30 Oktober 2012

ABB Industrial IT

IndustrialIT System 800xA
Harmony/INFI90 System
Extending Return-on-Investment
Harmony Systems: system hardware software releases increase operating efficiency extend life installed systems. products programs make decision evolve existing systems straightforward easy.
Achieving Extended Automation
scope with System 800xA: Personalized User Workplaces: Reduced time decision action achieved with 800xA Process Portal personalized workplaces. Information workplace layouts optimized maintenance, engineering, management, operating personnel preferences needs. Wide-ranging control functionality: Applicable control safety applications, 800M Control meet plant automation needs. 800M integration with Harmony systems made easy through INFI90 Function Code (FC) Library peerto-peer communications with Harmony controllers. Device Management: Device Management features lower lifecycle costs through significant savings design, implementation, operation field equipment. Asset Optimization: Significantly increase process uptime reduce maintenance costs through optimized remediation work processes early detection asset performance problems. Information Management: Improve visibility integrated information results effective decision-making.
Lowering System Lifecycle Costs
successful today's highly competitive business markets, companies drive their production facilities toward Operational Excellence (OpX) with defined goals maximizing Return Assets (RONA), lowering Total Cost Ownership (TCO), sharing best practices throughout enterprise, driving profitable, sustainable growth. Achieving these goals require more than what traditional Distributed Control System (DCS) offer. requires plant automation system that improve:
Plant effectiveness ability combine right decisions with optimized work processes Plant agility ability make `on-the-fly' adjustments business opportunities present themselves with same proficiency when performing routine Performance visualization ability provide users with realtime performance feedback
general, only achieved extending reach plant automation systems synchronize process operations within common environment operations, engineering, information. delivers this extended automation scope combining SYMPHONY Harmony system with Industrial Extended AutomationSystem 800xA's best-in-class productivity enhancement software. System 800xA Asset Optimization, Information Management, Process Portal personalized workplaces optimize productivity substantial cost savings. Where others promote "rip-and-replace" migration strategies, delivers true system evolution allowing Harmony owners build their strong foundation providing flexibility implement these functions incremental stepwise fashion.
Risk through System Evolution: Evolution programs ensure that automation systems continually optimized support customer business goals.
Harmony System
SYMPHONY Harmony proven process control system used demanding applications various industries. wide range Harmony references includes power generation, chemical, pharmaceutical, pulp paper, water wastewater, petrochemical, metals mining, food beverage, cement, sugar industries. These system owners first acquired their distributed control system because offered best solutions that helped them successful competitive. Whether ease engineering, system scalability, powerful control applications ergonomically designed user interfaces, system company's needs effective efficient manner. markets business conditions constantly changing, requiring faster turnarounds, greater customization, smaller sizes, lower overall costs. today's faced paced economy, companies under more pressure than ever their operation profitably achieve greater results with fewer resources. With reduced capital spending, system owners need perform smarter better substantial cost savings. business challenge they face squeeze most productivity from installed system adding functions features, extending useful life applications within reducing maintenance costs while improving overall reliability. addresses these challenges providing capabilities that enable Symphony Harmony system owners achieve Operational Excellence. Symphony Harmony system products enhanced improve their cost/performance curves make them more reliable while incorporating proven, technology enable step change benefits. While greenfield automation system installation readily take advantage latest capabilities, existing system installation faces many modernization challenges. These include:
24/7 production, short non-existent downtime Upgrades must performed without jeopardizing operation Maintenance budgets rather than large capital project funding Site made significant investments
plant mill
Control applications User interfaces Training plant personnel Standard Operating Procedures (SOP) based automation system Validation (for regulated industries) Hardware Software Other intellectual property Therefore, changes existing system must limited specific area interest, risk averse, protect owner's investments hardware, software, intellectual property. short, there must solid, measurable Return-onInvestment (ROI).
IndustrialIT System 800xA ABB's answer these issues founded evolution strategy. Evolution ABB's deliver continuous improvement installed systems; allowing system owners meet automation system business objectives incremental affording lowest risk best ROI. migration, "rip-and-replace"; well thought plan, allowing system owners adapt capabilities their pace, according their need. From product point view, this strategy business usual ABB. pledge Evolution through Enhancement (Figure extended life Return-on-Investment installed Harmony systems. Other vendors talk about investment protection, ABB's proven programs truly unique industry. told, from introduction Network 1980, through each evolutionary steps INFI 90®, INFI OPEN, SYMPHONYHarmony, this family systems represents largest contiguous installed base process automation system world. System 800xA represents most recent step on-going system evolution process. purpose this document summarize many opportunities available Harmony system owner enhancing value extending useful functionality their system. following pages details enhancements available Harmony foundation (see section "Extending Return-onInvestment Harmony Systems"); well opportunities available build extended automation scope from Harmony foundation (see section "Achieving Extended Automation Scope with System 800xA").
Harmony System
Extending Return-on-Investment Harmony Systems
continues traditional functionality Harmony system. This resulted variety functions technology updates Harmony products including Rack modules, Bridge Controllers, communication modules, Composer system configuration tools, operator consoles. following sections summarize most recent enhancements Harmony system.
Figure Evolution through Enhancement
IndustrialIT System 800xA
Harmony Control, I/O, Communications
Harmony Rack modules (Figure redesigned with modern board components surface mount technology, form, fit, functional equivalents Network INFI INFI OPEN modules. This provides backward compatibility ensure long lifecycle Harmony systems.
Figure Harmony Rack Modules
Harmony Rack Controllers. Harmony Rack controllers have remained state-of-theart through annual software hardware enhancement releases. Following ABB's commitment Evolution through Enhancement, system's flagship controllers, Harmony Bridge Controller (BRC) family, preserve existing system control logic configuration including support existing function code executions, custom user programs, foreign device interfaces. This provides predictable risk-free evolution system's control execution environment. BRC300 BRC400 (Figure represent latest additions family.
Harmony System
Harmony Controller Features
Form, functional equivalent Harmony rack controllers Deploys advanced Reduced Instruction Computer (RISC) microprocessor technology Motorola 32-bit Coldfire Retains Harmony controller (BRC, MFP, etc.) hardware software architecture Enhanced controller reliability Provides approximately (2x) function code execution rate BRC100, (4x) MFPxx, (8x) MFCxx Extended user configuration memory; 30,000 function blocks (BRC400 version) Preserves existing control logic configurations, providing predictable risk-free evolution:
Function code execution Custom user programs Foreign device interfaces Fast fail-over redundancy
High availability fault tolerance redundant pair configuration Controller configuration supported Composer engineering tool Supports Harmony systems, simultaneously providing support installed systems expansions:
Rack Block S800 (System 800xA)
Support Module Controlway communications
Figure Bridge Controller Family (BRC300, BRC400)
Harmony Rack I/O. Harmony Rack family includes wide variety input, output, signal conditioning modules. Module types, ranging from standard analog digital specialty such turbine control, Sequence Events (SOE), combined provide comprehensive functionality meet market industrial requirements. Additionally, Harmony remote capabilities have been enhanced with addition S800 (see section "S800 Harmony" details).
IndustrialIT System 800xA Another example ABB's continuing commitment protect investments made Harmony system assets found recent introduction Rack Remote alternative. Needed protect more than year investments made rack remote IMRIO02 module, this alternative minimizes change impact existing hardware architectures. Specifically, Rack Remote alternative leverages newer H-Net technology remote communications requires minimal change Remote interface block 146). Rack Remote alternative supports multiple links mixed with other Harmony types: Rack, Block, S800 I/O. Rack Remote alternative supports multiple links mixed with other Harmony types: Rack, Block, S800 I/O. Rack Remote architecture summarized Figure
Existing Fiber Optic Cables
Figure Harmony Rack Remote solution using H-Net
Harmony Communications. communication modules ensure long term viability installed systems. flagship Communication products, INNIS21/INNPM22 modules provide significant increases performance capacity compared previous generations. Additionally, INFI-NET Computer Interface INFI-NET INFI-NET Local Remote Bridge modules available. these communication modules form, fit, functional replacements their predecessors.
Harmony System
Composer Engineering Tools Harmony
Composer comprehensive engineering maintenance tools Harmony systems. provides configuration support controller INFI-NET (Cnet) communication options. working environment provided Composer simplifies configuration maintenance Harmony systems. base product contains functionality necessary create maintain control system configurations. addition, includes applications that support graphic configuration database management current operator console offerings. Composer's multiuser client server architecture allows configuration information accessed, created, modified simultaneously different users. Composer's project explorer provides user with ability organize, navigate, manage Harmony system configuration documents. Once documents located, Composer's explorer used launch editors which used develop Harmony configurations. Composer tools include:
Monitor: Provides ability view control configurations with live data from Windows based browser application network (Figure Maintenance Tools: Provides users with ability trouble shoot, perform diagnostics, maintain operating Harmony system Configuration Viewer: Offers users option view files view tune configurations controller without requiring Composer software projects Tools: Suite add-on applications that extends capabilities Composer reduces amount time required engineer configure Harmony system. Applications include Control Logic Editor, Revision Manager, Automatic Drawing Generator, Advanced Trend (runtime monitoring tuning) Data Manager (BDM): family engineering tools used creating, editing, managing, downloading, debugging batch, sequential, user defined function code configurations. discussed further section "System 800xA Production Management Harmony"
learn more about Composer Engineering Tools, please refer Composer Data Sheet, 3BUA000304Rxxxx.
Figure Composer View Monitor Mode
Operator Consoles Harmony operator console evolution dates back early 1980s with
introduction Operator Interface Unit (OIU). Since then, supported console enhancements graceful evolution newer technology through database process graphics compatibility conversion services. current console portfolio includes Conductor 800xA Process Portal (see section "System 800xA Process Portal Harmony Systems" operator console details). 3BUS094398
IndustrialIT System 800xA
Achieving Extended Automation Scope with System 800xA
Easy integration System 800xA's productivity enhancing applications, such Asset Optimization, allows Harmony system owners into their assets' unused productivity achieve sustainable competitive advantage (Figure Through incremental, stepwise evolution process, productivity gains realized substantial cost savings. following sections discuss 800xA Operations, Device Management, Asset Optimization, 800M Control I/O, Information Management solutions available Harmony system owners.
Remote Process Portal Clients
800xA Process Portal Workplaces
System Servers
Client Server Network (TCP/IP) INFINET
Control Network (TCP/IP)
Process Automation
Process Automation
800M SIL3
Controlway H-Net Rack
Additional 800Ms
Variable Speed Drives
S800 S900
Fieldbus High Speed Linking Devices HSE/H1, DP/PA)
Figure Extending Harmony Functionality with System 800xA
Harmony System
System 800xA Process Portal Harmony Systems
System 800xA Process Portal, industry's most comprehensive operations software automation, offers intuitive, easy-to-use system interface. Providing direct access relevant information through contextual navigation, 800xA Process Portal facilitates timely informed decision-making. Unique System 800xA Process Portal ability gather information from multiple plant sources transform into relevant information diverse users such maintenance technicians, process engineers, production managers plant operators (Figure
Engineering Management
Maintenance Operations
Energy Efficiency Material Efficiency Personnel Efficiency Uptime Efficiency
Production Variance Product Concentration
Planned Actual
Figure Personalized User Workplaces
enabling technology this data access, storage, management ABB's patented Aspect Objectframework. Aspect Objects relate plant data; aspects, specific plant assets; objects. example, aspects informational items associated with objects, such definitions, engineering drawings, process graphics, reports, trends, etc., that assigned each object system. Aspect Object navigation presents entire production facility consistent, easy-to-view fashion. This allows single window environment include smart field devices, asset optimization functions, information management, batch management, safety systems, manufacturing execution system (MES) applications. System 800xA Process Portal features include:
Workplaces Focused Information Access: Workplace layouts adjusted optimized user preferences needs with individualized menus, toolbar contents, display locations. Operator, maintenance, engineering, management personnel ease perform their responsibilities efficiently using Windows management functions, such safe areas pinning stacking priorities, thus minimizing operation errors.
IndustrialIT System 800xA
Flexible Navigation Fast Information Access: Familiar browser tools provide quick access displays information. Favorites, history lists, shortcuts, buttons provide navigation through process production facility quickly accurately. right mouse button provides access additional details (Figure Data Informed Decision-Making: extends automation reach integrating information from wide range applications, other automation systems, business systems into System 800xA common displays. This single window provides users much broader view facility from which make more informed decisions (Figure Operator Functionality Reliable Control: System 800xA Process Portal provides complete operator functions that includes realistic process graphics with standard faceplates, superior trending capabilities, intelligent alarm event handling, production reporting, remote messaging (Figure 10).
Figure Intuitive flexible contextual navigation
Figure Integrated data informed decision-making
Figure Comprehensive operator functionality reliable control
These personalized workplaces coexist with existing Harmony operator consoles. This provides option immediately gain added benefits from System 800xA Process Portal functionality without completely evolving existing Harmony operator consoles. However, Process Portal also offers extended operations environment with comprenhensive process information system operator. does this while preserving Harmony system data, standard Harmony displays, operator functions.
Harmony System following paragraphs describe unique Harmony Process Portal features. those requiring more details regarding general Process Portal functionality, please refer Industrial System 800xA Operations Overview document (#3BSE 034823). Preserving Harmony Configuration. Harmony Composer engineering tool provides basis 800xA Process Portal configuration. simple importing process from Composer sets Harmony configuration data standard Harmony informational views within Process Portal. Preserving Harmony Process Graphics. provides options existing Harmony process graphics. service provided convert existing graphics those users need maintain current operator process visuals navigation. Optionally, refresh current visuals with latest graphics technology thereby providing operators with enhanced view process. Harmony Standard Informational Views. Harmony importing process automatically creates control faceplates, trend displays, block details, module status, operating parameters, other Harmony specific, standard informational aspect views (Figure 11).
Figure Process graphics with contextual navigation Harmony control information
IndustrialIT System 800xA following Process Portal aspects easily modified meet operational requirement.
Figure Control faceplate views: Normal Extended Faceplates.
Faceplates include several views; from normal standard control point display view detailed control. Harmony Point Displays (Figure expanded faceplates that include trend elements that display trace process value state. Point displays occupy extended slot faceplate control those types. These faceplates automatically configured during data conversion process. Each Harmony types listed below (unless noted) associated faceplate extended point display. Device Driver (DD) Multi-State Device Driver (MSDD) Remote Control Memory (RCM) Report Trigger Remote Manual Constant (RMSC) Remote Motor Control Block (RMCB) Station Analog Enhanced Analog Enhanced Analog Digital Enhanced Digital Enhanced Digital display only) display only) display only) display only)
Details. Block Details aspect (Figure inspects function blocks within selected controller. Grouped within series tabs, Block Details aspect displays block's specifications with tuning options, outputs, additional related function code information. Tabs include:
Specifications Specification data (i.e. references another function block output, tunable non-tunable parameters) Outputs Current output value(s) block Description Description Address Enter block address NextBlock Jump next block address module
Harmony System
Figure Block details view
Figure Module Status View Module
Details. Module Details aspect (Figure provides detailed information about operational status selected Harmony module. Detailed information available through following navigation tabs:
General displays Type, Revision (firmware), Description, Mode, Collection Time, Status Bytes Status displays list status error messages that apply selected module time last scan Problems displays list problem report messages that apply selected module time last scan
Parameters. Operating Parameters aspect allows interaction with Harmony including examination parameters, tagging, inhibiting, value substitution (Figure 15). Tables summarize operating parameters included within General Harmony Tabs respectively. important feature operating parameters aspect Manual Inhibit option General tab. This used disable event reporting same
IndustrialIT System 800xA automatic inhibit. Substitute Value used enter substitute value tag. When substitution applied, "scan" automatically turned value controller unchanged. substitute value only performed Operator Workplace level. Only operators with proper, user selected security level access this function. feature available controllable types that support tagging. tagging method used place service (for maintenance other purposes) that prevents from being back into service unauthorized users. Typically only limited number users permitted implement this feature. pages defined each object type display operational data. This also allows user change state object (such tags), utilize manual inhibiting alarms, substitute values.
Figure Operating Parameters view
Type Description Security group Alarm status Quality inhibition Inhibit Inhibit Value Overall Inhibit Auto Inhibited Manual Inhibit Manual Inhibited Time stamp
type (Harmony station) Information entered during configuration that further describes function Security group that belongs Selected reporting alarm. This single overall alarm status indication Information reported from system about quality Information about inhibit status tag. inhibit disables event reporting that causes inhibit when inhibit value reached Value during configuration that causes inhibit Indicates that inhibited Selected automatically inhibited another system Enable manually inhibit event reporting Time when manually inhibited
Table Operating Parameters General
Harmony System
Loop Node Module Block
Loop number from that identifies communication network (loop) Harmony control unit Node number from that identifies interconnection point communication network Module number from that identifies device within Harmony control unit Function block location from 31,998 that identifies location specific function block Harmony configuration (controller) Selected disestablished Cnet-to-computer interface. becomes disestablished when substitute value been entered Value manually substituted Enable have system ignore Time when suspended (manually substituted) Number exception reports processed this tag. Time when specification data received from controller
Table Operating Parameters Harmony
Substituted Value Suspended Suspended Time stamp Exception Count Spec Time Stamp
Figure System Status Viewer System
Status. System Status Viewer (Figure used monitor status Harmony system applications. description field display following messages:
Alarm State (Normal Alarm) This displays normal long there other errors. status offline other errors exist, then displays alarm Status (Online Offline) Indicates that Online Offline CommErr Indicates that there some kind communication error InternalErr This internal error configuration
"View Monitor." Harmony Composer Configuration View Monitor function integrated with 800xA Process Portal. With right-click graphic tag, associated Control Logic Diagram viewed with live data monitoring. This "view only" function that maintains high security integrity control logic configuration. Events. Harmony's Sequence Events (SOE) system enables plant personnel closely monitor critical digital points where sequence changes state points groups points critical, must accurate possible.
IndustrialIT System 800xA systems allow collection precise state transition event data originating Sequence Events Recorder (SER), Distributed system within control system. Harmony system, digital state transitions recorded time stamped millisecond resolution time occurrence. reports (Figures created automatically, based triggered value property. Report action parameters configured. These parameters include: Time Limit, Isolated Priority, Attempts, System Messages, Report Templates, Export Paths. This feature allows flexibility configure specific reports based specific events. reports saved reviewed later, and/or printed Client system that Microsoft Excel installed. When integrated with 800xA Information Management, reports archived long-term storage.
Figure Report
Figure Report Trigger Point Display
Harmony System
S800 Harmony
Harmony remote capabilities expanded with S800 I/O. facilitate local mounting sensors plant, S800 family designed with small, modular form factor footprint. S800 provides options signal types ranging from basic analog digital inputs outputs pulse counters intrinsically-safe applications. S800 supports Sequence Events functionality with millisecond accuracy event timestamping source. communicates with Harmony Bridge Controller Hnet communications Harmony IOR-800 module (Figure 19). Redundant communication provides fault tolerant connection S800 I/O. Standard Composer tools configure Harmony IOR-800 Interface module S800 I/O, their individual channels. single Harmony Bridge Controller simultaneously supports both Rack S800 simple expansions ease system evolution.
Figure Interface Module S800 Modules
800M Control
Through their modular design, 800M controllers associated options contribute lower costs, higher engineering quality, higher operating efficiency. Equally effective small hybrid systems large, integrated automation applications, modularity subsystem results higher return assets providing flexibility choose specific functions required meet automation need. Designed plant automation SIL2 SIL3 safety applications, 800M controller family provides Harmony system owners with opportunity expand their automation system capabilities. Additionally, 800M controller associated modules support industry standard interfaces, network protocols, fieldbuses allowing wide range devices systems accessed their resident information used produce tighter more reliable control solutions. learn more about 800M controller subsystems, please refer System 800xA Control Overview document, 3BSE047351. Harmony system owners take advantage powerful flexible capabilities 800M controllers while protecting investments they have made their existing control assets. Whether replacing aging PLCs evolving existing
IndustrialIT System 800xA process control area with fieldbus devices, ABB's control evolution products minimize production risk while providing incremental stepwise evolution paths. These products include:
Gateway HPG800. HPG800 rack module addresses needs those system owners want extend their Harmony systems using 800M controllers. high performance, high capacity rack module that provides high speed, robust, real-time, peer-to-peer communication interface between Harmony 800M controllers. HPG800 communicates with Harmony controllers over Controlway INFINET standard function blocks. Harmony Gateway Software (HGS) maps INFI function blocks MODBUS points communicates those points over Ethernet port using MODBUS protocol. module provides physical MODBUS interface 800M. architecture communication paths interface shown Figure while module's features summarized Figure
Composer Harmony Consoles Harmony Connectivity Server(s) Function Designer Aspect Server(s) 800xA Process Portal
800xA CNET
ODBUS aster"
Exception Reports: AOL, DOL, etc. Control-Way Signals: AIB, DIB, etc.
ODBUS Slave"
Harmony Gateway Software
ODBUS Ethernet
Switch Connect Redundant 800M Controllers
Figure HPG800 connects Harmony controllers 800M controllers
Harmony System
Harmony Gateway (HPG800) Features
Communicates with 800M controllers Communicates with other Harmony INFI controllers Controlway standard function codes Bi-directional communication 4,000 MODBUS points less Ethernet port using MODBUS protocol Deploys adva nced RISC microprocessor technology Motorola 32-bit Coldfire with megabytes onboard DRAM High availability fault tolerance redundant pair configuration Configuration supported Composer Engineering Tool (version 5.0, later) Ability interface third-party PLC's devices MODBUS
learn more about HPG800 peer-to-peer rack module, please refer 3BUS094832.
800M. INFI90FCLib 800M evolutionary library that contains INFI Function Codes. purpose INFI Function Block library allow Harmony system owners protect intellectual property embedded within their existing controllers. Specifically, library designed make evolution Harmony control applications 800M straightforward simple. INFI90FCLib does this providing equivalent function block 800M function codes from Harmony. Table lists 61131-3 Function Block Types (FBTs) provided INFI90FCLib.
IndustrialIT System 800xA
800M FnGen LeadLag PulsePosn PulseRate Sqroot RateLimiter XferReal HiLowComp Sum2Real ErrPID DeltaPID BasicStation TSTQ TRIP SRMem TimerBool XferDint DelayReal XferBool Blink DSum REMSET TSTALM Station Exec UpDnCount ElapTimer ExExec MODST RedAI
800M RedDI SLSEL Rung5 Rung10 Rung20 JumpMCR RecipeBool RecipeReal MuxBool MuxReal DeviceDriver SeqMon DevMon DMuxReal MSDD MULTIMON SEQMGR RMCB SeqMstrSlv SeqMstrSlv TexSel APID SeqGen MovAvg Integrator POLY INPOL TRIG EXP1 POWER Log1 DAANG DADIG
Table INFI90FCLib 2.0-0 List FBT's
Table depicts standard 800M system functions that provide equal superior functionality those provided INFI function codes. When following INFI function codes applied, corresponding 800M system functions used with equal better results going forward.
Harmony System
INFI Name 800M System Function LIMIT HISEL LOSEL SUM4 MULT real variable limit(real) max(real) min(real) add(real) mul(real) div(real) not(bool)
INFI Name 800M System Function AND2 AND4 ON/OFF A-INT TREND ETREND boolean variable dint variable required 800M (bool) (bool)
Table 800xA System Functions INFI FC's
Function Designer used configure maintain INFI90FCLib control configurations. Function Diagrams (FD) provide same "look feel" graphical documentation Composer's Control Logic Diagrams (CLD) have done INFI based control logic within Harmony. Figure compares with converted counterpart. preserving "look feel" control logic documentation, engineering re-training minimized. Also, providing automated conversion service, engineering costs further reduced protecting investments system owners have made their documentation assets.
Figure (left) Conversion Function Diagram (right)
INFI90FCLib features include: 1-for-1 each INFI90 Function Code 800M Function Block Based same field proven field tested function code algorithms Inputs, outputs, parameters provide same behavior re-tuning converted loops required Same operator faceplates those used with 800xA Harmony Same graphical "look feel" within 800M's engineering tool Function Designer Function Designer standard loop templates provided Basic Loop Basic Cascade Loop Basic Valve Control Loop Compatible with 800M's other 61131-3 control languages (Sequential Function Charts, Ladder Diagrams, Structured Text, Instruction Lists)
IndustrialIT System 800xA read more about 800M's INFI evolutionary library, please refer INFI90 Function Code Library 800M Application Overview, 3BUS094839.
Harmony Termination Unit (TU) prefabricated cables. minimize risk costs re-terminating field wires, created family cables that preserves investments made standard Harmony field wiring terminations. These prefabricated cables allow module upgrade S800 without ever touching field wires. cables used place traditional NKTU cables. They connect existing S800 modules standard cable plug-ins. S800 cables exist Digital I/O, 4-20 mADC Analog I/O, (ASM01, ASM02, ASM03) termination units. Similar solutions exist Harmony Block bases (AIN, AOT, DIN, DOT).
Whether replacing aging PLCs incrementally upgrading older Network INFI based controllers, especially AMM, LMM, COM, modules, these control evolution products allow seamless evolution 800M S800 without costs risks associated with "rip-and-replace" controller upgrade methods (summarized Table
Traditional "Rip Replace" Upgrades Re-engineering translation control applications algorithms result process control behaviors Long commissioning start-up periods (re-configuration re-tuning loops) Create documentation Results Greater loss production Increased risk Higher project costs INFI90FCLib 800M upgrades Minimal engineering required Process control same before Minimal commissioning start-up re-tuning loops) Documentation converted enhanced Results Minimal loss production Minimal risk Lower project costs
Table avoiding high project costs production risks, control evolution upgrades cost less than "rip-and-replace" alternatives
System 800xA Device Management Harmony
System 800xA's Device Management features (Figure lower lifecycle costs through significant savings design, implementation, operation field equipment. harnessing untapped potential from substantial installed base HART® devices conforms with Advisory Group analysis that: "Users employ many their HART field devices with generation automation architectures, making migration process automation system more economical while increasing availability intelligent data that long been under utilized."
Figure System 800xA's Device Management
Harmony System Digital information from HART devices accessed System 800xA Fieldbus Management tools that physically connect HART multiplexer units. These multiplexers receive HART device data cable connections from standard Harmony Termination Units (Figure 24). ABB's HART solution supports device parameterization remote monitoring signal status process variables. also supports diagnostic information through device specific Device Type Managers (DTMs), which supplied respective device manufacturers. addition, tight integration HART devices within Harmony enables improved device maintainability through asset monitoring optimization.
Figure Simple Cable Connections Provide Access System's Smart Device's HART Data
Foundation Fieldbus Profibus interfaces available through System 800xA 800M controller. more details, please refer System 800xA Device Management Overview, 3BDD013081. With access installed HART field device information, Harmony system owners System 800xA Asset Optimization take full advantage System 800xA's Asset Optimization features. application (Figure exploits wealth field resident information accessible through Harmony
HART Fieldbus higher-level systems access document equipment conditions real-time. addition field devices, System 800xA asset monitoring features inspect health status operations network, including networking equipment such PCs, routers, printers, etc. These functions enable personnel implement proactive predictive maintenance services. Additionally, software seamlessly integrates plant maintenance calibration management systems greatly reduce time repair through streamlined work processes.
IndustrialIT System 800xA System 800xA Asset Optimization highlights include:
Asset Optimization: Provides higher return plant assets through optimized remediation work processes early detection failure single environment engineering, operations, notification. Monitoring Maintenance Conditions Automatic Alarms: Real-time monitoring asset Performance Indicators (KPI's) facilitates fast, reliable implementation corrective actions. Adoption Predictive Proactive Maintenance Strategies: Collects, aggregates, analyzes real-time plant asset information provide advanced warning degrading performance impending failure. Reporting Plant Asset Health Status: Reporting features provide visualization current health conditions. Analysis features provide ability drill down root cause failure. Time Repair through Optimized Work Processes: Integration disparate Computerized Maintenance Management System (CMMS) data, calibration system data, condition monitoring system data, control system asset data provides users single application view, leading quick efficient assessment maintenance needs status.
Figure Asset Optimization
Additionally, 800xA Asset Optimization reviews health condition Harmony control network. provides detailed information Harmony Process Control units, controllers, bridges, modules system, module/loop faults overall performance (Figure 26). 800xA Asset Monitoring leverages diagnostic information resident system's traditional diagnostic views Harmony Control Network individual system nodes (PCU). These displays provide information about current Harmony equipment sub-conditions, severity, asset monitor status, fault report availability, work order availability when integrated with plant's CMMS system.
Harmony System
Traditional Diagnostics View
Harmony Performance Statistics
800xA Harmony Asset Monitor Views
Harmony Loop Topology
Harmony Loop Asset Monitor Display
Harmony Exception Report Statistics
Harmony Asset Monitor Alarm List
Harmony Network Event Error Counters
Harmony Node (PCU) Topology
Harmony Node (PCU) Asset Monitor Display
Figure Harmony Control Network Health Status Reporting
more details, please refer System 800xA Asset Optimization Overview, 3BUS094382 System 800xA Asset Optimization Advanced Harmony Control System Monitoring Datasheet, 3BUS094351.
System 800xA Production Management Harmony
800xA Production Management suite automates, monitors, controls, documents compliant with cGMP (current Good Manufacturing Practices) manufacturing processes. This enables users achieve operational excellence real-time manufacturing execution, quality, performance management. ABB's production management capabilities built S88, 61512, 61131-3 standards.
IndustrialIT System 800xA
800xA Production Management provides batch production management solutions, delivering unsurpassed batch-to-batch consistency, quality, productivity. These measurable results achieved through unmatched level scope batch control integrated with scheduling, electronic batch records, inventory management, quality control, HSI, history, controllers.Whether process manual, automated both, 800xA Production Management offers solutions stand-alone environments integrated operation with MES, etc. Batch Management component 800xA Production Management powerful application software package configuring, scheduling, managing batch operations. such, 800xA Batch Management provides:
Real-time resource management Flexible on/off-line recipe management Batch data collection history integrated
with 800xA Information Management
800xA Batch Management server supervises execution control recipe procedures. server sends formulation data issues commands equipment phase logic PHASEX function block running Harmony controllers. PHASEX block executes equipment phase logic communicates status information batch server. more details, please refer 800xA System Batch Management Overview, 3BUS092077. Batch Data Manager Tools (from Composer Phase Logic). Batch data manager (BDM) family engineering tools creating, editing, managing, downloading, debugging batch equipment phase logic Harmony systems. heart Batch 90programming language which enables engineer create equipment phase logic using clear, concise, natural syntax control statements. Batch layers regulatory discrete device control function code logic Harmony. Equipment phase logic change controller points, turn discrete devices off, change modes, other equipment supervisory operations written Batch PHASEX function code provides programmatic interface between Batch regulatory discrete control configured using INFI function blocks.
Harmony System
System 800xA Information Management Harmony
achieve sustainable competitive advantage, manufacturing non-manufacturing businesses must able adapt quickly market changes. This makes timely collection distribution reliable information plant's decision-makers critical. System 800xA Information Management provides ability collect securely store present business well process data from plant data sources. This data analyzed transformed into useful information, then presented personnel (e.g. Plant Manager's Workplace, Figure improve operations efficiency profitability. System 800xA Information Management features include:
Information Presentation: Desktop displays provide concise, enterprise-wide system process information familiar office presentation format without requiring personnel leave their office workplaces. discrete ticker continuously shows business Performance Indicators (KPIs), providing fingertip, real-time, historical information planned versus actual production status. ticker information supplemented with trend display when more detailed information status required. System Actions: Versatile scheduling options provide automatic triggers system actions such process data collection, running calculations process data, report generation, historical information archiving, history data consolidation provide single, plant-wide history repository, well system back-up functions. Scheduled actions based cyclic scheduling event-driven, time based, performed demand, requiring minimal effort perform repetitive system activities.
Report Generation Distribution: variety reporting software supported including Microsoft® Excel Crystal Report very familiar, easy-touse formats. Standard report templates included, which offer quick report setup. These reports fulfill plant regulatory agency documentation requirements well provide powerful tools decision-making planning improved operations performance. Historical Data Storage Access: Fault tolerant distributed data configurations provide dependable data information availability. information also protected user access restrictions offline storage. Users confident that electronic record keeping requirements being that their decisions based upon reliable information.
IndustrialIT System 800xA
Energy Efficiency Material Efficiency Personnel Efficiency Uptime Efficiency
Production Variance Product Concentration
Planned Actual
Figure Manager's Desktop Information Workplace
Information Management integrated with Harmony, ensuring that process data events securely collected, stored, archived. Plant users then able access, analyze, report, document Harmony data improve plant operations. more details, please refer System 800xA Information Management Overview, 3BUS092079. Smart Client provides Harmony users with browser-based thin client displaying cpmPlus Smart Client Harmony information from System 800xA (Figure 28). cpmPlus Smart Client true
thin client that seamlessly retrieves data from ABB's System 800xA connected third-party systems. Displays available inside outside plant facility, long connection plant exists (i.e. VPN). cpmPlus Smart Client utilizes extended automation capabilities System 800xA technology provide intelligent data access viewing functions assist levels personnel making quick, informed decisions taking appropriate action, thereby improving performance. Major benefits cpmPlus Smart Client include:
duplicate engineering using existing data definitions. information defined System 800xA, including upper lower limits, seamlessly available inside cpmPlus Smart Client.
Harmony System
display configuration requires programming. Displays configured using drag-and-drop display components information from System 800xA property browser. additional costs based count. Information from connected System 800xA's available.
These benefits allow companies lower their overall cost ownership leverage advantages ABB's System 800xA extended automation environment. feature cpmPlus Smart Client includes:
client based graphical displays statistical process control Excel Interface Event Reporting
Trending Alarm
Figure Using Smart Client, information from System 800xA Harmony connected third-party data sources readily available users' easily customized allow access precise data needed make better decisions
more details, please refer cpmPlus Smart Client brochure, 3BTG6000PM1002.
IndustrialIT System 800xA
Lowering System Lifecycle Costs Risk through System Evolution
stated earlier, long-standing commitment system owners that ensures future advances system technologies will enhance rather than compromise their current system investments. over years, ABB's evolution policies have allowed system owners maximize useful life both their control systems intellectual assets built upon them. Through stepwise their system evolution solutions, risk associated with system change mitigated; minimizing process/ system down-time protecting owner's long-term investments control applications, process graphics, historical data. Working side-by-side with Harmony system owners guided owner's business goals, assists development evolution path pace. Regardless whether initial investment made years ago, installed automation system still vital sustainable part business manufacturing strategy that enhanced extended years come that presents lowest lifecycle costs lowest risk.
Four-Point Evolution Strategy
Superior products cornerstone ABB's evolution strategy; however, simply incorporating products into existing system will ensure success provide desired results. ABB's evolution commitment consists four-point strategy that represents comprehensive solution provides roadmap successful system evolution. This four-point strategy includes: Product Planning Process ABB's system planning development strategy fundamental features capabilities must adapted seamlessly with minimum impact existing applications. development process involves rigid guidelines ensure compatibility differing versions models system components. Each step natural progression current system offering never behaves like plug-in adaptation someone else's product. example, application code runs when first developed controllers seamlessly coexist same control network previous generation controllers. order fulfill individually tailored upgrade path, system enhancements provide unique blend flexibility scalability. ability match hardware software different generations major strength. services solutions that preserve system owner's investments. This ensures continued base control hardware infrastructure protects intellectual asset investment made software applications. example:
Graphics: Save time expense re-engineering intensive user/operator retraining History data preservation restores existing historical data transferred directly history platform Wiring: Eliminates need field re-wiring reduces time costs re-testing when existing replaced with product applications: Preservation field proven control configurations documentation minimizes production risk project engineering costs
Database: Field
Harmony System Customer Evolution Planning Process successful evolution program begins with solid plan driven owner's business goals. Good planning critical incremental, stepwise evolution minimize negative production impact actual upgrade process. simplify improve yearly budgeting process facilitate better system upgrades planned plant shutdowns. Individualized planning essential. Different industries invariably have different strategies business issues going forward. ABB, account managers technical experts work with system owners individually address their unique needs. collaborative relationship results best strategies each individual site. After comprehensive audit existing system, with understanding business drivers, will:
year plan reviewed revised necessary. ABB's incremental approach supports flexibility; allowing changes plan required over time. target which facilities greatest risk production loss those that have greatest potential increased production. each phase identified, will provide value assessments Return-on-Investment support consideration order facilitate successful project appropriation requests. long-term plan periodically; update required reflect changing business needs solutions. This approach takes guessing budgeting process. part this planning process, specific projects identified implemented.
Customer Evolution Programs promotes proactive approach hardware software upgrades; working with system owners stay current avoid hitting brick wall obsolescence through stepwise, incremental upgrades. This philosophy allows system owners continuously improve productivity technologies automation product offerings become available. evolution programs provide financial flexibility move from existing automation system products new, higher performance human system interfaces, system engineering tools, controllers, control networks, information management functional area time. ABB's Automation Sentinel software management program assists system owners actively managing their lifecycle costs control system software. With this program, they keep control software up-to-date maintain flexible path forward system software technology. Automation Sentinel helps manage software assets with timely delivery latest software releases, thus providing subscribers:
Better Lower
productivity through enhanced software functionality support cost simpler software management through known annual subscription fees stay current with latest industry standards Access most current system documentation Evolution higher levels human system interface, control, information management, connectivity
IndustrialIT System 800xA Automation Sentinel program deliverables summarized below Table Licenses versions installed software products Software maintenance updates Software licenses evolution equivalent functions newer technology products, including System 800xA Extended support System 800xA software version. seven years Technical phone support assist with system software updates On-line website access downloads: updates notes updates bulletins manuals Software security management: security patch validation status party virus scanner qualification System 800xA computer hardware qualification replacement models available Device Library management updates 800xA systems: Fieldbus Auto notification email: updates release information
Table Automation Sentinel deliverables
Solutions Delivery Delivery sound system solutions based evolution plans another important process evolution value chain. ABB's system engineers highly trained, skilled, equipped with tools resources right. These resources know what installed, know what needed meet future goals, have know deliver project begins with comprehensive review requirements formulated long-term plan. engineers work closely with system owner formulate project plan that achieves desired results. Based this collaborative effort, engineers design solution that delivers results, protects system investments, presents lowest risk possible during installation.
Harmony System
With today's economic restraints putting pressure capital spending, system owners need perform smarter better substantial cost savings. business challenge they face squeeze most productivity from their installed system through functions features, extend useful life applications within reduce maintenance costs while improving overall reliability. delivers extended automation scope that enables system owners successful today's highly competitive business markets evolving their existing Symphony Harmony system with Industrial Extended Automation System 800xA's best-in-class productivity enhancement software. Learn more about evolution Symphony Harmony systems System 800xA Extended Automation www.abb.com/controlsystems.
Open Control Systems Sweden Phone: Fax: E-Mail: processautomation@se.abb.com www.abb.com/controlsystems Industry Open Control Systems Singapore Phone: 6776 5711 Fax: 6778 0222 E-Mail: processautomation@sg.abb.com www.abb.com/controlsystems
Inc. Open Control Systems Wickliffe, Ohio, Phone: 8500 Fax: 8756 E-Mail: www.abb.com/controlsystems Automation GmbH Open Control Systems Mannheim, Germany Phone: 1805 Fax: 1805 E-Mail: www.abb.de/controlsystems
reserve right make technical changes modify contents this document without prior notice. With regard purchase orders, agreed particulars shall prevail. does accept responsibility whatsoever potential errors possible lack information this document. reserve rights this document subject matter illustrations contained therein. reproduction, disclosure third parties utilization contents-in whole parts-is forbidden without prior written consent ABB. IndustrialIT wordmark, Aspect Objects, above mentioned names form xxxxxxIT registered pending trademarks ABB. rights other trademarks reside with their respective owners. Copyright 2009 ABB. rights reserved. 3BUS094398 USCS 1495


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