Heritage System Evolution - ABB Group
Transcript of Heritage System Evolution - ABB Group
© ABBSlide 1 -April 15, 2016
© ABBSlide 1 -April 15, 2016
Heritage Evolution Stepwise Advant Evolution to 800xA
Glenn Törnkvist, BU CT Heritage Evolution 2016
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© ABBSlide 2 -April 15, 2016
800xAIt’s all about control
…security
...costs
… productivity
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© ABBSlide 3 -April 15, 2016
”It’s all about Control”Everyone has the same picture of what’s going on in the plant
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800xA Collaboration Table
”It’s all about Control”Fully utilize Heritages Systems plant assets in 800xA
Alarm Analysis
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Improving Operator Effectiveness…through integrated information
System 800xA lets you monitor, control, optimize, and maintain from one powerful interface.
Seamless integration of actionable information through Aspect Object Technology
Relevant, filtered information based on user’s role and responsibility
One click to all Information you need…
Control
Faceplates
Trend
Graphics
Video
Asset Health
Reports
DocumentationERP/ CMMS
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Typical Heritage systems installation
CMMSERPDMSCADVideo…
DMZMI Servers
AC 800M
S800 I/O
WirelessHARTgateway
WirelessHART
MotorController
VariableSpeed Drive
LVSwitchgear
BusinessSystems
BaseSystemServers
Inte
rnet
AC450
S100 I/O
S800 I/O
Advant Station
AC 800M
S800 I/O
CI856 to S100 I/O
Control Builder:Laptop with PU410
TU40x with S800 I/O
Advant Station 140
VariableSpeed Drive
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Typical Heritage systems installationDo risk increase by the age of a system?
AC450
S100 I/O
S800 I/O
Advant Station Advant Station 140
VariableSpeed Drive
What happens around a system over time:
Product/System technical knowledge diminishes
It could be difficult to find new employees due to less attraction from the younger generation
ABBs suppliers have increasing difficulties maintaining test systems for older parts and sourcing components making it harder for ABB to support our older products
Products and software is no longer developed, opening up for cyber security concerns
If problems occur, it might be challenging to support the system…
…but if you are lucky, you won’t have any troubles...
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Stepwise Advant Evolution to 800xASix main areas
Operator Interface (HMI)
Engineering Tool
Communications network
Controllers
I/O’s
Drives
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Stepwise Advant Evolution to 800xAEvolving the HMI - challenge
Operator Interface (HMI)
Obsolete hardware and Software:
HP Unix Workstations, Monitors and keyboards
PC Workstations for Windows NT
HP Unix Software
AdvaCommand Software
Windows XP
800xA 3.1 to 5.0
Missing functions and features from newer 800xA versions.
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Stepwise Advant Evolution to 800xAEvolving the HMI - solution
Operator Interface (HMI)
Evolve HMI to:
800xA Revision 6.0.1
Investigate and Utilize 800xA Extended Automation values in the Evolved Heritage system
HMI tool-based graphics Evolution from Unix or VB6to PG2
Service provided by ABB
Use Automation Sentinel Maintain and Evolve
Changes:
800xA 6.0.1 requires PU410 for communication with the controllers and engineering tool. All RTA modules of PU515 and PU516 series must be replaced.
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Stepwise Advant Evolution to 800xAEvolving the Engineering Tool - solution
Engineering Tool
PU410 communication box for MB300 and Serial Interface
Flash card programmer:
OmniDrive USB2 LF(/SD)
CardWare 7.0
Used for application software backup
Improved cybersecurity with this solution
2015Control Builder A 1.4 for Windows 8.1 and Windows 2012 Server and Windows 7
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System 800xA – the climb
3
4
5
5.1
• First version release w/ complete system concept• Single environment from independent solutions• Redundancy on all levels
• Alarm and Event Improvements• Remote Clients via MS Terminal Services
• Large screen / Multi-screen • Digital Security Improvements• Virtualization offering for 800xA• MS WPF Graphics (PG2)• Snap-shot report• Multi-system Integration
• Alarm Response, Shelving, Analysis, Grouping, Alarm Help
• Tabbed Navigation w/ Alarm Status• Extended Operator Workplace• Mobility guide• Smart client w/ PG2 Graphic Support• Point of Control• Whitelisting• Security Monitoring and Management
(integration w/ Industrial Defender)• Embedded Video System• High Performance Graphics Elements• Application Change Management• AdvantMaster Central Backup
• Improved System Performance• Improved Cyber Security• Central System Installation• Automation Network Components• Read Only Clients • Decathlon Services• 800xA History• Public Address• 800xA Collaboration Table
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Stepwise Advant Evolution to 800xA
Worldwide delivering to customers since 2005
Key offerings:
Standardized conversion
Tool based one-to one conversion of 800xA Visual Basic graphics(version 3.1, 4.1, 5.0) to 800xA Process Graphics 2 (version 5.1, 6.0)
Tool based HMI evolution from various ABB DCS systems to 800xA, including Process Graphics 2 and Visual Basic graphics
Enhancements:
Value adding graphics enhancements to fully capitalize on new platformcapabilities: 3D objects, animations, optimizations
Remote support
Complete ABB DCS System Evolution project management
Human-Machine Interface Evolution Services by ABB
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High Performance Graphic Elements
PG 2 Graphic Elements promoting best practices in High Performance HMI
Increases detection of abnormal siutations before affecting production
Fully configurable Bars, Radar Plots, Normalized Trends, and Gauges complete with range indications
Properties can be static or dynamic (i.e. Dynamic boundaries and ranges)
Also included are alarm elements that represent the alarm status by color and shape.
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Stepwise Advant Evolution to 800xAEvolving the Communications System - challenge
Communications network
MasterBus 300
Yellow cable and transceivers ages - increase re-sendings that slows down the communication speed.
After some more years the communication fails.
Spares for transceivers and Ethernet HUBs not available
1987 -MasterBus 300
Thick Ethernet Trancievers
1995 -MasterBus 300Ethernet HUBs
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Stepwise Advant Evolution to 800xAEvolving the Communications System - solution
Communications network
MasterBus 300
ABB Switches(10 Mbit for controller connections, 100 or 1000 Mbit between switches.)
Network supervision of switches and port
RJ-45 Connection for controller,CS513A with RJ-45 connection and 100 Mbit(available during 2016 for the AC450)
Optical fiber between switches
10-Based/T network will be supported for the at least ten more years.
2015 -MasterBus 300ABB Switches
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Stepwise Advant Evolution to 800xAEvolving the controller - challenge
Controllers
Mechanical wear (fans)
Corrosion
Aging components
Brittle plastic
Contact discontinuity in the rack backplane
Dirtiness
The CPU has passed the intended life time and is at risk
1984MP200
1995AC410
1995AC450
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Stepwise Advant Evolution to 800xAEvolving the controller - solution
Controllers
Controller replacement
MP200, AC410, AC450 to AC 800M
Stepvise replacement of controllerdue to MB300, AF100 protocol
Application software conversion
Latest engineering tool and software release
Several AC 800M CPU’s, size and performance
Increased cyber security controller and network
Support most open serial and Ethernet based protocol and Heritage protocol like AF100, MB300 and S100 I/O connector.
Support of User defined protocol (serial and Ethernet based)
G3 coated hardware modules
2005 -AC 800M
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Stepwise Advant Evolution to 800xAAchieving seamless control
Several Ethernet based protocol that provides intelligent data from the field to support a higher plant availability, due to improved instrumentation, interlock or predictive maintenance information
Design seamless control solutions with different communication with one single tool
Flexible to all device manufacturers and in brownfield installations
Support of Heritage protocol like AF100, MB300 and S100 I/O connector.
Mix up to 12 communication interfaces to each AC 800M
Support of User defined protocol (serial and Ethernet based)
CI853SerialModbus
CI854AProfibusDP
CI860FoundationFieldbusHSE
CI867Modbus TCP
CI868ElectricalIntegrationIEC-61850
CI871ProfiNet
CI873Ethernet /IPDeviceNet
SerialDeviceNetviaGateway
FoundationFieldbus H1via LinkingDevice
Profibus PAvia LinkingDevice
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Evolution of Advant Master to AC 800MKey benefits, Engineering environment
Control Builder M using modern and efficient multi user environments to attract the next programming generation.
Control Diagrams Editor
Function Designer
Application Libraries
Comprehensive set of libraries with pre-defined type solutions (libraries), advanced calculation, library version handling included.
Object types, for implementation of type solutions
Unlimited re-use by instantiations of proven Object types Automatic updates of instances
Control Builder M has several embedded tools for optimization, supervision and evaluation of the application software and code execution.
Multiple Soft controller for application code simulation
Conversion of the application in Advant controller to AC 800M reduces the risk and saves engineering and testing
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Stepwise Advant Evolution to 800xAEngineering of AC 800M in Control Builder M
Control Diagram EditorEasy to work with
Compatible with FBD, CMD, ST, SFC
Parallel engineering supported
Open interface (XML) Modern conveniences…
Automation declaration of variables
Advanced insert dialog with recent and favorite lists
Undo / Redo several steps Paste ‘special’ dialog with
replace name options Documentation
SIL support
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Stepwise Advant Evolution to 800xAEngineering of AC 800M in Control Builder M
Function Designer for top down design
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Advant Master application software evolution to 800xA MP200, MP100, MP90, AC70, AC410 and AC450 to AC 800M
Control Builder A AMPL code to Control Builder M function block
1:1 tool based conversion
Provided by ABB Process Automation Process Industries, Sweden
Supports PidconA, Pidcon, Motcon and Valvecon using Pulp & Paper function block library
Very limited testing needed
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PAPI Sweden controller application software evolution Reference list September 2015
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Advant Master application software evolution to 800xAMP200, AC410 and AC450 to AC 800M
Control Builder A, AMPL to Minerals Library based on Control Diagrams
Provided by ABB Process Automation Process Industries, Switzerland
Workflow: Restore Tag data such as name, description, limits from AMPL Source code to a database
The tool generates XML code based on a type circuit library for AC800M Control diagram editor
Manual addition of interlocks and more
FAT and SAT testing is needed
Control Builder A, AMPL reengineering to 800xA Function Designer
Using new type circuits for better control and diagnostics
Provided by ABB Process Automation Service, Sweden
Tools and manual work needed
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Stepwise Advant Evolution to 800xAEvolving the I/O’s - challenge
I/O’s
I/O cards are 20 to 30 years old
Plastic in connectors and backplane will brittle with age
Relay for outputs gets unsecure
Opto-coupler for Digital Inputs deteriorates
Analog cards get reduced accuracy due to aging components
Failure rate increases significant after 20 Years
1978S100
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Stepwise Advant Evolution to 800xAEvolving the I/O’s - solution
I/O’s
Redesigned rack I/O cards
Optical extension available for distributed S100 I/O racks
Possible to replace MP200/1 racks with AC450 I/O racks
Step up offers
S100 old to S100 new version A with very attractive exchange pricing to end of March 2017
2000S100 version A
2016 (planned release)S100 version A, G3 coated
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Stepwise Advant Evolution to 800xARack I/O Evolution – AC800M Interface to S100 I/OCI856, S100 I/O connector
The communication board CI856 together with the control software gives support for migration of the installed base of S100 I/O.
• Each CI856 board supports up to five S100 I/O racks.
• Possible to use one CI856 for each I/O rack thus reducing single point of failure risk.
• No support for Redundant Bus couplers.
The CI856 interface support DSBC 174/176 bus extender slave and the following S100 I/O boards:
DSAI 130/130A Analog input board, 16 ch.DSAI 130D Analog input board, 16 ch. With 4 sets of filter timesDSAI 133 / 133 Analog input board , 32 ch.DSDI 110 /110A /110AV1 Digital input board, 32 ch. 24VDSDI 120 /120A /120AV1 Digital input board, 32 ch. 48VDSDO 110 Digital output board, 32 ch.DSDO 115 Digital output board, 32 ch.DSDO 115A Digital output board, 32 ch., OSP controlDSDO 130 Digital output board, 16 relay ch., 24-240 VAC/VDCDSDO 131 Digital output board, , 16 relay ch., 24-240 VAC/VDCDSAO 110 Analog output board, 4 ch.DSAO 120 Analog output board, 8 ch.DSAO 120A Analog output board, 4 ch., OSP controlDSAO 130 Analog output board, 16 ch.DSAO 130A Analog output board, 16 ch., OSP controlDSAX 110 /110A Analog input/output board, 8+8 ch.DSDP 010 Absolute binary decoder with hardware strobe, 2 ch.DSDP170 Pulse counter board, 4 ch.
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© ABBSlide 34 -April 15, 2016
Stepwise Advant Evolution to 800xAEvolving the I/O’s – S800 I/O solution
I/O’s
Change to ModuleBus by changing communication interface to TB820V2, TB840A and modems TB825, TB826
Supports redundancy and 1 ms SOE.
Allows addition of HART modules supporting DTM.
Change to PROFIBUS DP by changing communication interface to CI801, CI840 and optical modems.
Supports redundancy.
Allows addition of HART modules supporting DTM.
Change to the new Ethernet based communication interface and modems(planned release beginning of 2017)
Redundant Master and slave. Will be the preferred solution
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Stepwise Advant Evolution to 800xAEvolving the drives solution
Drives
Drives control via the PROFINET module
Ethernet based protocol provides more intelligent data from the field to support a higher plant availability, due to interlock or predictive maintenance information
Drives control via the DriveBus module
Drives control via the PROFIBUS DP module
Drives control via ModuleBus on the AC 800M
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Stepwise Evolution from AC450 to AC 800MReuse of Advant OSC Cabinet
Redundant AC450 with S100 I/O
Replace the AC450 with a redundant AC 800M and heritage communication interfaces
Extend with new communication interfaces
Extend with S800 I/O via ModuleBus
Upgrade to redundant power supply
Stepwise replace the S100 I/O to S800 I/O via PROFIBUS/Ethernet*
*Release in the end of 2016
System 800xA System 800xAAdvant OCS Advant OCS
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Stepwise Advant Evolution to 800xAKey benefits
Extend the plant life cycle by fully utilize Heritages Systems plant assets in 800xA
Stepvise evolution of HMI,Controller and I/O.
800xA brings The Power Of Integration.
Extended Cyber security, Alarm management; Asset Optimization; Smart Client; …
The AC 800M brings:
Extended device asset information via Ethernet based communication.
Extended Cyber security
Ethernet based I/O communication (S800 I/O via ethernet end of 2016)
An attractive, modern and effective Engineering tools compared with Control Builder A.
Conversion of the application in Advant controller to AC 800M, reduces risk and saves engineering and testing hours
Preservation of I/O (preserves costs for replacement, testing, drawings, training)
Navigation from code to Faceplate