation /EisBaer OPC UA
BACNetIP OPC Modbus TCP/IP IEC61850
Room Wiring & Control Gateway
Industrial Edge Gateway
Smart Sensor Gateway
Naveo®Pro/ Nexus®Pro Gateway
Modbus TCP/IP
Application Control/KNX IP
Application Control/KNX IP
EQ Matic /CMS
CBXi /FLX
BACNet Interface
CBXi /FLX
OPC UA
POWER DISTRIBUTION
HVAC CONTROL
LIGHTING CONTROL
ROOM WIRING & CONTROL
EMERGENCY LIGHTING
DRIVES & MOTORS
ENERGY MANAGEMENT
ACCESS CONTROL
EV CHARGING
VIDEO MONITORING
EMAX 2
TMAX XT
LIGHT DIMMING
SWITCH/ KEY PADS
TERRA DC CHARGER
TERRA AC CHARGER
EQ METERS GAS METERS (3° PARTY)
VSD
MOTORS
VAV, PTAC, FCU
AIR HANDLING UNITS
LIGHTING CONTROL PANEL
DALI GATEWAY
PICTOGRAM EXIT
MV SWITCHGEAR
UPS
SELF CONTAINED DALI
DRIVES & METERS
ROOFTOP UNITS
PIR SENSOR
BLIND/SHUT- TER CONTROL
FIRE & SAFETY
WATER METERS (3° PARTY)
WIRELESS CONDITION MONTROING SENSOR
FLEET CHARGING
ROOM TOUCH SCREEN
PIR SENSOR
LV MCC SWITCHGEAR
MV RELAYS
PROCESS AUTOMATION
PUMPS FUSION AIR SENSOR
TIMERS LUX SENSOR
STREET, HIGHWAY & AMENITY LIGHTING
CP600
AC500
TERRA DC FAST CHARGERS
CURTAIN CONTROL
AIR QUALITY
LV SWITCHGEAR
CENTRAL BATTERY
UV LIGHTING INTERFACE
ROBOTICS
LV SUB DISTRIB.
I NDUSTR I AL BU I LDI NG SOLUT ION
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— Power Distribution
A reliable and energy efficient electrical distribution is needed to keep a building powered, so that computers, lights, heat, and more keep the business running smoothly. ABB offers a wide range of electrical distribution devices to protect a building from overloads, short circuits, ground or arc faults as well as meters to monitor the electricity consumption.
I NDUSTR I AL BU I LDI NG SOLUT ION
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— Power Distribution
Example of power distribution application
Electrical power distribution system might receive power at one or more sources. Power distribution and safety system generally include panel enclosure, bus bar, circuit breaker, fuse, relay, feeder, protection devices, safety devices etc.
Overview - Motivation & Key Elements Efficiency and consumption monitoring • Metering systems are provided for each zone and main services such as lighting, heating, air conditioning • The ABB supervision system makes integration of water and gas meters easy and simple • ABB Ability Energy and Asset Manager provides a common interface and can use analytics,for real-time understanding of building energy consumption and efficient identification of areas of improvement Safety • The office building is designed to hosts hundreds of employees for working activities and visitors, therefore special attention to people safety and protection is important • One of the most critical exposure happening in electrical system is an electric arc inside a switchboard Continuity of service • Protection devices have been selected to ensure total safety • Redundancy of UPSs for monoblock structures or redundancy at module level for modular UPSs is pro-posed to ensure high reliability Maintainability • Monitor performance indicators of protection devices, transformers, generator and automatic transfer switches • To reduce maintenance cost, it is suggested the adoption of a predictive maintenance program
I NDUSTR I AL BU I LDI NG SOLUT ION
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— Power Distribution Overall Architecture MV Distribution
Reference Architecture
From Utility
CHP
CHP
EcoFlex
11 kV - 15 kV - 20 kV
PV System (opt.)
BESS (opt.)
MV Distribution
MV/LV Transformer
Emergency DG
LV Distribution
CSS Substation
I NDUSTR I AL BU I LDI NG SOLUT ION
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— Power Distribution Overall Architecture LV Distribution
Reference Architecture
Low Voltage SWG
Main Distribution Board
Main Distribution Board
Power Conditioning system
Main Distribution Board
Power Conditioning system
Main Distribution Board
UPS
MCC
Main Distribution Board
UPS
UPS
Sub Distribution Board
Conveying Production Chain Machine
Picking
S900 Remote IO
AC800M Controller
Compressors
Chillers Ventilation Fan
Lighting
Conventional Sockets
Conventional Sockets
Storages
Server
IT Equipment's
Life Sciences Manufacturing Shop Floor
Battery Manufacturing Process Areas
Packing Machines
Process Motor
System 800xA
Field Information Manager
Refrigeration System
AHU
Pumps
AC Load
Security System
Emergency System
Manufacturing Process Area /Shop Floor
Processing Machines
Process control system
Cooling ,Ventilation ,Clean Room and Refrigeration Load
Conventional Building load
IT and Building safety system
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